Volkswagen Polo 1995 - 2010 Workshop Manual

Service

Workshop Manual

Bora 1999 ➤ , Bora Variant 1999 ➤ ,

CC 2010 ➤ , Eos 2006 ➤ , Golf 1998 ➤ ,

Golf 2004 ➤ , Golf 2009 ➤ ,

Golf Plus 2005 ➤ , Golf Plus 2009 ➤ ,

Golf Variant 1998 ➤ , Lupo 1999 ➤ ,

Lupo 3L 1999 ➤ , Passat 1997 ➤ ,

Passat 2006 ➤ , Passat CC 2009 ➤ ,

Passat Variant 1997 ➤ , Phaeton 2003 ➤ ,

Polo 1995 ➤ , Polo 2002 ➤ ,

Polo 2010 ➤ , Polo KH IN 2010 ➤ ,

Polo Lim IN 2011 ➤ ,

Polo Lim RUS 2011 ➤ , Scirocco 2009 ➤ ,

Sharan 1996 ➤ , Sharan 2011 ➤ ,

Tiguan 2008 ➤ , Touareg 2003 ➤ ,

Touareg 2010 ➤ , Touran 2003 ➤

Edition 07.2010

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Electrical System, General Information ante e

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Service

List of Workshop Manual Repair GroupsList of Workshop Manual

Repair GroupsList of Workshop Manual Repair Groups

Repair Group

27 - Starter, current supply, CCS

90 - Gauges, instruments

a ut ho r i s ed

92 - Windscreen wash/wipe system

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94 - Lights, bulbs, switches - exterior

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96 - Lights, bulbs, switches - interior

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97 - Wiring

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Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2010 Volkswagen AG, Wolfsburg K0059101320

Contents

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Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

b y V uar ante e

Battery terminal connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Electrical System, General Information - Edition 07.2010

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27 - Starter, current supply, CCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

1.1

1.2

1.3

1.4

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fundamentals for batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Types of batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warning notices and safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1

1

1

2

2 Checking battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

2.1

Checking the various types of batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

2.2

Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

2.3

Checking colour display of magic eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

2.4

Battery tester with printer VAS 5097 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

2.5

2.6

2.7

2.8

3

3.1

Battery tester with printer VAS 6161 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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Current draw test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Checking no-load voltage of battery on stock and stored vehicles . . . . . . . . . . . . . . . . . . 23

pr

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Charging battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 in p y

C

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Battery charger VAS 5095 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.2

3.3

Battery charger VAS 5900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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3.4

Battery charger VAS 5906 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

3.5

Midtronics INC 940 battery charger only for USA/Canada . . . . . . . . . . . . . . . . . . . . . . . . . . 55

3.6

Solar panel VAS 6102A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

3.7

Totally discharged batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

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4 Cruise control system (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

4.1

Activating and deactivating cruise control system (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . . 61

90 - Gauges, instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

92 - Windscreen wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

1 Washer fluid line hose couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

1.1

Windscreen and rear window washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

1.2

Headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

2 Hose repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

2.1

General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

2.2

Repairing smooth pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

2.3

Repairing corrugated pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

3 Distinguishing features of jointless wiper blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

94 - Lights, bulbs, switches - exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

1 Operation and safety notes for gas discharge bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

96 - Lights, bulbs, switches - interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

1 12 V socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

1.1

Removing and installing 12 V socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

1.2

Removing and installing socket illumination bulb L42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

2 Cigarette lighter U1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

2.1

General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

2.2

Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

2.3

Removing and installing cigarette lighter socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

2.4

Removing and installing cigarette lighter illumination bulb L28 . . . . . . . . . . . . . . . . . . . . . . 76

97 - Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Contents i

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

1 Vehicle diagnostic, testing and information systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

1.1

Connecting vehicle diagnostic tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

1.2

Connecting vehicle diagnostic tester Golf Model Year 1998 - 2003 . . . . . . . . . . . . . . . . . . 80

2 Repairing wiring harnesses and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

2.1

Wiring harness repair set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

2.2

Tool descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

2.3

General notes concerning repairs to vehicle electrical system . . . . . . . . . . . . . . . . . . . . . . 85

2.4

Repairs to wiring harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

2.5

Repairs to contact housings and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

2.6

Releasing and dismantling contact housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

3 Contact surface cleaning set VAS 6410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

3.1

Using contact surface cleaning set VAS 6410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

4 Renewing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

4.1

Renewing LSF Lambda probe (4-pin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

4.2

Renewing LSU Lambda probe (6-pin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

4.3

Types of protective tube on uniform Lambda probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

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Contents

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

27 – Starter, current supply, CCS

1 Battery

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a

WARNING ho r i s ed

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Danger of injury! Observe warning notices and safety regula‐

tions ⇒ page 2

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!

Caution

To prevent damage to the battery and vehicle, the following should be observed concerning types of battery

⇒ page 1

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1.1

To ensure long use of the battery, the battery must be checked, serviced and maintained according to the specifications in this manual.

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Apart from supplying energy for starting the engine, the battery has other tasks: it acts as a buffer and supplies electrical energy

1.2

Fundamentals for batteries

Types of batteries

General notes g in p y

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Caution

The description for the following batteries is for maintenancefree batteries. No stickers may be removed and do not replen‐ ish with distilled water. Only perform a visual check. Refer to

chapter, Checking battery ⇒ page 5

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1.2.1

Battery with magic eye

This is a maintenance-free battery with liquid electrolyte (wet bat‐ tery).

Caution

No stickers may be removed and do not replenish with distilled water. Only perform a visual check. Refer to chapter, Checking

battery ⇒ page 5

.

WARNING

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle!

Danger of explosion when checking and charging or slave/ jump starting.

These batteries must be renewed.

1. Battery

1

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

This battery is equipped with a magic eye. The magic eye pro‐ vides information concerning the level of the electrolyte and the charge state of the battery via a coloured display. Checking colour display of the magic eye

⇒ page 6

1.2.2

Absorbent glass mat battery

Maintenance-free battery with a contained electrolyte and no magic eye.

Lead-acid battery where the electrolyte is contained within a mi‐ croscopic glass mat (AGM). The battery is sealed and fitted with valves.

AGM is the abbreviation for absorbent glass mat.

Due to containment of the electrolyte, this type of battery may not have a magic eye. Absorbent glass mat batteries are identified by the abbreviation AGM on the battery.

Note s

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1.3

1.3.1

Warning notices and safety regulations

Dangers when handling vehicle batter‐ ies

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Always replace an absorbent glass mat battery with another ab‐ sorbent glass mat battery.

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Recognition and avoidance of dangers

Batteries can be dangerous. These dangers can be avoided when the warnings on the battery, in the operating manual and in ELSA are observed.

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2

Rep. gr.27 - Starter, current supply, CCS

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

WARNING

♦ Untrained personnel e.g. apprentices, trainees etc. may only work on batteries when supervised by a vehicle me‐ chanic/foreman or vehicle electrician/foreman.

♦ Acid is highly corrosive. There is a considerable danger of acid burns if personnel do not handle batteries correctly.

Therefore suitable measures must be taken to ensure that equipment/solutions etc. are available to neutralize acid burns. A suitable solution is: e.g. a soap solution.

♦ If electrolyte leaks from a battery it may cause skin burns or acid corrosion and rusting on the vehicle. This may damage safety relevant components on the vehicle.

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♦ The gas which forms when charging and the gas which may escape through vent valves is explosive. In extreme m it t e d

u cases a battery may explode if the battery is not handled correctly.

batteries. Smoking is also prohibited. Sparks generated by electrostatic charging must also be avoided. Always touch the vehicle body before touching the battery.

♦ Only work on batteries in well ventilated and suitable rooms.

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♦ Batteries must be renewed where the magic eye is col‐ ourless or light yellow. They must not be checked or s

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b when checking and charging or slave/jump starting.

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♦ It is prohibited to cause sparks through grinding, welding, cutting operations and use naked lights in the vicinity of ny li a b li i y t

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1.3.2

Safety markings on battery

e m c

Safety markings on battery m o

1. - Fires, sparks, naked flames and smoking are prohibited when handling batteries. Avoid sparks as well as electrostatic discharge r

c when working with cables and electrical units. Avoid short circuits.

Therefore never lay a tool on a battery.

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3. - Keep children away from acid and batteries.

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fo may only be disposed of through a suitable collection centre and only in accordance with respective legislation.

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4. - Disposal: old batteries are classed as hazardous waste. They ht b

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6. - There is a danger of an explosion when working with batteries.

A highly explosive gas is produced when batteries are charged.

7. - Always follow instructions on battery, in ELSA "Electrical Sys‐ tem, General Information" and in owner's manual.

8. - Battery acid is very caustic; therefore wear eye protection and gloves when working with batteries. Do not tilt battery. Acid can leak out of the gas vents of some batteries.

th n a m

1. Battery

3

1.4

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

Battery terminal connection

Caution

To prevent damage to the battery clamps and battery termi‐ nals, the following should be observed: s

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♦ The battery clamps should only be fitted by hand and with‐ out using force.

n l e s

♦ Battery terminals should not be coated with grease.

♦ The battery clamps should be fitted so that the battery ter‐ minal is either flush with the clamp or protruding from it.

♦ Once the battery clamps have been tightened to the speci‐ fied torque, the threaded connections should not be tight‐ ened any further.

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4

Rep. gr.27 - Starter, current supply, CCS

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

2 Checking battery

WARNING

Danger of injury! Observe warning notices and safety regula‐

tions ⇒ page 2 !

Caution

To prevent damage to the battery and vehicle, the following should be observed concerning types of battery

⇒ page 1

.

2.1

Checking the various types of batteries

2.1.1

Checking battery with magic eye

WARNING

Danger of injury! Observe warning notices and safety regula‐

tions ⇒ page 2 !

Carry out procedure in sequence as follows:

1.

Visual check

⇒ page 6

2.

Check colour display of „3-colour“ magic eye ⇒ page 6

or „2-colour“ magic eye

⇒ page 7

.

WARNING

b y

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.

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Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle!

Danger of explosion when checking and charging or slave/ jump starting

These batteries must be renewed.

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3.

Perform a battery load test using battery tester with printer

-VAS 5097 A- ⇒ page 9 .

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– Battery test with battery tester with printer -VAS 6161-

⇒ page 14 .

4.

Depending on the result of the battery test, „perform current

draw test“ ⇒ page 22

.

ny li a i b li t y

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c

2.1.2

Absorbent glass mat battery

Carry out procedure in sequence as follows: c

1.

Visual check

⇒ page 6

e

2.

Perform a battery load test using battery tester with printer

-VAS 5097 A- ⇒ page 9 .

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– Battery load test with battery tester with printer -VAS 6161-

⇒ page 14

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2. Checking battery

5

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

3.

Depending on the result of the battery test, „perform current draw test“

⇒ page 22 .

2.2

Visual check

WARNING

Danger of injury! Observe warning notices and safety regula‐ tions

⇒ page 2

!

It is essential to visually inspect the external condition, to check the terminals and to ensure proper attachment of the battery be‐ fore performing extensive tests.

Caution

♦ The battery will be damaged if the battery is not secured correctly.

♦ Vibrations shorten the life of the battery, there is a danger of an explosion, the cell plates may be damaged and the clamping bracket may damage the battery housing.

♦ Check battery is securely seated, if necessary tighten se‐ curing bolt to specified torque.

Performing this test establishes:

♦ If battery housing is damaged Electrolyte can leak out if the housing is damaged. If battery acid leaks out, serious damage to the vehicle could be caused. Treat components affected by leaked battery acid immediately with acid neutraliser or a soap solution.

a ut ho r i s ed

V

♦ Check whether the battery terminals (battery wire connec‐ tions) are damaged. The necessary contact on the battery

n o t

p e r m it t e d

u n l e s s clamps cannot be guaranteed if the battery terminals are dam‐ aged. When connecting the battery clamps, tighten the battery n ot g uar ante e

or a c c ep t a clamps to torque specified in this workshop manual „Electrical system“ for the respective vehicle. If the battery clamps are not correctly seated and tightened, the wiring may burn. Which will cause malfunctions in the electrical system. Therefore it can no longer be guaranteed that the vehicle will function cor‐ rectly.

r i o rt a

w n

2.3

Checking colour display of magic eye

ny li a i b li t y

w ith

r s e c e p o t

t e th

c

2.3.1

Checking colour display of „3-colour“ magic eye

m m

WARNING a t e

o r

c o iv

Danger of injury! Observe warning notices and safety regula‐ tions

⇒ page 2

!

g o p y in

C h t. rig p y y co

b c t ed te

Pro G.

n A ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

6

Rep. gr.27 - Starter, current supply, CCS

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

General information on magic eye:

Applies for all batteries with „1J0“, „7N0“ and „3B0“ indexes in original equipment and for all replacement batteries 191 915 105

AB and from „000 915 105 AX“ index.

The magic eye provides information concerning electrolyte level and the charge state of the battery.

Before carrying out a visual check, tap the magic eye lightly and carefully using the handle of a screwdriver. The air bubbles, which can influence the display, will dissipate when doing this. The col‐ our display of the magic eye will therefore be more accurate.

Note

♦ Air bubbles can form below the magic eye particularly when the battery is being charged, including during normal vehicle operation. These distort the colour displayed by the magic eye.

♦ Because the magic eye is located in only one cell, the display applies only to this cell. An exact determination of the battery condition is only possible through a battery load test

⇒ page 9

or a battery test

⇒ page 14 .

♦ The magic eye can be located at various positions on the bat‐

♦ »Green«, battery is charged sufficiently.

w h o le

, is

n tery.

Three different colour displays are possible:

♦ »Colourless or light yellow«, battery must be renewed.

o t

p e r m it t e d

u n l e s s

a ut ho r i s ed

b

WARNING olk sw completely discharged a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t a ny li a b r i o rt a n

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle!

Danger of explosion when checking and charging or slave/ jump starting li i y t

w ith

r s e p c e t th o

t

c e

These batteries must be renewed.

2.3.2

m o r

c

Checking colour display of „2-colour“ magic eye

o e t a

tions

iv pr r

fo g in y

WARNING p

⇒ page 2 t.

!

h rig p y y co

b c t ed te

Pro G.

A n ge a sw olk

V y ht b rig

C o py t.

en um c o

d

th n a m

2. Checking battery

7

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

General information on magic eye:

For batteries from „5K0“ index in original equipment and for re‐ placement batteries 191 915 105 AC from „000 915 105 DX“ index, the »green« colour display for charge state display has been discontinued. The introduction of the new colour display will take place gradually, i.e. there will be a transition period for both displays. In the future, the only remaining colours will be »black« or »colourless or light yellow«.

The magic eye provides information concerning the electrolyte level of the battery.

The charge state of the battery can no longer be read from the magic eye, a battery load test must be carried out for this

⇒ page 9

Before carrying out a visual check, tap the magic eye lightly and carefully using the handle of a screwdriver. The air bubbles, which can influence the display, will dissipate when doing this. The col‐ our display of the magic eye will therefore be more accurate.

Note

♦ Air bubbles can form below the magic eye particularly when the battery is being charged, including during normal vehicle operation. These distort the colour displayed by the magic eye.

♦ Because the magic eye is located in only one cell, the display applies only to this cell. An exact determination of the battery condition is only possible through a battery load test

⇒ page 9 .

♦ The magic eye can be located at various positions on the bat‐ tery.

Three different colour displays are possible:

a ut ho r i s ed

♦ »Black«, electrolyte level is OK.

♦ »Colourless or light yellow«, electrolyte level too low. The bat‐ tery must be renewed.

n o t

p e is

, r m it t e d

u n l e s s

WARNING o h le r i o rt

w

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle!

a n

Danger of explosion when checking and charging or slave/ jump starting

b y V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t

a ny li a b li i t y

w ith

r s e c e p o t

t e th

c

These batteries must be renewed.

2.4

c

Battery tester with printer -VAS 5097 A-

o r

c

WARNING

o e t a iv tions

⇒ page 2

!

r pr

Danger of injury! Observe warning notices and safety regula‐ p y

C o t. h rig y

It is not necessary to remove or disconnect battery when using battery tester with printer -VAS 5097 A- .

Battery tester with printer -VAS 5097 A- can be used to test 12 V starter batteries.

p

co y

b c t ed te

Pro G.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

8

Rep. gr.27 - Starter, current supply, CCS

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

♦ 80 - 520 A low-temperature test current according to DIN

(Deutsche Industrie Norm (German Industrial Standard))

1)

♦ 95 - 574 A cold cranking current according to IEC (Interna‐ tional Engineering Consortium)

♦ 136 - 855 A cold cranking current according to EN/ SAE (Eu‐ ropean Norm/Standard of Automotive Engineers)

1) Batteries with cold cranking current higher than 499 A according to DIN (e.g.

520 A, 580 A or 600 A) can be temporarily tested using setting for 499 A according to DIN.

For test purposes the battery is loaded with a current which is similar to the starting current required to start the vehicle. The

Observe the ⇒ instruction manual of Battery tester with printer -

VAS 5097 A- or the sticker ⇒ Brief instructions for battery tester with printer -VAS 5097 A- on the unit or table: Cold cranking cur‐

rent ⇒ page 11

2.4.1

.

Description of battery tester with printer

-VAS 5097 A-

a ge battery is assessed on this loading and the result is printed out.

Note r i o rt a

w n o h le is

,

n o t

p e r m it t e d

u n l e s s

a ut ho r i s ed n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t a ny li a i b li t y

w ith

r s e c e p o t

t e th

c

Battery tester with printer -VAS 5097 A-

1 - Green LED, „unit operating“ c

3 - Red LED, „battery cannot be tested“, recharge battery.

c o m m

4 - Start button o r a t e

5 - Cold cranking current selection switch pr iv r g

fo

6 - ON/OFF and functions switch external test point in engine compartment)

8 - Paper feed button in y o p

C t. rig p y y co

b c t ed

9 - Printer te

Pro G.

n A ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

2.4.2

Performing battery load test using bat‐ tery tester with printer -VAS 5097 A-

WARNING

Danger of injury! Observe warning notices and safety regula‐

tions ⇒ page 2 !

Special tools and workshop equipment required

2. Checking battery

9

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

♦ Battery tester with printer -VAS 5097 At e d

u n l e s s

a ut ho r i s ed

b y V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t

a

Note r m it

n o t

p e

Observe technical product information TPI 2012182 for battery tester with printer -VAS 5097 A- .

Performing battery load test: r i o rt a

w n o le

WARNING ny li a b li i t y

w ith

r s e c e p o t

t e th

c

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle!

Danger of explosion when checking and charging or slave/ c

These batteries must be renewed.

c o m m

o r t e a iv r pr

Note g

fo y in

C o p t. rig p y y

co

b c t ed te

G.

n A a ge

– Check magic eye on batteries with magic eye ⇒ page 5 .

sw olk y

V

– Check low-temperature test current in amperes (A) according to DIN from indications on battery or set setting range on bat‐ tery tester with printer -VAS 5097 A- according to table

⇒ „2.4.3 Table: cold cranking current“, page 11

.

ht b rig py o

C t.

en um c o

d

th n a m

Note

If the battery values are shown in IEC or EN/SAE instead of DIN then convert figures using table

⇒ „2.4.3 Table: cold cranking current“, page 11 or using table

on unit.

– Select low-temperature test current via low-temperature test

current selection switch ⇒ page 9 .

– Select measuring range 80 - 379 A or 380 - 499 A with ON/

OFF and functions switch ⇒ page 9

.

10

Rep. gr.27 - Starter, current supply, CCS

Note

w h o le

, is

n s

a ut ho ed

b y V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar

Electrical System, General Information - Edition 07.2010

Batteries with cold cranking current higher than 499 A according to DIN (e.g. 520 A, 580 A or 600 A) can be temporarily tested using setting for 499 A according to DIN.

– Connect red terminal „+“ of tester to positive terminal.

a n r i o rt o t

p e r m it t e d

u n l e s

– Connect black terminal „-“ of tester to negative terminal.

ante e c ep t

a ny li a b li i y t

w ith

r s e p c e t th o

t

c e

Note

♦ Ensure test clamps have a good contact!

♦ Observe technical product information TPI 2012182 for battery

c a t e

o r o m tester with printer -VAS 5097 A- .

iv – Select point of connection of test terminals with selection

fo switch ⇒ page 9 g

in

.

1 - Connected directly to battery h t.

C o p y

2 - Connected to external test points in engine compartment

b c t ed te

G.

n A a ge sw olk y

V

– Check that the figures given on the battery are correct for the settings on the battery tester.

– Press start test button

⇒ page 9

.

The green LED lights up ⇒ page 9

. The test program runs through automatically. The test result is printed out by the printer

⇒ page 12

. If the unit does not start (LED does not light up, no

print out), recharge battery ⇒ page 25

and test again.

– Switch off unit ⇒ page 9 .

– Remove test terminals.

ht b rig py o

C t.

en um c o

d

th n a m

Note

♦ The test is completed after about 20 seconds.

♦ The result of the test is printed out by the printer.

♦ Perform test once only. Repeating the test falsifies the result.

♦ The tester requires approx. 30 minutes to cool down before it is ready for the next test.

2.4.3

EN/ SAE

136 – 17

178 – 219

220 – 261

262 – 303

304 – 345

346 – 387

388 – 429

430 – 471

472 – 513

Table: cold cranking current

Cold cranking current in A

IEC ⇒

95 – 124

125 – 154

155 – 184

185 – 214

215 – 244

245 – 274

275 – 304

305 – 334

335 – 364

⇒

⇒

⇒

⇒

⇒

⇒

⇒

⇒

⇒

DIN

80 – 104

105 – 129

130 – 154

155 – 179

180 – 204

204 – 229

230 – 254

255 – 279

280 – 304

2. Checking battery

11

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

EN/ SAE

514 – 555

556 – 597

598 – 639

640 – 657

658 – 675

676 – 693

694 – 711

712 – 729

730 – 747

748 – 765

766 – 783

784 – 801

802 – 819

820 – 837

838 – 855

Cold cranking current in A

IEC ⇒

365 – 394

395 – 424

425 – 454

455 – 464

465 – 474

475 – 484

485 – 494

495 – 504

505 – 514

515 – 524

525 – 534

535 – 544

545 – 554

555 – 564

565 – 574

⇒

⇒

⇒

⇒

⇒

⇒

⇒

⇒

⇒

⇒

⇒

⇒

⇒

⇒

⇒

DIN

305 –329

330 – 354

355 – 379

380 – 389

390 – 399

400 – 409

410 – 419

420 – 429

430 – 439

440 – 449

450 – 459

460 – 469

470 – 479

480 – 489

490 – 499

2)

1)

2) 1) Batteries with cold cranking current higher than 499 A according to DIN (e.g. 520 A, 580 A or 600 A) can be temporarily tested using setting for 499 A according to DIN.

b y

V olk sw a ge n AG

.

V olk s w a g en AG do es

2.4.4

Evaluating test result of battery load test

mum voltage.

r i o rt a

w n o h le is

,

n o t

p e r m it s

Because of the high load on the battery during this test (a high current flows) the battery voltage drops.

a ut ho r i s ed

♦ If the battery is OK, the voltage value drops only to the mini‐

♦ If the battery is defective or has a low charge, the battery volt‐ age quickly drops below the minimum voltage.

♦ After the test is completed, this low voltage value remains over a longer period, and the voltage increases very slowly again.

♦ Perform test once only. Repeating the test falsifies the result.

n ot g uar ante e

or a c c ep t a ny li a i b li t y

w ith

r s e c e p o t

t e th

c

♦ The tester requires approx. 30 minutes to cool down before carrying out another test or testing another battery to ensure the results are not falsified.

e m c m

c r o e t

o a d

th n a m iv pr r um c o

fo g in y p

C o t. h rig p y y co

b c t ed te

Pro G.

n A ge a sw olk

V y ht b rig py

C o t.

en

12

Rep. gr.27 - Starter, current supply, CCS

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

2.4.5

Comments concerning test print out

1 - Measuring range selected on tester

2 - Diagram -arrow- indicates battery condition.

3 - Test result

4 - Battery voltage during load test.

5 - Vehicle data and date Must be completed by test personnel

♦

Note

n o t

p e ed

The test printout is required for warranty claims.

a ut ho r i s

♦ Perform test once only. Repeating immediately the test falsi‐ fies the result.

r m it t e d

u n l e s s

b y V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t

a

2.4.6

o h le is

,

Assessing test results

Printout from battery tester rt a

w n

Starting capability very good

Measure to be performed

Battery OK.

ny li a b li i t y

w ith

r s e c e p o t

t e th

c

Starting capability good

Starting capability sufficient

Battery OK.

Evaluation by carrying out a current draw test when charg‐ ing

⇒ page 22

Starting capability poor m m e c o r

c

Starting capability very poor r pr iv a t e

o

Cannot be tested g

fo in y o p

C h t. y rig p y

co

b

Evaluation by carrying out a current draw test when charg‐ ing

⇒ page 22

Evaluation by carrying out a current draw test when charg‐ ing

⇒ page 22

Perform battery charging

⇒ page 25 and repeat test.

olk y

V c t ed te

Pro G.

n A a ge sw ht b rig py o

C t.

en um c o

d

th n a m

2. Checking battery

13

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

2.5

Battery tester with printer -VAS 6161-

General description

WARNING

Danger of injury! Observe warning notices and safety regula‐ tions

⇒ page 2

!

It is not necessary to remove or disconnect battery when using battery tester with printer -VAS 6161- .

The battery tester with printer -VAS 6161- does not load the bat‐ tery any more. It works on the principle of dynamic conductance acquisition.

Every battery type is stored in the tester.

Data can be stored on an SD card.

The battery tester with printer -VAS 6161- can be updated via an interface or an SD card, so that battery data from Volkswagen are always up to date.

The integrated temperature sensor improves measurement qual‐ ity.

A 2D scanner is available as an option to read data directly from the bar code of the battery.

Note

Observe the ⇒ operating manual of the battery tester with printer

-VAS 6161- .

2.5.1

Description of battery tester with printer

-VAS 6161-

1 - Integrated printer

a ut ho r i s ed

b y V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t

a

2 - Operating lever for paper compartment

3 - Paper slot r m it t e d

u n l e s s

4 - LCD screen with main menu

n o t

p e

5 - Control panel with On/Off button

6 - Connection for battery test cable

7 - Memory card slot a r i o

8 - Infrared temperature sensor

w n ny li a b li i t y

w ith

r s e c e p o t

t e th

c

9 - Data transmitter for PC e m c m

c r o e t

o a iv pr r

fo g in y p o

C t. h rig y p

14

Rep. gr.27 - Starter, current supply, CCS

co y

b c t ed te

Pro G.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

2.5.2

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

Perform battery test with battery tester with printer -VAS 6161- .

WARNING

Danger of injury! Observe warning notices and safety regula‐

tions ⇒ page 2 !

Special tools and workshop equipment required

♦ Battery tester with printer -VAS 6161-

Performing battery test:

WARNING s

a ut ho r i s ed

b y V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle!

Danger of explosion when checking and charging or slave/ jump starting

w h o le

, is

n o t

p e r m it t e d

u

These batteries must be renewed.

– Switch off ignition and all electrical consumers.

– Check magic eye on batteries with magic eye

⇒ page 5

.

c ep t

a ny li a b li i y t

w ith

r s e p c e t th o

t

c e

– Switch on unit.

– Connect red terminal „+“ of tester to positive terminal.

– Connect black terminal „-“ of tester to negative terminal.

c e m

Note m r

c o

o

Ensure test clamps have a good contact!

r pr

– Select one of the following functions.

p o

C t.

tionary and stock maintenance programme

♦ Service test ⇒ page 16

b c t ed te

Pro

⇒ page 16

G.

) n A ge a

♦ Guarantee test

⇒ page 17

sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

2. Checking battery

15

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

Note

♦ The test is completed after about 10 seconds.

♦ The result of the test is printed out by the printer.

♦ The tester requires no cooling phase before it is ready for the next measurement.

2.5.3

Performing maintenance test

WARNING

Danger of explosion when checking and charging or slave/ jump starting

These batteries must be renewed.

w h o le

, is

n o t

p e r m it t e d

u a n r i

– Select „Maintenance test“ in the menu.

s

a ut ho r i s ed

b y

V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c n l e s

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle!

– Connect scanner.

c ep t a ny li a b li i y t

w ith

r s e p c e t th o

t

c e

Note

If no scanner is available, write vehicle identification number on test printout by hand.

m m e c o

c

– Scan in vehicle identification number.

e

o r t a iv

– Select „On battery terminal“ or „On jump-start point“.

g

fo

– Scan in barcode or select type and manufacturer manually in menu.

h t.

C o p y in rig

– Measure temperature. Hold temperature sensor about 5 cm above terminal connection until temperature stabilises.

c t ed te

– Start test.

– Print out test log if necessary.

2.5.4

Perform service test

Pro

WARNING

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle!

Danger of explosion when checking and charging or slave/ jump starting

These batteries must be renewed.

G.

n A ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

– Select „Service test“ in the menu.

– Select „On battery terminal“ or „On jump-start point“.

– Select vehicle type.

– Measure temperature. Hold temperature sensor about 5 cm above one battery terminal until temperature stabilises.

16

Rep. gr.27 - Starter, current supply, CCS

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

– Select battery type „Normal“, „AGM“, „2*6V“ or „Gel“.

– Select „CCA“, „JIS“, „DIN“, „SAE“, „IEC“ or „EN“ norm.

– Start test.

– Print out test log if necessary.

2.5.5

Perform guarantee test

WARNING

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle!

Danger of explosion when checking and charging or slave/ jump starting

These batteries must be renewed.

– Select „Guarantee test“ in the menu.

– Select „In vehicle“ or „Outside vehicle“.

– Select „On battery terminal“ or „On jump-start point“.

– Select vehicle type.

– Measure temperature. Hold temperature sensor about 5 cm above one battery terminal until temperature stabilises.

– Select battery type „Normal“, „AGM“, „2*6V“ or „Gel“ or scan in.

– Select battery capacity or scan in.

– Start test.

– Print out test log if necessary.

2.5.6

Comments concerning test print out

n l e s s

a ut ho r i s ed

b y

V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c

1 - Check type.

2 - Battery test result t

p e r m it

3 - Measured voltage

w h o le

, is

n o t e d

u

4 - Measured cold start value of battery.

5 - Nominal cold start value of battery selected on tester.

6 - Measured temperature of battery.

7 - Fitting location of battery c ep t a ny li a b li i y t

w ith

r s e p c e t th o

t

c e

8 - Position of battery clamp selected on tester

9 - Selected battery technology.

Note c e m

The test printout is required for warranty claims.

e

o r

c o m a t

2.5.7

Assessing test results

Battery test results

Battery OK iv r pr g

fo y in o p t.

C rig

Measures c t ed te

G.

n A ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

2. Checking battery

17

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

Battery test results Measures

Battery OK - recharge.

Charge battery ⇒ page 25

. In case of discharging, look for fault

Perform current draw test

Renew battery.

n l e s s

a ut ho r i s

Perform current draw test

⇒ page 22

. Fully charge bat‐

tery ⇒ page 25

and repeat test.

y V olk sw a ge n AG

.

V olk s w a g en AG do es

Disconnect battery and repeat test. The result „Renew battery“ may be caused by a weak cable contact.

Battery cell defective - renew. Renew battery.

n ot g uar ante e

or a c

Check connection.

n r i o h le

, is

n o t

p e r m it t e d

u

Connect cable directly to bat‐ tery and not to jump start termi‐ nal.

Evaluating battery test results for maintenance test

w

Battery test results

Battery OK rt a

Measures

No measure c ep t

a ny li a b li i y t

w ith

r s e p c e t th o

t

c e

Charge battery immediately.

Charge battery fully

⇒ page 25

.

Mark as defective.

Mark as defective.

Noises

2.6

e m

Check connection.

m o r

c

Disconnect battery and repeat test. The result „Check tester connection“ may be caused by a weak cable contact.

o e t a iv pr r

Connect cable directly to bat‐ tery and not to jump start termi‐ nal.

g

fo in y p o

C t. h rig

Wait until measured value ap‐ pears on display.

p y

Midtronics -MCR340V- battery tester only for USA/Canada vehicles

G.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

General description

⇒ page 18

Perform battery test with Midtronics -MCR340V- battery tester

⇒ page 19 .

Dealing with problems with Midtronics -MCR340V- battery tester

⇒ page 21

2.6.1

General description

WARNING

Danger of injury.

Before working on the battery, read through the warning and safety regulations carefully, and comply with them

⇒ page 2 .

Dispose of electrolyte (mixture of sulphuric acid and water) safely! Waste electrolyte is only allowed to be disposed of at appropriately indicated collecting points. Comply with the lo‐ cally applicable disposal guidelines.

Do not test batteries that are liberating gas. Otherwise, there is a danger of explosion.

18

Rep. gr.27 - Starter, current supply, CCS

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Electrical System, General Information - Edition 07.2010

WARNING

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle!

Danger of explosion when checking and charging or slave/ jump starting

These batteries must be renewed.

Note

To prevent damage to the battery and vehicle, note the types of battery and the remarks given

⇒ page 1 .

Batteries in VW vehicles are only allowed to be tested with battery testers approved by VW. In the USA/Canada, it is permitted for the Midtronics -MCR340V- battery tester to be used.

Read all the information about safety, setup and operation in the operating instructions for the Midtronics -MCR340V- battery test‐ er and follow the instructions to the letter.

s ut ho y V olk sw a ge

Refer to ⇒ Self-study programme No. ; Vehicle batteries for more information.

a r i s ed

b n AG a g en AG do es n ot g uar ante e

or a c teries, all battery installation locations (engine compartment or luggage compartment) and battery purposes (starter battery or second/convenience battery).

h e r

Always comply with the safety regulations, the regulations for setting up the battery tester, the display menu/display buttons,

LEDs and the operating procedures described in the ⇒ operating manual MCR340V .

r i o rt a n

w

Note c ep t

a ny li a b li i y t

w ith

r s e p c e t th o

t

c e

Observe and comply with all subsections, remarks and referen‐ ces to the vehicle and battery type, etc. to be tested.

2.6.2

e m m

Prerequisites: t e

o r

c o a iv r pr g

fo

Performing battery test with Midtronics -

MCR340V- battery tester

WARNING y in

Before working on the battery, read through the warning and

safety regulations carefully, and comply with them

y

co

b c t ed te

G.

n A a ge sw

⇒ page 2

olk

V

.

o py

C t.

en

Danger of explosion when checking and charging or slave/ jump starting

These batteries must be renewed.

um c o

d

th n a m

– Read general description ⇒ page 18 .

– Perform visual check

⇒ page 6 .

2. Checking battery

19

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Electrical System, General Information - Edition 07.2010

– Open bonnet or cover for other installation location of battery.

– Determine whether battery type is „Standard“ or „AGM“.

– Remove covers from battery positive and negative terminals.

– Use wing covers or other kinds of cover before you use equip‐ ment in engine compartment or interior.

– Close all doors.

Note

♦ Battery temperature must be at least 10 °C.

♦ For additional information, refer to the ⇒ operating manual

INC 940 .

a ut ho r i s ed

Perform test: t e d

u n l e s s

b y V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t

a

WARNING r m it

n o t

p e

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle!

o h le

Danger of explosion when checking and charging or slave/ jump starting rt a r i o

w n

These batteries must be renewed.

ny li a b li i t y

w ith

r s e c e p o t

t e th

c

– Switch off ignition and all electrical consumers.

– Check magic eye on batteries with magic eye ⇒ page 5 .

c

– Switch on tester.

m e m

c

– Connect black terminal „-“ of tester to negative terminal.

r pr iv a t e

o r

Note o g

fo p y in

C o h t.

Ensure test clamps have a good contact!

p y rig y

co

b c t ed

– Select „In vehicle“ or „Outside vehicle“.

– Select „Warranty test“.

te

Pro

Note

Use the print function of the Midtronics -MCR340- tester if the test results are required for handling warranty applications.

– Select battery type „Standard “ or „AGM“.

– Make a note of the DIN value of the battery as shown on the battery sticker. If there is no DIN value on the sticker, make a note of the SAE value.

– Enter DIN value in tester and perform battery test ⇒ operating manual MCR340V .

– If you are using SAE value, access „Miscellaneous“ menu and change from „DIN“ to „SAE“ ⇒ operating manual MCR340V .

G.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

20

Rep. gr.27 - Starter, current supply, CCS

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Electrical System, General Information - Edition 07.2010

Note

Always use DIN value from battery sticker! Otherwise, test result will be falsified.

2.6.3

Assessing test results

Results of battery test:

Battery test results

Battery OK

Good - charge

Use Incharge

Renew battery.

Battery cell defective

Measures

None

Charge battery

⇒ page 55 .

Charge battery

⇒ page 55 .

Renew battery ⇒ Electrical sys‐ tem; Rep. gr. 27 ; Removing and installing battery

Renew battery ⇒ Electrical sys‐ tem; Rep. gr. 27 ; Removing and installing battery

2.6.4

Dealing with problems with Midtronics -

MCR340V- battery tester

Under certain circumstances, the display may show errors or messages according to status.

The most frequent display messages are listed below, together with suggested solutions.

Note

For messages not listed here, please refer to ⇒ operating manual

MCR340V .

Display message

No display

Measures y

V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c nected to battery terminals.

w h o le

, is

n o t

p e r m it t e d

u

– Check battery terminals are tightened according to reg‐ ulations and do not have corrosion.

– Charge battery

⇒ page 55 .

s

a ut ho r i s ed

b

– Check whether terminals of battery tester are firmly con‐ c ep t a ny li a b li i y t

w ith

r s e p c e t th o

t

c e

System noise – Switch off all electrical con‐ sumers.

– Wait until all electrical loads monitored by onboard sup‐ ply control unit have switch‐ ed off.

m e c

– Remove ignition key.

e

o r

c o m a t

– Disconnect any suspect r pr

fo connected to onboard sup‐ ply as standard.

C o h t. rig p y y co

b c t ed te

Pro G.

n A um t.

en

C o rig py y

V ht b sw olk a ge

2. Checking battery

21 o c

d

th n a m

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

Wait a few minutes and test again ⇒ page 19

.

Note

If you have performed test at jump-start point and message does not disappear, perform test directly on battery.

2.7

Current draw test

WARNING

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle!

Danger of explosion when checking and charging or slave/ jump starting s

a ut ho r i s

These batteries must be renewed.

n l e s ed y

V olk sw a ge es n ot g uar ante e

or a c

♦

Note

w h o le

, is

n o t

p e r m it t e d

u

Ensure that the correct charging mode is set on the charger so that the current draw test is not falsified.

♦

♦

VAS 5095 A

VAS 5900

⇒ page 26

⇒ page 30

c ep t a ny li a b li i y t

w ith

r s e p c e t th o

t

c e

♦ VAS 5903

⇒ page 41

To quickly ascertain the state of discharged batteries, the battery current draw test whilst charging helps to determine whether the battery must be replaced or fully recharged.

m m e c o

Note e

o r

c t a iv

For battery tester with printer -VAS 6161- , the current draw test g

fo must always be performed when the test result „Perform current p y h t.

C o p y rig

The current draw test must be carried out when the test result with c te

G.

n A

1 - Starting output sufficient ge

2 - Starting output poor

3 - Starting output very poor

4 - Cannot be tested – charge battery and repeat test.

- and when the tester will not switch on (no LED, no printout)

Depending on the test result

⇒ page 13 with battery tester with

printer -VAS 5097A- , further procedures or tests may be required before making a final decision on the condition of the battery.

Performing a current draw test whilst charging a battery will quick‐ ly establish whether a partly or fully discharged battery

⇒ page 59 can be recharged to return it to a serviceable condi‐

tion.

a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

22

Rep. gr.27 - Starter, current supply, CCS

s

a ut ho

Test requirements r i s ed

b y

V olk sw a ge n AG

.

V olk s w a g en AG do

Electrical System, General Information - Edition 07.2010

e

♦ When charging a battery, battery temperature must be at least

≥ +10 °C.

n

♦ The charger must be capable of outputting a charge current of at least 30 A, as for example with VAS 5095A, VAS 5900, VAS

w h o le

, is

n o t

p e r

5903 m it t e d

u

♦ The battery's current draw must be measured with a current r i o rt a pick-up clamp, e.g. VAS 5051B/7, when charging with battery charger -VAS 5095A- . Battery charger -VAS 5900- and bat‐ tery charger -VAS 5903- display the current draw on the unit.

or a c c ep t a ny li a b li i y t

w ith

r s e p c e t th o

t

c e

– Connect battery to battery charger and start charging se‐ quence.

– Measure charging current of battery after 5 minutes.

c e a m again.

o m

(e.g. > 6.1 A for a 61 Ah battery), fully charge battery and test a iv r pr g

fo

Note p y in battery. Example for Eos: the 50 Ah battery must have a charge current higher than 2.5 A after 5 minutes of starting the charging sequence.

C o t. h

For Eos with two 6V absorbent glass mat batteries, the charge c t ed te

G.

n A a ge sw olk y

V ht b rig py o

C t.

en um c o

d

th n

– Fully charge the battery when the charge current is higher than

10 % of the nominal capacity (observe exception for Eos in above note).

– Perform battery test after allowing battery to rest for two hours

⇒ page 9

.

If the charge current, in amperes, lies below 10 % of the nominal capacity after 5 minutes of starting the charging sequence (5 % for the 2 x 6 volt batteries in Eos) (example for 50 Ah battery <

5A), renew battery. For Guarantee and ex-gratia cases: complete battery test sheet and keep it with the battery.

2.8

Checking no-load voltage of battery on stock and stored vehicles

WARNING

Danger of injury! Observe warning notices and safety regula‐

tions ⇒ page 2 !

Note

♦ The no-load voltage test may only be carried out to assess the condition of the battery on stock and stored vehicles within the framework of prescribed maintenance.

♦ The no-load test serves to determine whether a battery on a stock or stored vehicle requires recharging ⇒ Maintenance tables „Service for stock and stored vehicles“ .

Special tools and workshop equipment required

2. Checking battery

23

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Electrical System, General Information - Edition 07.2010

♦ Hand multimeter -V.A.G 1526 B-

Test conditions

The battery must not have been charged or discharged within the last 2 days.

– Check battery no-load voltage with hand multimeter -V.A.G

1526 B- .

No-load voltage

11.60 V

Charge

0 %

Condition of battery

Discharged, no capacity Heavily discharged

⇒ page 59 .

Measured value

No-load voltage ≥ 12.5 V

No-load voltage < 12.5 V r m it t e d

u n l e s s

n o t

p e is

, o h le r i o rt a

w n

a ut ho r i s ed

b y V olk sw a ge n AG

.

V olk s w a g en AG do

Measure to be performed

No-load voltage OK

Charging battery

⇒ page 25

es n ot g uar ante e

or a c c ep t

a ny li a b li i t y

w ith

r s e c e p o t

t e th

c e m c m

c r o e t

o a iv pr r

fo g in y p o

C t. h rig y p

co y

b c t ed te

Pro G.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

24

Rep. gr.27 - Starter, current supply, CCS

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

3 Charging battery

WARNING

Danger of injury! Observe warning notices and safety regula‐

tions ⇒ page 2 !

a ut ho r i s ed

Caution t e d

u n l e s s

b y

V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t a

To prevent damage to the battery and vehicle, the following should be observed concerning types of battery

,

⇒ page 1

.

o h le

n o t

p e r m it

WARNING r i o rt a

w n

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle!

ny li a i b li t y

w ith

r s e c e p o t

t e th

c

Danger of explosion when checking and charging or slave/ jump starting

These batteries must be renewed.

3.1

o e t a iv

This chapter describes the basic functions of the battery charger g

fo

-VAS 5095 A- . For additional information refer to ⇒ operating instructions for battery charger -VAS 5095 A- .

p

C o h t. rig p y

Note c e m m o r

c

Battery charger -VAS 5095 A-

y co

b c t ed te

Pro G.

n A ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

♦ The effective charging current can not be read on these units.

The charge current must be read externally using a pick-up clamp.

♦ Observe ⇒ operating instructions for battery charger -VAS

5095 A- .

3.1.1

Description of battery charger -VAS

5095 A-

The battery charger -VAS 5095- is suitable for charging all 12V batteries supplied by Volkswagen.

3. Charging battery

25

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Electrical System, General Information - Edition 07.2010

The battery charger charges without peaks in amperage or volt‐ age. This will not adversely effect the onboard electronics. The battery can remain in the vehicle while it is being charged and need not be disconnected.

Battery charger -VAS 5095 A-

1 - ON / OFF switch (0 = charger OFF) t e d

u n l e s s

a ut ho r i s ed

b y

V olk

2 - Charging current indicator (I > 12 A) r m it

n o t

p e

3 - Charging current indicator, battery partially charged > 90 % sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t a

4 - Maintaining charge; lights up green when battery is fully charg‐ ed h is

,

5 - Malfunction indicator

6 - Support mode indicator r i o rt a

w n ny li a i b li t y

w ith

r s e c e p o t

t e th

c

7 - Support mode/normal mode changer-over switch

8 - Charger cable, red terminal „+“, black terminal „-“

9 - Battery type change-over switch (on base of charger unit) c e

3.1.2

tions

Charging battery with battery charger -

VAS 5095 A-

WARNING

⇒ page 2

!

m m

c o

o r t e iv a r pr g

fo y in o p

C t. rig p y y co

b c t ed te

Pro G.

n A ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

Special tools and workshop equipment required

♦ Battery charger -VAS 5095 A-

Caution

Always set battery type 2.4 V/C (volts/battery cell) when charg‐ ing! This applies for all batteries.

Note

The battery must have a temperature of at least 10 °C.

26

Rep. gr.27 - Starter, current supply, CCS

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Electrical System, General Information - Edition 07.2010

WARNING

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle!

Danger of explosion when checking and charging or slave/ jump starting

These batteries must be renewed.

– Switch off ignition and all electrical consumers.

– Check setting for battery type on type of battery switch

⇒ page 25

s

a ut ho r i s ed

b sw es n ot g uar

. Must be set to 2.4 V/C (volts/battery cell).

ante e

or a c – Connect red terminal clamp „+“ of charger unit to positive ter‐ minal on battery.

w h o le

, is

n o t

p e r m it t e d

u

Note

In vehicles with start/stop function and battery monitor control unit

-J367- fitted, black terminal clamp „-“ must be connected to body earth. Connecting it to battery negative terminal will cause start/ stop system to malfunction.

rt a n r i o c ep t

a ny li a b li i y t

w ith

r s e p c e t th o

t

c e

– Connect black terminal clamp „-“ of battery charger to negative terminal.

– Switch on battery charger

⇒ page 25 .

The charging current indicators ⇒ page 26

-2- and -3- light up e c a m m

c

o r e a t r pr

⇒ page 26

– Switch off charging unit in

-4- the charger has switched

⇒ page 25 .

– Remove charger unit terminals from battery terminals.

h t.

C o p y

3.1.3

Charging totally discharged battery with battery charger -VAS 5095 A-

ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n

WARNING

Danger of injury! Observe warning notices and safety regula‐

tions ⇒ page 2 !

The charger unit automatically recognises totally discharged bat‐ teries and initiates a gentle charging procedure with a low charg‐ ing current. The charging current is automatically adapted to suit the charge condition of the battery.

Note

♦

Observe notes in chapter ⇒ page 59

.

♦ Totally discharged batteries in vehicles before registration must be exchanged prior to delivery. Preliminary damage can‐ not be excluded.

♦ The battery voltage must be at least 0.6 V.

3. Charging battery

27

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Electrical System, General Information - Edition 07.2010

WARNING

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle!

Danger of explosion when checking and charging or slave/ jump starting

These batteries must be renewed.

– Charge battery

3.1.4

o t

p e r n l e

Charging battery in support mode with battery charger -VAS 5095A-

General notes:

w h o le

, is

n m it t e d

u

a ut ho r i s ed

b

⇒ page 26 .

The support mode provides the onboard supply with power when the battery is removed or disconnected.

a n

For further information, refer to the ⇒ operating manual VAS

5095A .

y V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t

a ny li a b li i y t

w ith

r s e p c e t th o

t

c e

The support mode is suitable in the following situations:

♦ Support mode of onboard supplies without installed battery

♦ Power conservation when renewing the battery c e a m m o tions r

c

o t e a iv

WARNING

Danger of injury! Observe warning notices and safety regula‐

⇒ page 2

p

C o

!

h t. rig p y

WARNING y

co

b c t ed te

Pro G.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle!

Danger of explosion when checking and charging or slave/ jump starting

These batteries must be renewed.

– Switch off ignition and all electrical consumers.

28

Rep. gr.27 - Starter, current supply, CCS

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Electrical System, General Information - Edition 07.2010

Caution

♦ The terminal polarity protection in operating mode „charg‐ ing totally discharged batteries/support mode“ is not ac‐ tive. Connect battery charger terminal clamps correctly to battery terminals.

♦ It can cause sparks through a short-circuit.

♦ Danger of explosion

♦ Do not press

START / STOP

button when charger unit cables are connected incorrectly. The charger unit may be damaged.

– Remove battery.

n o t

p e r m it t e d

u n l e s s

a ut ho r i s ed

b y

V olk sw a ge n AG

.

V olk s w a g en

♦ Ensure charger terminal clamps are seated securely.

AG do es n ot g uar ante e

or a c c ep t a is

,

Caution r i o rt a

w n o h le

When battery is removed, ensure there is no contact between terminal clamp connected to positive clamp and body earth.

Also ensure there is no contact between battery clamps.

ny li a i b li t y

w ith

r s e c e p o t

t e th

c

– Connect red terminal clamp „+“ to positive terminal of vehicle.

c e

Note m m o r

c e t a

-J367- fitted, black terminal clamp „-“ must be connected to body earth. Connecting it to battery negative terminal will cause start/ stop system to malfunction.

o in p y

C o h t. rig – Connect black terminal clamp „+“ to negative terminal of ve‐ hicle.

b

Pro

– Check setting for battery type on normal/support mode switch

⇒ page 25 . It must be switched on support mode.

c t ed te

– Check polarity of charger unit cables.

– Switch on battery charger.

The battery charger starts with support mode.

End battery support mode:

– Switch off battery charger.

– Disconnect black terminal clamp „-“ of charger unit from neg‐ ative terminal of vehicle.

– Disconnect red terminal clamp „+“ of charger unit from positive terminal of vehicle.

– Pull charger plug out of battery charger.

G.

n A ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

3. Charging battery

29

3.1.5

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

WARNING t e d

u n l e s s

a ut ho r i s ed

Danger of injury! Observe warning notices and safety regula‐ tions

⇒ page 2

!

o h le is

,

WARNING r i o rt a

w n

n o t

p e r m it

b y

Charging battery in maintenance mode with battery charger -VAS 5095 A-

es n ot g uar ante e

or a c c ep t a ny li a i b li t y

w ith

r s e c e p o t

t e th

c

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle!

Danger of explosion when checking and charging or slave/ jump starting e c

These batteries must be renewed.

r

c o m m

o a t e iv charged condition.

pr that the battery is charged correctly and is maintained in fully p y in o

– Proceed as for charging battery ⇒ page 26

h

t. .

p y rig

Note y co

b c t ed te

Pro

♦ When a battery is being charged in maintenance mode and a electrical consumer draws current from the battery, the battery charger -VAS 5095 A- automatically compensates the charge.

♦ The maintenance mode can be continued for an unlimited pe‐ riod.

♦ The battery is always ready for use.

G.

n A ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

3.2

Battery charger -VAS 5900-

WARNING

Danger of injury! Observe warning notices and safety regula‐ tions

⇒ page 2

!

WARNING

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle!

Danger of explosion when checking and charging or slave/ jump starting

These batteries must be renewed.

This chapter describes the basic functions of the battery charger

-VAS 5900- . For additional information refer to ⇒ operating in‐ structions for battery charger -VAS 5900- .

30

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Electrical System, General Information - Edition 07.2010

Note

♦ The effective charging current can be read directly on these charging units.

♦ Observe ⇒ operating instructions for battery charger -VAS

5900- .

3.2.1

Description of battery charger -VAS

5900-

Battery charger -VAS 5900-

1 - Display

w h o le

, is

n o t

p e r

2 - Adjustment button „Up“ it t e

↑ d

u

3 - Adjustment button „Down“

↓

4 -

START / STOP r i o rt a n

5 -

INFO s

a batteries supplied by Volkswagen.

ut ho r i s ed

b y

V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t a ny li a b li i y t

w ith

r s e p c e t th o

t

c e

3.2.2

Charging battery with battery charger -

VAS 5900-

e m m

WARNING

WARNING o

c r

o e t

Danger of injury! Observe warning notices and safety regula‐

tions ⇒ page 2 !

fo g in p y

C o h t. rig p y y co

b c t ed te

Pro

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle!

Danger of explosion when checking and charging or slave/ jump starting

These batteries must be renewed.

G.

n A ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

Special tools and workshop equipment required

♦ Battery charger -VAS 5900-

3. Charging battery

31

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

Note

The battery must have a temperature of at least 10 °C.

– Switch off ignition and all electrical consumers.

– Connect charger plug to battery charger. The last selected type of battery will appear on display.

– Set battery to respective operating mode with

INFO

.

In the display the symbol -1- for „standard charge for wet batter‐ ies“ or symbol -2- for „standard charge for gel/absorbent glass mat batteries“ will appear.

– Set battery capacity (Ah) of battery for charging using respec‐ tive button „Up“

↑

or „Down“

↓

.

– Connect red terminal clamp „+“ to positive terminal on battery.

Note

In vehicles with start/stop function and battery monitor control unit

-J367- fitted, black terminal clamp must be connected to body earth. Connecting it to battery negative terminal will cause start/ stop system to malfunction.

– Connect black terminal clamp „-“ to negative terminal.

The charger unit recognises the voltage required for the connec‐ ted battery (6 V, 12 V or 24 V) and initiates the charging sequence.

At a charge condition of approx. 80 - 85 % the battery charger switches to the „final charge“ mode. The fourth bar appears in display -1-. The battery is ready for use.

r i o rt a n

w h o le

, is

n o t

p e r m it t e d

u n l e s s

a ut ho r i s ed

b y

V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t a ny li a b li i y t

w ith

r s e p c e t th o

t

c e c e m m o r

c

o t e a iv pr r

fo g in p y

C o h t. y rig

32 p y co

Rep. gr.27 - Starter, current supply, CCS

G.

n A ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

At a charge condition of 100 % all bars appear in display.

Note

♦ In the battery type „standard charge“ the parallel use of con‐ sumers while charging is possible. The charging period will be longer.

a ut ho r i s ed

b y V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t

a

♦ The battery charger will switch to maintenance mode after about 1-7 hours, depending on type of battery. To achieve a

100 % charge the battery should remain connected for this period.

n o t

p e r m it t e d

u n l e s s

Possible faults and fault rectification o h le

1 - Displayed battery voltage is not as per nominal voltage: r i o rt a

w n

– Press respective button „Up“ sequence starts.

↑

or „Down“

↓

until charging ny li a b li i t y

w ith

r s e c e p o t

t e th

c

2 - Displayed battery voltage is not as per nominal voltage – charging sequence already started:

– Press

START / STOP

twice.

– Press respective button „Up“ sequence starts again.

m m c ↑

or „Down“

↓

until charging r

c o age is less than 2 V:

Display remains unchanged.

fo

The battery type and ampere hours (Ah) as set is displayed.

C

Ending battery charging sequence:

– Press

START / STOP rig

.

p y

co y

b c t ed olk y

V n A a ge sw te

Pro G.

– Disconnect black terminal clamp „-“ of charger from negative terminal.

– Disconnect red terminal clamp „+“ of charger from positive terminal on battery.

– Pull charger plug out of battery charger.

ht b rig py o

C t.

en um c o

d

th n a m

3.2.3

Charging battery in service mode with battery charger -VAS 5900-

WARNING

Danger of injury! Observe warning notices and safety regula‐

tions ⇒ page 2 !

Caution

The operating mode „service charge“ is not permitted on VW vehicles as the voltage peaks will damage the onboard elec‐ tronics.

If there is a requirement to use „service charge“ the battery must be disconnected from the onboard supply.

3. Charging battery

33

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

WARNING

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle!

Danger of explosion when checking and charging or slave/ jump starting

These batteries must be renewed.

Caution

When charging always set the battery charger to the correct type of battery ⇒ operating instructions for battery charger -

VAS 5900- !

The „service mode“ is suitable for:

♦ Wet batteries where the magic eye allows charging (magic eye black or green)

The operating mode „service charge (SERV)“ is only used on sulphated batteries. The battery is charged at a voltage of

> 14.4 V. This can result in a partial reduction of the sulphated layer. After charging, always check the colour of the magic eye before using the battery

⇒ page 6

.

Special tools and workshop equipment required

♦ Battery charger -VAS 5900y V sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c n l e s s

a ut ho r i s ed

b

w h o le

, is

n o t

p e r m it t e d

u r i o rt a n c ep t

a ny li a b li i y t

w ith

r s e p c e t th o

t

c e

Note

The battery must have a temperature of at least 10 °C.

m e c m r

c o e

o

– Connect charger plug to battery charger. The last selected pr r g

fo in p y

C o h t. rig

⇒ page 31

.

p y y

co

b c t ed te

Pro G.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

34

Rep. gr.27 - Starter, current supply, CCS

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

– Set battery to respective battery type with

INFO

.

In the display, the symbol -1- for „Service charge for wet batteries“ or symbol -2- for „Service charge for gel/absorbent glass mat bat‐ teries“ will appear.

– Set battery capacity (Ah) of battery for charging using respec‐ tive button „Up“

↑

or „Down“

↓

.

– Connect red terminal clamp „+“ to positive terminal on battery.

r i o rt a n l e s r i s ed

b y

V olk sw es n ot g uar earth. Connecting it to battery negative terminal will cause start/ stop system to malfunction.

w h o

Note n a ge n AG

.

V olk s w a g en AG do

In vehicles with start/stop function and battery monitor control unit

-J367- fitted, black terminal clamp „-“ must be connected to body s

a ut ho c ep t a ny li a b

The charger unit recognises the voltage required for the connec‐ ted battery (6 V, 12 V or 24 V) and initiates the charging sequence.

le

, is

n m it t e d

u

– Connect black terminal clamp „-“ to negative terminal.

o t

p e r

At a charge condition of approx. 80 - 85 % of the battery voltage, the battery charger switches to the „final charge“ mode. The fourth bar appears in display -1-. The battery is ready for use.

ante e

or a c li i y t

w ith

r s e p c e t th o

t

c e

Note c

The success of the „service charge“ depends on the severity of the sulphation of the battery

Possible faults and fault rectification:

c o m m e

1 - Displayed battery voltage is not as per nominal voltage: a t e

o r

– Press respective button „Up“

↑

or „Down“

↓

until charging

fo t.

in

2 - Displayed battery voltage is not as per nominal voltage – charging sequence already started:

– Press p y co

START / STOP c t ed n A sw olk

V y ht b

C o py

G.

a ge

– Press respective button „Up“

↑

or „Down“

↓

until charging sequence starts.

twice.

Pro en

3 - Battery charger does not detect a battery, when battery volt‐ age is less than 2 V:

Display remains unchanged.

The operating mode and ampere hours (Ah) as set are displayed.

Ending battery charging sequence:

– Press

START / STOP

.

– Disconnect black terminal clamp „-“ of charger from negative terminal.

– Disconnect red terminal clamp „+“ of charger from positive terminal on battery.

– Pull charger plug out of battery charger.

um c o

d

th n a m

3. Charging battery

35

3.2.4

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

Charging totally discharged batteries with battery charger -VAS 5900-

WARNING

Danger of injury! Observe warning notices and safety regula‐ tions

⇒ page 2

!

WARNING

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle!

Danger of explosion when checking and charging or slave/ jump starting

These batteries must be renewed.

r m it t e d

u n l e s s

a ut ho r i s ed

b y

V olk sw a

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t a

Caution

♦ The terminal polarity protection in operating mode „charg‐ ing totally discharged batteries/support mode“ is not ac‐ tive. Connect battery charger terminal clamps correctly to battery terminals.

r i o rt a

w n o h le

n o t

p e

♦ When charging always set the battery charger to the cor‐ rect type of battery ⇒ operating instructions for battery charger -VAS 5900- !

ny li a i b li t y

w ith

r s e c e p o t

t e th

c

♦ Totally discharged battery is not recognised by battery charger

⇒ page 59 .

♦ Do not press damaged.

START / STOP m c

button when charger unit iv a t e

o r

c o m e cables are connected incorrectly. The charger unit may be

Batteries with a voltage of less than 2 volts will not be recognised y in p

C o t. rig p y

♦ Battery charger -VAS 5900y co

b c t ed te

Pro G.

n A ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

36

Rep. gr.27 - Starter, current supply, CCS

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

Note

♦

Observe notes in chapter ⇒ page 59

.

♦ Totally discharged batteries in vehicles before registration must be exchanged prior to delivery. Preliminary damage can‐ not be excluded.

♦ The battery must have a temperature of at least 10 °C.

– Switch off ignition and all electrical consumers.

– Connect charger plug to battery charger. The last selected operating mode will appear on display

⇒ page 31 .

r i o rt a n

w h o le

, is

n o t

p e r m it t e d

u n l e s s

a ut ho r i s ed

b y

V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t a ny li a b li i y t

w ith

r s e p c e t th o

t

c e e m c m

c r o e t

o a iv pr r

fo g in y p o

C t. h rig y p y co

b c t ed te

Pro G.

n A ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

3. Charging battery

37

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

– Set battery to respective battery type with

INFO

.

In the display, the symbol -1- for „Service charge for wet batteries“ or symbol -2- for „Service charge for gel/absorbent glass mat bat‐ teries“ will appear.

– Set battery capacity (Ah) of battery for charging using respec‐ tive button „Up“

↑

or „Down“

↓

.

– Connect red terminal clamp „+“ to positive terminal on battery.

Note

In vehicles with start/stop function and battery monitor control unit

-J367- fitted, black terminal clamp must be connected to body earth. Connecting it to battery negative terminal will cause start/ stop system to malfunction.

– Connect black terminal clamp „-“ to negative terminal.

– Press

START / STOP

for approx. 5 seconds. The menu

„charging totally discharged batteries/support mode“ will be activated.

– Press respective button „Up“

↑

or „Down“

↓

to set respective battery voltage (6 V, 12 V or 24 V).

Note

If a button is not pressed within 5 seconds the charger will return to the main menu (select operating mode).

– Confirm the selected battery voltage with

Then follows the enquiry for "is charger cable terminal polarity correct".

a ut ho r i s ed

START / STOP

b y

V olk sw a ge s

.

w a

– Check polarity of charger unit cables.

e d

u n l e

– Confirm polarity of charger unit cables with r m it t

START / STOP

.

g en AG do es n ot g uar ante e

or a c c ep t a

Charger will start charging sequence for totally discharged bat‐ tery.

n o t

p e

Ending battery charging sequence:

– Press o h le

START / STOP

.

– Disconnect black terminal clamp „-“ of charger from negative terminal.

r i o rt a

w n ny li a i b li t y

w ith

r s e c e p o t

t e th

c

– Disconnect red terminal clamp „+“ of charger from positive terminal on battery.

– Pull charger plug out of battery charger.

3.2.5

General notes: c

Charging battery in support mode with battery charger -VAS 5900-

o a t e iv

The support mode provides the onboard supply with power when y in p

C o t. For further information, refer to the ⇒ operating manual VAS

5900 .

p y y co

b c t ed te

G.

n A ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

38

Rep. gr.27 - Starter, current supply, CCS

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

♦ Support mode of onboard supplies without installed battery

♦ Power conservation when renewing the battery

♦ Ancillaries test without battery

WARNING

Danger of injury! Observe warning notices and safety regula‐

tions ⇒ page 2 !

WARNING

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle!

Danger of explosion when checking and charging or slave/ jump starting

These batteries must be renewed.

Caution

, is

n o t

p e

a ut ho r i s ed

b y V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t

a

– Switch off ignition and all electrical consumers.

r m it t e d

u n l e s s o h le

♦ The terminal polarity protection in operating mode „charg‐ ing totally discharged batteries/support mode“ is not ac‐ r i o rt a

w n tive. Connect battery charger terminal clamps correctly to battery terminals.

ny li a b li i t y

w ith

r s e c e p o t

t e th

c

♦ It can cause sparks through a short-circuit.

♦ Danger of explosion

♦ Ensure charger terminal clamps are seated securely.

♦ Do not press damaged.

c m t e

o r

c o m e START / STOP

button when charger unit cables are connected incorrectly. The charger unit may be a iv

– Remove battery.

r pr

Caution

fo g

– Connect charger plug to battery charger. The last selected operating mode will appear on display p y y

co

b c t ed te

⇒ page 31

Pro

.

G.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

When battery is removed, ensure there is no contact between terminal clamp connected to positive clamp and body earth.

Also ensure there is no contact between battery clamps.

– Connect red terminal clamp „+“ to positive terminal of vehicle.

Note

In vehicles with start/stop function and battery monitor control unit

-J367- fitted, black terminal clamp must be connected to body earth. Connecting it to battery negative terminal will cause start/ stop system to malfunction.

3. Charging battery

39

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

– Connect black terminal clamp „+“ to negative terminal of ve‐ hicle.

– Press

START / STOP

for approx. 5 seconds. The menu

„charging totally discharged batteries/support mode“ will be activated.

– Press respective button „Up“

↑

or „Down“

↓

to set respective battery voltage (6 V, 12 V or 24 V).

Note

If a button is not pressed within 5 seconds the charger will return to the main menu (select operating mode).

– Confirm the selected battery voltage with

START / STOP

.

Then follows the enquiry for "is charger cable terminal polarity correct".

– Check polarity of charger unit cables.

– Confirm polarity of charger unit cables with

START / STOP

.

The battery charger starts with support mode.

End battery support mode:

– Press

START / STOP

.

– Disconnect black terminal clamp „-“ of charger unit from neg‐ ative terminal of vehicle.

– Disconnect red terminal clamp „+“ of charger unit from positive terminal of vehicle.

r i o rt a

w n

– Pull charger plug out of battery charger.

3.2.6

t e d

u n l e s s

Note

a ut ho r i s ed

b y

V olk sw a ge n AG AG do

Charging battery in maintenance mode with battery charger -VAS 5900-

ante e

or a c c ep t a o h le

♦ When a battery is being charged in the maintenance mode and is

,

n o t

p e r m it an electrical consumer draws current from the battery, the battery charger -VAS 5900- automatically compensates the charge.

♦ The maintenance mode can be continued for an unlimited pe‐ riod.

♦ The battery is always ready for use.

ny li a i b li t y

w ith

r s e c e p o t

t e th

c

♦ Observe battery manufacture's maintenance instructions!

e m c

WARNING m o

Danger of injury! Observe warning notices and safety regula‐ r

c iv a t e

o

⇒ page 2

!

r pr g

fo in p y

C o h t. rig p y y co

b c t ed te

Pro G.

n A ge a sw olk

V y ht b rig o py

C t.

en um c o

d

th n a m

40

Rep. gr.27 - Starter, current supply, CCS

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

WARNING

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle!

Danger of explosion when checking and charging or slave/ jump starting

These batteries must be renewed.

When the battery is fully charged the battery charger -VAS 5900switches to maintenance mode.

– Proceed as for charging battery

At a charge condition of 100 % all bars appear in display.

a ut ho r i s ed r m it t e d

u n l e s s

n o t

p e

⇒ page 31

.

b y V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t

a is

, o h le r i o rt a

w n ny li a b li i t y

w ith

r s e c e p o t

t e th

c

3.3

Battery charger -VAS 5903-

WARNING

tions ⇒ page 2 !

c

Danger of injury! Observe warning notices and safety regula‐

c o m m e

o r t e a iv r pr

WARNING g

fo in y p o

Danger of explosion when checking and charging or slave/ jump starting

C

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle!

c te

These batteries must be renewed.

G.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

This chapter describes the basic functions of the battery charger

-VAS 5903- . For additional information refer to ⇒ operating in‐ structions for battery charger -VAS 5903- .

Note

Observe ⇒ operating instructions for battery charger -VAS 5903- .

3. Charging battery

41

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

3.3.1

Description of battery charger -VAS

5903-

The battery charger -VAS 5903- is suitable for charging all 12V batteries supplied by Volkswagen.

Battery charger -VAS 5903-

1 - Display

2 - Adjustment button „Up“

↑

3 - Adjustment button „Down“

↓

4 -

START / STOP

5 -

INFO

3.3.2

Charging battery with battery charger -

VAS 5903-

WARNING

Danger of injury! Observe warning notices and safety regula‐ tions

⇒ page 2

n l e s

!

s

a ut ho r i s ed

b y

V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c a o t

p e r

Batteries where the magic eye is colourless or light yellow must

w h o le

, is

n m it t e d

u

WARNING not be checked or charged. Do not slave/jump start the vehicle!

Danger of explosion when checking and charging or slave/ jump starting r i

These batteries must be renewed.

c ep t a ny li a b li i y t

w ith

r s e p c e t th o

t

c e

Special tools and workshop equipment required

♦ Battery charger -VAS 5903e m c m

c r o e t

o a iv pr r

fo g in y p o

C t. h rig y p y co

b c t ed te

Pro G.

n A ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

Note

The battery must have a temperature of at least 10 °C.

– Switch off ignition and all electrical consumers.

– Connect charger plug to battery charger. The last selected operating mode will appear on display

⇒ page 42

.

42

Rep. gr.27 - Starter, current supply, CCS

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

– Set battery to respective operating mode with

INFO

.

In the display the symbol -1- for „standard charge for wet batter‐ ies“ or symbol -2- for „standard charge for gel/absorbent glass mat batteries“ will appear.

– Set battery capacity (Ah) of battery for charging using respec‐ tive button „Up“

↑

or „Down“

↓

.

– Connect red terminal clamp „+“ to positive terminal on battery.

Note

In vehicles with start/stop function and battery monitor control unit

-J367- fitted, black terminal clamp must be connected to body earth. Connecting it to battery negative terminal will cause start/ stop system to malfunction.

– Connect black terminal clamp „-“ to negative terminal.

The charger unit recognises the voltage required for the connec‐ ted battery (6 V, 12 V or 24 V) and initiates the charging sequence.

At a charge condition of approx. 80 - 85 % the battery charger switches to the „final charge“ mode. The fourth bar appears in display -1-. The battery is ready for use.

r i o rt a

w n o h le is

,

n o t

p e r m it t e d

u n l e s s

a ut ho r i s ed

b y

V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t a ny li a i b li t y

w ith

r s e c e p o t

t e th

c e m c m

c r o e t

o a iv pr r

fo g in y p o

C t. h rig y p y co

b c t ed te

Pro G.

n A ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

3. Charging battery

43

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

At a charge condition of 100 % all bars appear in display.

Note

♦ In the battery type „standard charge“ the parallel use of con‐ sumers while charging is possible. The charging period will be longer.

♦ The battery charger will switch to maintenance mode after about 1-7 hours, depending on type of battery. To achieve a

100 % charge the battery should remain connected for this period.

Possible faults and fault rectification:

1 - Displayed battery voltage is not as per nominal voltage:

– Press respective button „Up“

↑

or „Down“

↓

until charging sequence starts.

2 - Displayed battery voltage is not as per nominal voltage charging sequence already started:

– Press

START / STOP

twice.

– Press respective button „Up“

↑

or „Down“

↓

until charging sequence starts again.

3 - Battery charger does not detect a battery, when battery volt‐ age is less than 2 V:

Display remains unchanged.

The battery type and ampere hours (Ah) as set is displayed.

Ending battery charging sequence:

a ut ho r i s ed

– Press

START / STOP

.

t e d

u n l e s s

– Disconnect black terminal clamp „-“ of charger from negative terminal.

– Disconnect red terminal clamp „+“ of charger from positive terminal on battery.

is

,

– Pull charger plug out of battery charger.

3.3.3

r i o rt a

w n o h le

n o t

p e r m it

Charging battery in refresh charge

b y

V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t a

mode with battery charger -VAS 5903-

ny li a i b li t y

w ith

r s e c e p o t

t e th

c

WARNING

Danger of injury! Observe warning notices and safety regula‐ tions

⇒ page 2

!

m m e c o r

c

o a t e iv

WARNING pr r

fo g in y o t. h

Danger of explosion when checking and charging or slave/ jump starting p y rig

These batteries must be renewed.

y co

b c t ed te

Pro G.

n A ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

44

Rep. gr.27 - Starter, current supply, CCS

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

The operating mode „refresh charge“ is not permitted on VW tronics.

Caution s

a ut ho r i s ed

b

If there is a requirement to use „refresh charge“ mode the bat‐ tery must be disconnected from the onboard supply.

y

V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c vehicles as the voltage peaks will damage the onboard elec‐

w h o le

, is

n o t

p e r m it t e d

u n l e s

Caution

When charging always set the battery charger to the correct type of battery ⇒ operating instructions for battery charger -

VAS 5903- !

r i o rt a n c ep t a ny li a b li i y t

w ith

r s e p c e t th o

t

c e

The „refresh charge“ mode is suitable for:

♦ Wet batteries, where distilled water can be replenished.

m e c

Do not use operating mode „refresh charge“ with maintenancefree wet batteries.

o r

c o m a t e iv pr

The „refresh charge (refr)“ operating mode is only used on sus‐ in pect defective batteries (e.g. sulphation). The battery will be charged to maximum specific gravity and the plates will be reac‐ tivated (dissipation of sulphur layer).

fo

Special tools and workshop equipment required rig p y y co

b c t ed te

Pro

♦ Battery charger -VAS 5900-

G.

n A ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

Note

The battery must have a temperature of at least 10 °C.

– Switch off ignition and all electrical consumers.

– Connect charger plug to battery charger. The last selected operating mode will appear on display

⇒ page 42 .

3. Charging battery

45

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Electrical System, General Information - Edition 07.2010

– Set battery to respective operating mode with

INFO

.

In the display the symbol -1- for „refresh charge for wet batteries“ or symbol -2- for „refresh charge for gel/absorbent glass mat bat‐ teries“ will appear.

– Set battery capacity (Ah) of battery for charging using respec‐ tive button „Up“

↑

or „Down“

↓

.

– Connect red terminal clamp „+“ to positive terminal on battery.

Note stop system to malfunction.

w h o le

, is

n o t

p e r m it t e d

u

– Connect black terminal clamp „-“ to negative terminal.

n l e s s

a ut ho r i s ed

b

-J367- fitted, black terminal clamp must be connected to body earth. Connecting it to battery negative terminal will cause start/

The charger unit recognises the voltage required for the connec‐ ted battery (6 V, 12 V or 24 V) and initiates the charging sequence.

rt a n r i o

At a charge condition of approx. 80 - 85 % of the battery voltage, the battery charger switches to the „final charge“ mode. The fourth bar appears in display -1-. The battery is ready for use.

y

V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t a ny li a b li i y t

w ith

r s e p c e t th o

t

c e

Note c e m

The success of the „refresh charge“ depends on the severity of the sulphation of the battery.

c

o t e iv a pr Possible faults and fault rectification: r

fo g

1 - Displayed battery voltage is not as per nominal voltage: p y in

C o

– Press respective button „Up“

↑

or „Down“

↓

until charging sequence starts.

t.

2 - Displayed battery voltage is not as per nominal voltage – charging sequence already started:

– Press

START / STOP

twice.

h

– Press respective button „Up“

↑

or „Down“

↓

until charging sequence starts.

3 - Battery charger does not detect a battery, when battery volt‐ age is less than 2 V:

Display remains unchanged.

The operating mode and ampere hours (Ah) as set are displayed.

Ending battery charging sequence:

– Press

START / STOP

.

– Disconnect black terminal clamp „-“ of charger from negative terminal.

– Disconnect red terminal clamp „+“ of charger from positive terminal on battery.

– Pull charger plug out of battery charger.

rig y p y co

b c t ed te

Pro G.

n A ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

46

Rep. gr.27 - Starter, current supply, CCS

3.3.4

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

Charging totally discharged battery with battery charger -VAS 5903-

WARNING

Danger of injury! Observe warning notices and safety regula‐

tions ⇒ page 2 !

WARNING

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle!

Danger of explosion when checking and charging or slave/ jump starting

These batteries must be renewed.

n l e s s

a ut ho r i s ed

b y

V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c

Caution tive. Connect battery charger terminal clamps correctly to battery terminals.

♦ When charging always set the battery charger to the cor‐ rect type of battery ⇒ operating instructions for battery charger -VAS 5903- !

r i o rt a n

w h o le

, is

n o t

p e r m it t e d

u

♦ The terminal polarity protection in operating mode „charg‐ ing totally discharged batteries/support mode“ is not ac‐ c ep t a ny li a b li i y t

w ith

r s e p c e t th o

t

c e

♦ Totally discharged battery is not recognised by battery

charger ⇒ page 59

.

♦ Do not press

START / STOP cables are connected incorrectly. The charger unit may be damaged.

m m e o

button when charger unit r

c

o t e

Batteries with a voltage of less than 2 volts will not be recognised automatically by battery charger -VAS 5903- .

g

fo

♦ Battery charger -VAS 5903in p y

C o h t. p y rig y co

b c t ed te

Pro G.

n A ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

3. Charging battery

47

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Electrical System, General Information - Edition 07.2010

Note

♦ Observe notes in chapter

⇒ page 59 .

♦ Totally discharged batteries in vehicles before registration must be exchanged prior to delivery. Preliminary damage can‐ not be excluded.

♦ The battery must have a temperature of at least 10 °C.

– Switch off ignition and all electrical consumers.

y

V olk sw a ge

.

V olk s w a g en AG do

– Connect charger plug to battery charger. The last selected operating mode will appear on display

w h o le

, is

n o t

p e r m it t e d

u n l e s s

a ut ho

⇒ page 42

.

es n ot g uar ante e

or a c r i o rt a n c ep t a ny li a b li i y t

w ith

r s e p c e t th o

t

c e e m c m

c r o e t

o a iv pr r

fo g in y p o

C t. h rig y p y co

b c t ed te

Pro G.

n A ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

48

Rep. gr.27 - Starter, current supply, CCS

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

– Set battery to respective operating mode with

INFO

.

In the display, the symbol -1- for „Service charge for wet batteries“ or symbol -2- for „Service charge for gel/absorbent glass mat bat‐ teries“ will appear.

– Set battery capacity (Ah) of battery for charging using respec‐ tive button „Up“

↑

or „Down“

↓

.

– Connect red terminal clamp „+“ to positive terminal on battery.

Note

In vehicles with start/stop function and battery monitor control unit

-J367- fitted, black terminal clamp must be connected to body earth. Connecting it to battery negative terminal will cause start/ stop system to malfunction.

– Connect black terminal clamp „-“ to negative terminal.

– Press

START / STOP

for approx. 5 seconds. The menu

„charging totally discharged batteries/support mode“ will be activated.

– Press respective button „Up“

↑

or „Down“

↓

to set respective battery voltage (6 V, 12 V or 24 V).

Note s

a ut ho r i s ed

b y V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c correct".

a n r i

w h o le

,

– Check polarity of charger unit cables.

n l e s

If a button is not pressed within 5 seconds the charger will return to the main menu (select operating mode).

is

n o t

p e

START / STOP

.

Then follows the enquiry for "is charger cable terminal polarity

– Confirm polarity of charger unit cables with

START / STOP

.

c ep t

a ny li a b li i y t

w ith

r s e p c e t th o

t

c e

Charger will start charging sequence for totally discharged bat‐ tery.

Ending battery charging sequence: c

– Press

START / STOP

.

e m terminal.

m

– Disconnect black terminal clamp „-“ of charger from negative t e

o r

c o a iv

– Disconnect red terminal clamp „+“ of charger from positive terminal on battery.

– Pull charger plug out of battery charger.

g in p y

C o h t. rig p y

3.3.5

Charging battery in support mode with battery charger -VAS 5903-

y

co

b c t ed te

Pro

General notes:

The support mode provides the onboard supply with power when the battery is removed or disconnected.

For further information, refer to the ⇒ operating manual VAS

5903 .

The support mode is suitable in the following situations:

G.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

3. Charging battery

49

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

♦ Support mode of onboard supplies without installed battery

♦ Power conservation when renewing the battery

♦ Ancillaries test without battery

WARNING

Danger of injury! Observe warning notices and safety regula‐ tions

⇒ page 2

!

WARNING

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle!

Danger of explosion when checking and charging or slave/ jump starting

a ut ho r i s ed

These batteries must be renewed.

t e d

u n l e s s

b y V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t

a

– Switch off ignition and all electrical consumers.

r m it

n o t

p e

Caution o h le is

,

♦ The terminal polarity protection in operating mode „charg‐ ing totally discharged batteries/support mode“ is not ac‐ a r i o rt

w tive. Connect battery charger terminal clamps correctly to battery terminals.

♦ It can cause sparks through a short-circuit.

ny li a b li i t y

w ith

r s e c e p o t

t e th

c

♦ Danger of explosion

♦ Ensure charger terminal clamps are seated securely.

♦ Do not press

START / STOP

button when charger unit m damaged.

o r

c o m t e a

– Remove battery.

fo

– Connect charger plug to battery charger. The last selected

Caution

C t. rig p y y

co

b c t ed te

Pro

⇒ page 31

G.

.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

When battery is removed, ensure there is no contact between terminal clamp connected to positive clamp and body earth.

Also ensure there is no contact between battery clamps.

– Connect red terminal clamp „+“ to positive terminal of vehicle.

Note

In vehicles with start/stop function and battery monitor control unit

-J367- fitted, black terminal clamp must be connected to body earth. Connecting it to battery negative terminal will cause start/ stop system to malfunction.

50

Rep. gr.27 - Starter, current supply, CCS

– Connect black terminal clamp „+“ to negative terminal of ve‐ hicle.

n l e s

– Press

w h o

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

s

a ut ho r i s ed

b

START / STOP y V

– Press respective button „Up“ olk sw a ge n AG

.

V olk s w a g en AG do

Electrical System, General Information - Edition 07.2010

„charging totally discharged batteries/support mode“ will be activated.

Note r i o rt a n le

, is

n o t

p e r m it t e d

u

for approx. 5 seconds. The menu

↑

or „Down“ battery voltage (6 V, 12 V or 24 V).

↓

to set respective e

or a c c ep t

a ny li a b li i y t

w ith

r s e p c e t th o

t

c e

If a button is not pressed within 5 seconds the charger will return to the main menu (select operating mode).

– Confirm the selected battery voltage with e c

START / STOP

.

Then follows the enquiry for "is charger cable terminal polarity correct".

o r

c o m m t e

– Check polarity of charger unit cables.

r pr

– Confirm polarity of charger unit cables with y in

START / STOP

.

The battery charger starts with support mode.

h t.

C o p

End battery support mode:

– Press

START / STOP

.

p y rig

co y

b c t ed te

Pro G.

n A ge a sw olk

– Disconnect black terminal clamp „-“ of charger unit from neg‐ ative terminal of vehicle.

– Disconnect red terminal clamp „+“ of charger unit from positive terminal of vehicle.

– Pull charger plug out of battery charger.

3.3.6

Charging battery in maintenance mode with battery charger -VAS 5903-

y

V ht b rig py o

C t.

en um c o

d

th n a m

Note

♦ When a battery is being charged in the maintenance mode and an electrical consumer draws current from the battery, the battery charger -VAS 5903- automatically compensates the charge.

♦ The maintenance mode can be continued for an unlimited pe‐ riod.

♦ The battery is always ready for use.

♦ Observe battery manufacture's maintenance instructions!

WARNING

Danger of injury! Observe warning notices and safety regula‐

tions ⇒ page 2 !

3. Charging battery

51

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Electrical System, General Information - Edition 07.2010

WARNING

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle!

Danger of explosion when checking and charging or slave/ jump starting

These batteries must be renewed.

When the battery is fully charged the battery charger -VAS 5903switches to maintenance mode.

– Proceed as for charging battery ⇒ page 42 .

At a charge condition of 100 % all bars appear in display.

r i o rt a

w n o h le is

,

n o t

p e r m it t e d

u n l e s s

a ut ho r i s ed

b y

V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t a ny li a i b li t y

w ith

r s e c e p o t

t e th

c c e m m o r

c

o t e a iv pr r

fo g y in o p

C t. h rig p y y co

b

52 c t ed te

Rep. gr.27 - Starter, current supply, CCS

Pro G.

n A ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

3.4

Battery charger -VAS 5906-

3.4.1

General description

Battery charger - VAS 5906-

WARNING

Danger of injury! Observe warning notices and safety regula‐

tions ⇒ page 2 !

WARNING t e d

u n l e s s

a ut ho r i s ed

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle!

r m it

b y V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t

a

Danger of explosion when checking and charging or slave/ jump starting o h le is

These batteries must be renewed.

r i o rt a

w n

Battery charger -VAS 5906- has been specially developed for charging in vehicle onboard supply during vehicle presentation.

ny li a b li i t y

w ith

r s e c e p o t

t e th

c

It has an automatic charging characteristic for starter batteries, 3

- 300 AH.

The maximum charging voltage 14.4 V is not exceeded. All elec‐ trical loads are supported by up to 30 A by the trickle charging.

e c

For sustained operation, battery charger -VAS 5906- changes to o m m trickle charging once battery is fully charged.

r

c

Tester starts fully automatically and does not require any settings.

iv a t e

o pr

For further information, refer to the ⇒ operating manual VAS

5906 .

3.4.2

p

C o h t. rig y

Charging battery with battery charger -

VAS 5906-

c t ed te

Pro G.

n A ge a sw olk y

V ht b rig

C o py t.

en um c o

d

th n a m

WARNING

Danger of injury! Observe warning notices and safety regula‐

tions ⇒ page 2 !

WARNING

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle!

Danger of explosion when checking and charging or slave/ jump starting

These batteries must be renewed.

3. Charging battery

53

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Electrical System, General Information - Edition 07.2010

Overview of operating panel:

1 - Charge condition display 25 %.

2 - Charge condition display 50 %.

3 - Charge condition display 75 %.

4 - Charge condition display 100 %.

5 - Display ready

6 - Start/stop and Setup buttons for interrupting and resuming charging process. Entry to Setup menu and selection of characteristic type (press for 10 s).

7 - Malfunction display.

– Place charger in engine compartment or under vehicle.

– Connect mains cable to charger and plug it into mains.

Charger is in no-load operation - ready light is on.

WARNING

Danger of injury! Observe warning notices and safety regula‐ tions

⇒ page 2

!

– Switch off ignition.

– Connect red charging cable to positive terminal „+“ on battery.

Note

In vehicles with start/stop function and battery monitor control unit

-J367- fitted, black terminal clamp must be connected to body earth. Connecting it to battery negative terminal will cause start/ stop system to malfunction.

– Connect black charging cable to negative terminal „-“ on bat‐ tery.

Charging starts after about 2 seconds.

a ut ho r i s ed

b y V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t

a

Number of LEDs lit indicates charge condition of battery. Battery has been charged up once all lights are lit.

n o t

p e r m it t e d

u n l e s s

When battery is fully charged, battery charger -VAS 5906- auto‐ matically switches over to trickle charging.

Caution r i o rt a

w n ny li a b li i t y

w ith

r s e c e p o t

t e th

c

Danger of sparking if charging terminals are removed too soon.

Terminate charging by pressing start/stop button.

– Press start/stop button to terminate charging.

e c

– Disconnect black charging cable from negative terminal „-“ on battery.

r

c o m m

– Disconnect red charging cable from positive terminal „+“ on battery.

r pr iv a t e

o g

fo in p y

C o h t. rig p y y

co

b c t ed te

Pro

54

Rep. gr.27 - Starter, current supply, CCS

G.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

3.5

Midtronics -INC 940- battery charger on‐ ly for USA/Canada

Warning and safety regulations ⇒ page 2

General description

⇒ page 55

Charge battery

⇒ page 56

r m it t e d

u

.

b y

V olk sw a ge n AG

.

V olk s w a g en AG do es

Dealing with problems with Midtronics -INC 940- battery tester

⇒ page 58

3.5.1

n l e s s

a ut ho

General description of Midtronics -INC

940- battery tester

Batteries in VW vehicles are only allowed to be charged with bat‐ tery chargers approved by VW. In the USA/Canada, it is permitted for the Midtronics -INC 940- battery charger to be used.

o h le

Midtronics -INC 940- battery charger combines battery charging with a charge condition checks and a battery test.

o

The following charging and analysis procedures apply to all bat‐ teries, all battery installation locations (engine compartment or luggage compartment) and battery application purposes (starter battery or second/convenience battery).

n ot g uar ante e

or a c c ep t a ny li a i b li t y

w ith

r s e c e p o t

t e th

c

Always comply with the safety regulations, the regulations for setting up the battery charger, the display menu/display buttons,

LEDs and the operating procedures described in the ⇒ operating manual INC 940 .

m m e c

Read through ⇒ operating manual INC 940 carefully.

t e

o r

c o

Refer to ⇒ Self-study programme No. ; Vehicle batteries for more information.

WARNING r g

fo in p y

C o h t. rig

Danger of injury! Observe warning notices and safety regula‐

tions ⇒ page 2 !

p y

co te n A G.

ge a

No naked flames, sparking or smoking in the vicinity of batter‐ ies.

Battery charger must be switched off before cables are con‐ nected or disconnected.

Do not remove cell plugs during charging.

Overcharging sulphated batteries can lead to explosions.

Do not store precision tools in rooms where batteries are charged, because corrosion can ensue due to chemical reac‐ tions.

sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

WARNING

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle!

Danger of explosion when checking and charging or slave/ jump starting

These batteries must be renewed.

3. Charging battery

55

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Electrical System, General Information - Edition 07.2010

3.5.2

Charging battery

Prerequisites:

WARNING

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle!

Danger of explosion when checking and charging or slave/ jump starting

These batteries must be renewed.

INC 940 initial setup performed (dealership number, date/time) ⇒ operating manual INC 940 .

– Check general information ⇒ page 55

.

– Open bonnet or cover for other installation location of battery.

– Perform visual check of battery

– Determine whether battery type is „Standard“ (wet battery) or

„AGM“ (absorbent glass mat battery).

a ut ho r i s ed

– Close all vehicle doors.

t e d

u n l e s s

b y

V

V olk

⇒ page 6

s w

.

a g en AG do es n ot g uar ante e

or a c c ep t a

Note

n o t

p e r m it

♦ Battery temperature must be at least 10 °C.

♦ For additional information, refer to the ⇒ operating manual

INC 940 .

rt a r i o

w n o h le

Perform charging procedure: ny li a i b li t y

w ith

r s e c e p o t

t e th

c

– Switch off all electrical consumers.

– Switch off ignition and remove ignition key.

– Connect red terminal clamp „+“ of charger unit to positive ter‐ minal on battery.

m e c m o

Note o r

c a t e iv

In vehicles with start/stop function and battery monitor control unit in o t. h p y rig y co

V y ht b

b

G.

n A a ge sw olk

– Connect black terminal clamp „-“ of battery charger to negative terminal.

te rig

– Connect Midtronics -INC 940- battery charger to an earthed socket.

– Set „ON/OFF“ switch of Midtronics -INC 940- battery charger to „ON“.

– Select „Automatic“ or „Manual“ charging mode.

– Select test „In vehicle“ or „Outside vehicle“.

– Select battery type „Standard “ or „AGM“ (absorbent glass mat).

py o

C t.

en um c o

d

th n a m

56

Rep. gr.27 - Starter, current supply, CCS

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

– Select test type „Warranty“ or „Miscellaneous“. Note additional details (depending on type of test).

Note

♦ For additional information, refer to the ⇒ operating manual

INC 940 .

♦ If necessary, make a note of menu items required for „War‐ ranty“ test type ⇒ Warranty service circular .

Midtronics -INC 940- battery charger tests battery and starts charging procedure. Display then shows one of three results, as well as approximate charging time.

Result:

Battery OK

Charging required

Measures:

Battery can be returned to op‐ eration.

♦ Test found low charge level.

♦ Charging starts and approx‐ imate charging duration is displayed.

♦ Achieved cold-start per‐ formance and remaining charging time are displayed, and are updated regularly.

r i o rt a n

w h o le

, is

n o t

p e r m it t e d

Renew battery.

u n l e s s

a ut ho r i s ed

b

Note y V olk sw a ge n AG

.

V olk s w

Battery defective. Charging procedure is interrupted. Re‐ new battery.

ot g uar ante e

or a c plays other than those listed above, please refer to

⇒ page 58

.

WARNING c ep t

a ny li a b

Stop charging if battery is liberating a lot of gas. Press „Stop“ button on front.

li i y t

w ith

r s e p c e t th o

t

c e e m c m

c r o e t

o a

When charging and testing procedure has finished, Midtronics -

INC 940- battery charger displays „Battery good“ or „Renew battery“ and total charging time.

iv

There are three possible messages depending on individual cir‐ cumstance (printout for warranty, repair job, evaluation and filing):

th n

♦ Generate test code (only possible after automatic charging and test).

r pr o c um

♦ Print last test result (for warranty).

y in o p

C

Note rig p y y

co

b c t ed te

Pro G.

n A ge a sw olk y

V ht b rig py o

C t.

en a m

For additional information, refer to the ⇒ operating manual INC

940 .

3. Charging battery

57

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Electrical System, General Information - Edition 07.2010

3.5.3

Dealing with problems with Midtronics -

INC 940- battery tester

Under certain circumstances, the display may show errors or messages according to status.

The most frequent display messages are listed below, together with suggested solutions.

Note

For messages not listed here, please refer to ⇒ operating manual

INC 940 .

Display message

Check connection.

Measures

– Check whether terminals of battery charger are firmly connected to battery termi‐ nals.

Terminals connected?

System noise

– Check battery terminals are tightened according to reg‐ ulations and do not have corrosion.

r i o rt a

w n o h le is

,

n o t

p e r m it

Safety function of tester.

– Connect terminals to battery

– Switch off all electrical con‐ t e d

u n l e s s before starting charging pro‐ cedure.

ho

b sumers.

– Wait until all electrical loads monitored by onboard sup‐ ply control unit have switch‐ ed off.

a g en AG do es n ot g uar ante e

or a c c ep t

a

– Remove ignition key.

– Disconnect any suspect electrical equipment not connected to onboard sup‐ ply as standard.

ny li a b li i t y

w ith

r s e c e p o t

t e th

c

Wait a few minutes and repeat charging procedure

⇒ page 56

.

e m c m

c r o e t

o a iv pr r

fo g in y p o

C t. h rig y p

co y

b c t ed te

Pro G.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

58

Rep. gr.27 - Starter, current supply, CCS

3.6

3.6.1

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Electrical System, General Information - Edition 07.2010

Solar panel -VAS 6102A-

Charging battery in maintenance mode with solar panel -VAS 6102A-

s

a ut ho r i s ed

b y

V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c

Solar panel VAS 6102A

General description:

Solar panel -VAS 6102A- supports onboard supply and prevents spontaneous battery discharging.

w h o le

, is

n o t

p e r m it t e d

u

Solar panel -VAS 6102A- achieves max. voltage of 14.3 V and a charging current of max. 255 mA.

r i o rt a n c ep t a ny li a b li i y t

w ith

r s e p c e t th o

t

c e

Solar panel -VAS 6102A- is allowed to be used for charging all rechargeable lead or lead gel batteries.

Solar panel -VAS 6102A- is connected to diagnostic connection in vehicle.

A green LED is integrated in the frame to indicate its function. The m o m e brighter the LED, the higher the charging current.

Integrated electronics prevent battery overcharging.

a t e

o r

c iv

– Secure solar panel -VAS 6102A- on interior mirror -1-.

– Place underside on dash panel -2-.

g o p y in

C h t. rig p y

Note y co

b c t ed te

Pro G.

n A ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

Solar panel -VAS 6102A- is not allowed to lie fully on dash panel.

It is only allowed to be positioned with the bottom edge for sup‐ port. Placing it fully on the surface can result in discolouration of the dash panel.

– Pull attachment string tight so that solar panel -VAS 6102A- is positioned close to windscreen.

– Connect solar panel -VAS 6102A- to diagnostic connection of vehicle. Connection procedure is as for vehicle diagnostic

tester ⇒ page 78

– Check function of solar panel -VAS 6102A- . Green LED indi‐ cates function of solar panel -VAS 6102A- .

3.7

Totally discharged batteries

WARNING

Danger of injury! Observe warning notices and safety regula‐

tions ⇒ page 2 !

A battery is designated „totally discharged“ when the no-load volt‐ age is less than 11.6 V.

3. Charging battery

59

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Electrical System, General Information - Edition 07.2010

WARNING

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle!

Danger of explosion when checking and charging or slave/ jump starting

These batteries must be renewed.

Caution

♦ Totally discharged batteries freeze prematurely.

♦ Frozen batteries should no longer be used.

♦

Note s

a ut ho r i s ed

b not be excluded.

y V olk sw a ge n AG

.

V olk s w a g en

Totally discharged batteries in vehicles before registration must be exchanged prior to delivery. Preliminary damage can‐ e

or a c

♦ Batteries that have not been used for a long period of time discharge themselves, e.g. those fitted in stored vehicles.

♦

♦

w h o le

, is

n

In totally discharged batteries, the electrolyte is comprised al‐ o t

p e r m it t e d

u

Totally discharged batteries sulphate, that means, the entire plate surfaces of the battery harden.

c ep t

a ny li a b r i o rt a n

♦ If a battery is recharged shortly after it has totally lost its charge, the sulphation will mostly dissipate.

♦ If these batteries are not recharged, the plates continue to harden and the ability to recharge is reduced. The result of which is a reduction in the battery output.

li i y t

w ith

r s e p c e t th o

t

c e

– Check battery no-load voltage ⇒ page 25 .

c e m m o r

c

o t e a iv r pr g

fo in p y

C o h t. rig p y y

co

b c t ed te

Pro G.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

60

Rep. gr.27 - Starter, current supply, CCS

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Electrical System, General Information - Edition 07.2010

4 Cruise control system (CCS)

General description:

The functions of the cruise control system are controlled by the engine control unit.

– The cruise control system can be activated/deactivated

⇒ page 61 .

Fault detection and fault display

Faults on the CCS are output via the engine control unit.

For fault finding, use vehicle diagnosis, testing and information system in „Guided fault finding“ mode.

4.1

Activating and deactivating cruise con‐ trol system (CCS)

n l e s s

a ut ho r i s ed

b y

V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c

– Connect vehicle diagnostic tester

w h o le

, is e r m it t e d

u

⇒ page 78 .

– Select „Guided fault finding“ mode in vehicle diagnostic tester .

– Using „GoTo“ button, select „Functions/component“ and the following menu options in succession: a n r i o rt

♦ Drive c ep t a ny li a b li i y t

w ith

r s e p c e t th o

t

c e

♦ Engine code

♦ 01 - On Board Diagnostic capable systems

♦ Engine management/diesel direct injection and glow plug sys‐ tem m e c m

♦ Functions o

o r

c a t e r pr

fo g in y o p

C h t. rig p y y co

b c t ed te

Pro G.

n A ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

4. Cruise control system (CCS)

61

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Electrical System, General Information - Edition 07.2010

90 – Gauges, instruments

r i o rt a n

w h o le

, is

n o t

p e r m it t e d

u n l e s s

a ut ho r i s ed

b y V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t

a ny li a b li i y t

w ith

r s e p c e t th o

t

c e e m c m

c r o e t

o a iv pr r

fo g in y p o

C t. h rig y p

co y

b c t ed te

Pro G.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

62

Rep. gr.90 - Gauges, instruments

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Electrical System, General Information - Edition 07.2010

92 – Windscreen wash/wipe system

1 Washer fluid line hose couplings

The following hose coupling types are used to connect the hoses to pumps and spray jets and/or as points of separation:

1.1

Windscreen and rear window washer system

– Pull the two coupling sections apart (no securing device) to loosen the connection.

– To secure the connection, push the two coupling sections to‐ gether, until you hear and feel them engage.

s

a ut ho r i s ed

b y V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c

– To loosen the connection, rotate the lock ring -1- through 90°

-arrow- and pull off the hose connection.

w h o le

, is

n o t

p e r m it t e d

u r i o rt a n n l e s

– To secure the connection, push on the hose connection and rotate the lock ring -1- -arrow- until it engages.

c ep t

a ny li a b li i y t

w ith

r s e p c e t th o

t

c e

– To loosen the connection, pull up the lock ring -1- by approx.

m o m e

1 mm -arrow- and pull off the hose connection.

– To secure connection, attach hose connection and press in clip -1- until it engages.

iv a t e

o r

c

– To secure connection, attach hose connection and press in clip -1- until it engages.

g in p y

C o h t. rig p y y

co

b c t ed te

Pro G.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

1. Washer fluid line hose couplings

63

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Electrical System, General Information - Edition 07.2010

– To loosen the connection, pull up the lock ring -1- -arrow- and pull off the hose connection.

– To secure connection, attach hose connection and press in clip -1- until it engages.

1.2

Headlight washer system

– To loosen the connection, push the lock ring -1- -arrow- and pull off the hose connection.

– To secure the connection, push and hold the lock ring

-arrow- and push on the hose connection. Check that the se‐ curing clip has correctly engaged by depressing and trying to pull off without the clip.

t e d

u n l e s s r m it

n o t

p e

a ut ho r i s ed

b y

V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t a is

, o h le r i o rt a

w n ny li a i b li t y

w ith

r s e c e p o t

t e th

c e m c m

c r o e t

o a iv pr r

fo g in y p o

C t. h rig y p y co

b c t ed te

Pro G.

n A ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

64

Rep. gr.92 - Windscreen wash/wipe system

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Electrical System, General Information - Edition 07.2010

2 Hose repair

A new repair concept has been developed for repairs to washer system hoses. Various connectors, special EPDM hoses (ethyl‐ ene-propylene terpolymer) and heat-shrink hose are available as spare parts.

2.1

General description

♦ The replacement parts can be found in the electronic parts catalogue (ETKA).

♦ Replacement parts are available for repair of both smooth and corrugated pipes.

2.2

Repairing smooth pipe

Smooth pipe with a diameter or 5x1 mm or 6x1 mm can be re‐ paired with EPDM hose.

– Cut damaged section at right angles out of smooth pipe which is to be repaired.

– Select the appropriate EPDM hose -2- and cable ties accord‐ ing to the electronic parts catalogue (ETKA).

– Cut EPDM hose -2- so that ends -1- and -3- of smooth pipe can each be pushed about 10 mm into the EPDM hose -2-.

– Secure the repair joints with cable ties -1-.

r i o rt a

w n o h le is

,

n o t

p e r m it t e d

u n l e s s

a ut ho r i s ed

b y

V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t a

2.3

Repairing corrugated pipe

Special tools and workshop equipment required

♦ Hot air blower -VAS 5179- or ny li a i b li t y

w ith

r s e c e p o t

t e th

c e m c m o r

c

o e t a iv pr r

fo g in y o p

C t. rig p y

♦ Hot air blower -VAS 1978/14-

Pro G.

n A ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

2. Hose repair

65

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Electrical System, General Information - Edition 07.2010

Note

♦ Repair points must not be subjected to pulling or bending forces.

♦ If the damaged section is longer than 20 mm, a new piece of corrugated pipe must be used and the procedure described below must be performed twice.

– Cut damaged section at right angles out of corrugated pipe which is to be repaired.

– Select suitable end pieces -2- and -3- and correct sized shrinkfit piping from the electronic parts catalogue (ETKA).

– Heat end of corrugated pipe -1-.

– Push connector -2- into corrugated pipe -2- -arrow A-.

– Heat end of corrugated pipe -4-.

– Push connector -3- into corrugated pipe -4- -arrow B-.

– Cut heat-shrink hose so that ends of corrugated pipe are each covered by about 20 mm -dimension x- of heat-shrink hose.

– Push heat-shrink hose over corrugated pipe, join connectors and secure repair joints with heat-shrink hose.

r i o rt a

w n o h le is

,

n o t

p e r m it t e d

u n l e s s

a ut ho r i s ed

b y V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t

a ny li a b li i t y

w ith

r s e c e p o t

t e th

c e m c m

c r o e t

o a iv pr r

fo g in y p o

C t. h rig y p

co y

b c t ed te

Pro

66

Rep. gr.92 - Windscreen wash/wipe system

G.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

r i o rt a n

w h o le

, is

n o t

p e r

3

m it t e d

u n l e s s

a ut ho r i s ed

b y V olk sw a ge

.

V olk s w a g

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

e

or a c

Distinguishing features of jointless wiper blades

Distinguishing features from Bosch and Federal Mogul.

When renewing wiper rubbers, note the make. When renewing wiper blades, the same make must be used.

Wiper blades can be identified according to wiper arm fastening.

Bosch wiper blades -1 and 2-: c ep t

a ny li a b li i y t

w ith

r s e p c e t th o

t

c e e m c m

c r o e t

o a iv pr r

fo g in y p o

C t. rig p y y

co

b c t ed te

Pro G.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

3. Distinguishing features of jointless wiper blades

67

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Electrical System, General Information - Edition 07.2010

94 – Lights, bulbs, switches - exterior

1 Operation and safety notes for gas discharge bulbs

s

a ut ho r i s ed

b y V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c

– If repairs are to be made to the headlight with gas discharge bulbs, observe the following: n l e s

w h o le

, is

n o t

p e r m it t e d

u

♦ Notes on dangerous high voltage/currents

⇒ page 68

♦ Notes on pressure, temperature, radiation/arcs ⇒ page 69

♦ Assembly notes for gas discharge bulbs

rt a

⇒ page 70

♦ Disposal regulations for gas discharge bulbs

⇒ page 70

c ep t

a ny li a b li i y t

w ith

r s e p c e t th o

t

c e

Special tools and workshop equipment required

♦ Protective goggles

♦ Gloves c e m

WARNING m o r

c

o t e a before working on parts of the gas discharge headlights marked with yellow high voltage symbols.

y in

Then switch dipped beam on and off again. This will eliminate any possible residual voltage.

The gas discharge lamp control unit must never be operated without a gas discharge lamp.

h rig p y y

Pro

Due to the high voltage (above 28000 V when igniting the gas discharge bulb) and temperatures, the gas discharge bulb must only be operated in the headlight housing.

G.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

WARNING

♦ Never change bulbs if you are not familiar with the appro‐ priate procedures, safety precautions and tools.

Notes on dangerous high voltage and current

WARNING

Control units for light systems, connectors and components pertaining to bulb holders conduct lethally high voltage.

Operating the control unit and the starter unit is permitted only with the bulb fitted.

68

Rep. gr.94 - Lights, bulbs, switches - exterior

a ut ho r i s ed t e d

u n l e s s

n o t

p e r m it

WARNING

• Switch off ignition and all electrical consumers and re‐ move ignition key.

• When working on headlight system, ensure that there is r i o rt a

w n o h le

b y

V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

t a ny li a i b li t y

w ith

r s e c e p no voltage in any components, including the dissipation of residual voltage after the headlights are switched off.

o t

t e th

c

• Residual voltage can be dissipated by turning the dipped beams on and then off again after withdrawing the ignition key.

• When working on the headlight system, ensure that the c e lights cannot be switched on.

m m o

Notes on pressure, temperature, radiation/arcs a t e

o r

c iv r pr

fo

WARNING in p y o

C y rig against explosion).

y co

b

Pro G.

a y tion of UV radiation, avoidance of dazzling light, protection te n A ge sw olk rig

• The glass of the bulbs can be very hot - danger of burns.

• Avoid looking directly into the beam, as the UV rays from the gas discharge bulb are about 2.5 times greater than normal halogen bulbs.

• Avoid looking into the light beam (danger of glare); vision may be impaired for a substantial time.

py o

C t.

en um c o

d

th n a m

WARNING

• Avoid contact with burst bulbs.

• H7 bulbs and gas discharge bulbs (xenon and bi-xenon) are under pressure and can explode while being changed

- danger of injury.

• Always wear protective goggles and gloves when remov‐ ing and installing gas discharge bulbs.

1. Operation and safety notes for gas discharge bulbs

69

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Electrical System, General Information - Edition 07.2010

Repair notes for gas discharge bulbs

Caution

♦ Before exchanging a bulb, always switch off the affected consumers.

s

a ut ho s ed

b y V olk sw a ge n AG

.

V olk s w a g en

♦ Switch off ignition and all electrical consumers and re‐ move ignition key.

r i

AG do es

♦ Do not touch the bulb glass with bare fingers; use clean cloth gloves. When the light bulb is switched on, the heat would vaporise the oil of the finger prints which would then settle on the reflector, impairing the brightness of the headlight.

o t

p e r

♦ A light bulb must always be renewed with a bulb of the same sort. The designation appears on the base of the

w h o le

, is

n m it t e d

u

♦ Properly engage connectors during installation and en‐ sure tight seating of the connection.

n ot g uar ante e

or a c c ep t

a ny li a b li i y t

w ith

r s e p c e t th o

t

c e

Disposal regulations for gas discharge bulbs

• Gas discharge bulbs must be disposed of as hazardous waste; never dispose of gas discharge bulbs as conven‐ tional waste.

m m e

c e

o r t a

• Gas discharge bulbs contain metallic mercury (Hg) and traces of thallium; never destroy these bulbs.

y in

• These components must be recycled in accordance with national law.

h rig p y

co

• Dispose of only in containers intended for this purpose at an authorised collection point.

te n A G.

ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

70

Rep. gr.94 - Lights, bulbs, switches - exterior

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

96 – Lights, bulbs, switches - interior

1 12 V socket

1.1

Removing and installing 12 V socket

Caution

If excessive force is exerted on sockets without illumination, the retaining sleeve may be damaged.

Only illuminated sockets (cigarette lighter) can be removed with the puller T 40148.

The puller does not manage to release the locking lugs of sockets without illuminated retaining sleeve.

Usually sockets without illumination cannot be removed with‐ out being damaged.

Refer to removing and installing cigarette lighter -U1-

⇒ page 72

.

1.2

Removing and installing socket illumi‐ nation bulb -L42-

The removal of the socket illumination bulb -L42- is performed in the same way as the removal of the cigarette lighter illumination bulb -L28-

n

⇒ page 76

.

is

, o h le r i o rt a

w n t e d

u n l e s s

a ut ho r i s ed

b y

V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t a ny li a i b li t y

w ith

r s e c e p o t

t e th

c e m c m

c r o e t

o a iv pr r

fo g in y p o

C t. h rig y p y co

b c t ed te

Pro G.

n A ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

1. 12 V socket

71

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Electrical System, General Information - Edition 07.2010

2 Cigarette lighter -U1-

The following descriptions apply to the rear left cigarette lighter -

U3- , rear right cigarette lighter -U7- , rear cigarette lighter -U9- ,

12 V socket 2 -U18- , 12 V socket 3 -U19- , 12 V socket 4 -U20- , cigarette lighter 2 -U25- and 12 V socket 5 -U26- so far as they are illuminated.

Caution b y V olk sw a ge n AG

.

V olk s w a g en AG do

If excessive force is exerted on sockets without illumination, r m it t e d

u n l e s s

a ut ho r i s ed the retaining sleeve may be damaged.

es n ot g uar ante e

or a c c ep t

a

Only illuminated sockets (cigarette lighter) can be removed with the puller T 40148.

n o t

The puller does not manage to release the locking lugs of sockets without illuminated retaining sleeve.

r i o rt a

w n o

Usually sockets without illumination cannot be removed with‐ out being damaged.

le ny li a b li i t y

w ith

r s e c e p o t

t e th

c

2.1

General description

Caution c e the retaining sleeve may be damaged.

r

c o m m

Only illuminated sockets (cigarette lighter) can be removed with the puller T 40148.

r pr iv a t e

o

The puller does not manage to release the locking lugs of p y

C

Usually sockets without illumination cannot be removed with‐ out being damaged.

y

co

b c t ed te

Pro G.

n A

On some vehicles, the illumination is not provided by a light bulb, but by an LED (light-emitting diode), depending on the equipment level. This LED is permanently attached to the retaining sleeve and cannot be renewed separately.

Retaining sleeves with a light bulb are available in different ver‐ sions. On the one version, the light bulb can be replaced sepa‐ rately; on the other version, the light bulb cannot be replaced separately. In this case, the bulb carrier has to be replaced to‐ gether with the light bulb.

Depending on the space requirement, the vehicles are equipped with various electric sockets and cigarette lighter sockets. They differ in length and have different electrical connections. In the case of electric sockets or cigarette lighter sockets with a wiring tail, it may be necessary to perform additional work in order to gain access to the connector.

ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

72

Rep. gr.96 - Lights, bulbs, switches - interior

2.2

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Electrical System, General Information - Edition 07.2010

Assembly overview

Caution

If excessive force is exerted on sockets without illumination, the retaining sleeve may be damaged.

n ot g

Only illuminated sockets (cigarette lighter) can be removed s

a ut ho r i s ed

b y V with the puller T 40148.

es ante e

or a c

The puller does not manage to release the locking lugs of

Usually sockets without illumination cannot be removed with‐ out being damaged.

w h o le

, is

n o t

p e r m it t e d

u

1 - Cigarette lighter socket with wiring tail a

2 - Cigarette lighter c ep t

a ny li a b li i y t

w ith

r s e p c e t th o

t

c e

3 - Socket

4 - Cigarette lighter socket

5 - Retaining sleeve e c m m

7 - Bulb carrier a t e

o r

c iv r pr g

fo in p y o

C h t. rig y p y

co

b c t ed te

Pro G.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

2. Cigarette lighter U1

73

2.3

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Electrical System, General Information - Edition 07.2010

Removing and installing cigarette lighter socket

Note

The removal and installation procedure is the same for all sockets and is therefore described here only for the cigarette lighter sock‐ et.

Caution

If excessive force is exerted on sockets without illumination, the retaining sleeve may be damaged.

Only illuminated sockets (cigarette lighter) can be removed with the puller T 40148.

The puller does not manage to release the locking lugs of sockets without illuminated retaining sleeve.

Usually sockets without illumination cannot be removed with‐ out being damaged.

Special tools and workshop equipment required

♦ Puller -T 40148-

Removing

a ut ho r i s ed

– Remove cigarette lighter, dummy cigarette lighter etc. from socket if necessary.

n o t

p e r m it t e d

u n l e s s

b y

V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t a

Note r i o rt a

w n o h le is

,

For reasons of clarity, the socket is removed in the illustration.

ny li a i b li t y

w ith

r s e c e p o t

t e th

c

Caution

The socket or the retaining sleeve can be damaged.

Ensure that the puller is seated correctly, otherwise the retain‐ ing lugs of the retaining sleeve will not be released.

m m e c o r

c

o a t e iv r pr g

fo y in o p

C h t. rig p y

74 y co

Rep. gr.96 - Lights, bulbs, switches - interior

b c t ed te

Pro G.

n A ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

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Electrical System, General Information - Edition 07.2010

– Push puller -arrow- into socket so that locking lugs -1- engage in recesses -2-.

s

a ut ho r i s ed

b y

V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c n l e s

– Pull grip -3- in direction of -arrow- to release locking lugs of retaining sleeve.

w h o le

, is

n o t

p e r m it t e d

u a n r i

– Pull socket out of retaining sleeve using puller.

c ep t a ny li a b li i y t

w ith

r s e p c e t th o

t

c e

Caution

The socket wiring can be damaged.

c m m o r

c

o e t a iv

Depending on the fitting location, it is recommended to use the g

fo thrust piece 40148/1 -2- with the knurled nut -1-.

o p y in

Caution

C h t. p y rig y co

b c t ed

When using the thrust piece, ensure that no surrounding com‐ ponents are damaged.

te

G.

n A ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

– Pull off socket connector.

Note

Depending on the space requirement, the vehicles are equipped with various electric sockets and cigarette lighter sockets. They differ in length and have different electrical connections. In the case of electric sockets or cigarette lighter sockets with a wiring tail, it may be necessary to perform additional work in order to gain access to the connector.

2. Cigarette lighter U1

75

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Electrical System, General Information - Edition 07.2010

– Release puller locking lugs by pressing spindle -1- in direction of -arrow B-. Then release puller -2- by turning it briefly to left

-arrow A-. Remove puller from socket.

Note

Ensure that the puller locking lugs are not spread.

Caution

The cigarette lighter might be ejected out of the socket after the heating phase.

When the puller is mounted, the socket retaining springs are pressed apart and the retaining force is reduced.

a ut ho r i s ed

After removing the socket, carefully press the retaining springs together and check if the cigarette lighter remains in the re‐ moval position after the heating phase.

r m it t e d

u n l e s s

n o t

p e

– Carefully press socket retaining springs together -arrows-.

o h le

– Check if cigarette lighter remains in removal position after heating phase and ensure it is not ejected in vehicle interior.

Installing rt a

w n r i o

b y V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t

a ny li a b li i t y

w ith

r s e c e p o t

t e th

c

Install in reverse order of removal.

2.4

Note c e m m o

Removing and installing cigarette lighter illumination bulb -L28-

r

c

o a t e iv r pr g

fo y in o p

C h t. rig p y

co y

♦ On some vehicles, the illumination is not provided by a light bulb, but by an LED (light-emitting diode), depending on the equipment level. This LED is permanently attached to the re‐ taining sleeve and cannot be renewed separately.

♦ Retaining sleeves with a light bulb are available in different versions. On the one version, the light bulb can be replaced separately; on the other version, the light bulb cannot be re‐ placed separately. In this case, the bulb carrier has to be replaced together with the light bulb.

b c t ed te

Removing:

– Remove socket

⇒ page 74 .

Pro G.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

76

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Electrical System, General Information - Edition 07.2010

– Press retaining lugs -arrows- and remove retaining sleeve to‐ gether with bulb carrier.

– Unclip bulb carrier from retaining sleeve.

– Separate bulb carrier in areas -A- and -B-.

– Open part -B- of bulb carrier.

– Remove light bulb in direction of -arrow-.

t e d

u n l e s s

Installing: e

Installation is carried out in reverse order of removal.

n o t

p is

, r m it o h le r i o rt a

w n

a ut ho r i s ed

b y

V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t a ny li a i b li t y

w ith

r s e c e p o t

t e th

c e m c m

c r o e t

o a iv pr r

fo g in y p o

C t. h rig y p y co

b c t ed te

Pro G.

n A ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

2. Cigarette lighter U1

77

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Electrical System, General Information - Edition 07.2010

97 – Wiring

1 Vehicle diagnostic, testing and infor‐ mation systems

WARNING

♦ During testing or measuring operations using a vehicle di‐ agnostic information system, there is a risk of serious or even fatal injury!

♦ If the vehicle diagnostic information system is lodged in the activity area of an airbag during a testing or measuring operation, a triggered airbag can result in serious or even fatal injury!

♦ During testing and measuring operations, work with a per‐ son who can operate the vehicle diagnostic and informa‐ tion system from one of the back seats.

a ut ho r i s ed

b y V olk sw a ge n AG en AG do es n ot g uar ante e

or a c c ep t

a

Note

♦ All the operations described, e.g. adaptation, coding, etc. can be performed using the vehicle diagnostic tester .

n o t

p e r m it t e d

u n l e s s

♦ All work procedures can be found in „guided fault finding“ and

„guided functions“ modes.

♦ o h le

Additional information r i o rt a

w n

⇒ Self-study programme No. 202 ; Vehicle diagnostic, testing and information system VAS 5051 ny li a b li i t y

w ith

r s e c e p o t

t e th

c

⇒ Self-study programme No. 256 ; VAS 5052

⇒ Self-study programme No. 294 ; Online connection of VAS

5051

– Connecting vehicle diagnostic tester ⇒ page 78

m e c

1.1

m r

c o

o t e a

Note r pr iv

fo g in

Connecting vehicle diagnostic tester

y o h t. rig p y

co y c t ed te

Pro G.

Special tools and workshop equipment required n A a ge sw olk y

V ht b rig o py

C t.

en um c o

d

th n a m

78

Rep. gr.97 - Wiring

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Electrical System, General Information - Edition 07.2010

♦ Vehicle diagnostic tester

♦ Diagnostic cable -VAS 5051/6A- (5 m) r i o rt a n

w h o le

, is

n o t

p e r m

♦ Diagnostic cable -VAS 5051/5A- (3 m) s

a

Only these cables are to be used for diagnosis, as they are the it t e d

u

Note ut ho i s ed

b y

V olk sw only ones fitted with CAN wiring and therefore allowing CAN di‐

Connecting vehicle diagnostic tester :

– Apply handbrake.

a ge n AG es n ot g uar ante e

or a li a b

– Vehicles with automatic gearbox, move selector lever to posi‐ tion „P“ or „N“.

li i y t

w ith

r s e p c e t th o

t

– Vehicles with manual gearbox, move gearstick to neutral po‐ sition.

c e e m c

– With ignition switched off, connect vehicle diagnostic tester using diagnostic cable -VAS 5051/6A- to diagnostic interface

-arrow- in vehicle.

– Switch on ignition.

a m m n

c r o

o e

– Switch off all electrical consumers.

t a iv pr r

Note en o c um

fo g h t.

C o p y in

C t.

All other and the following vehicle diagnostic, testing and infor‐ above.

y co

G.

a ge olk y ht b o mation systems or vehicle diagnostic and service information p y rig rig py systems are connected accordingly in the sequence described c t ed te

Pro n A

V

d

th

1. Vehicle diagnostic, testing and information systems

79

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Electrical System, General Information - Edition 07.2010

1.2

Connecting vehicle diagnostic tester

Golf Model Year 1998 - 2003

– Apply handbrake.

– Vehicles with automatic gearbox, move selector lever to posi‐ tion „P“ or „N“.

– Vehicles with manual gearbox, move gear lever to neutral po‐ sition.

– Pull out trim -1- in direction of arrow.

– With ignition switched off, connect vehicle diagnostic tester using diagnostic cable to diagnostic interface -arrow- in vehi‐ cle.

– Switch on ignition.

– Switch off all electrical consumers.

Note

All other and the following vehicle diagnosis, testing and informa‐ tion systems or vehicle diagnostic and service information sys‐ tems are connected accordingly in the sequence described above.

r i o rt a n

w h o le

, is

n o t

p e r m it t e d

u n l e s s

a ut ho r i s ed

b y V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t

a ny li a b li i y t

w ith

r s e p c e t th o

t

c e e m c m

c r o e t

o a iv pr r

fo g in y p o

C t. h rig y p

co y

b c t ed te

Pro

80

Rep. gr.97 - Wiring

G.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

2

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Repairing wiring harnesses and con‐ nectors

2.1

Wiring harness repair set

2.1.1

Wiring harness repair set -VAS 1978-

Wiring harness repair set -VAS 1978- allows optimal repair quality to be achieved in the area of vehicle electrics. Using the tools, repairs to connectors and wiring open circuits can be carried out.

To do this, complete repair wire sections with contacts already crimped on are used and joined to the vehicle's own wiring har‐ ness with the aid of crimp connectors. A special set of pliers with n l e s s

a ut ho r i s ed

b the crimp connectors make a perfect electrical connection.

en three different crimp recesses and a hot air blower for shrinking

AG do es n ot g uar ante e

or a c

Note

Additional information:

w le

, is

n o t

p e r m it t e d

u

⇒ Operating instructions Wiring harness repair set -VAS 1978rt a n r i o c ep t a ny li a b li i y t

w ith

r s e p c e t th o

t

c e

2.1.2

Upgrade kit -VAS 1978/50-

Upgrade kit -VAS 1978/50- is required to bring the „old“ wiring harness repair set -VAS 1978- up to the latest standard of wiring harness repair set -VAS 1978A- . The upgrade kit comprises of 4 assembly and 10 release tools, a new set of crimping pliers for

1978/1-1- , 4.0 - 6.0 mm r

c o m e m

2 -VAS

2 -VAS 1978/2 A- and head adapter for

JPT contacts -VAS 1978/9-1- . Also included are new stickers, a a e t r pr mm 2 cable cross-section and a roll of black felt adhesive tape.

g

fo y in o p

C h t. rig p y y co

b c t ed te

Pro G.

n A

2.1.3

Wiring harness repair set -VAS 1978A-

The new wiring harness repair set -VAS 1978A- allows optimal repair quality to be achieved in the area of vehicle electrics. Using the new pliers, repairs to connectors and wiring open circuits can be carried out. To do this, complete repair wire sections with con‐ tacts already crimped on are used and joined to the vehicle's own wiring harness with the aid of four different types of crimp con‐ nectors. A new set of crimping pliers with head adapters and a hot air blower for shrinking the crimp connectors make a perfect electrical connection.

ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

Note

Additional information:

⇒ Operating instructions Wiring harness repair set -VAS 1978A-

2. Repairing wiring harnesses and connectors

81

2.1.4

o t

p e r ho r i s ed

b y V olk sw a ge

The set comprises of 26 different tools with which, for example, n AG

.

V olk s w a g en AG do es

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Electrical System, General Information - Edition 07.2010

w h o le

, is

n m it t e d

u n l e s s

a ut

Release tool set -VAS 1978/35-

Release tool set -VAS 1978/35- serves as a means of releasing various primary and secondary locking devices in Group vehicles.

round connector systems, flat contacts with one or two fasteners and also single wire seals can be released or fitted.

Allocation of the correct release tool to the respective locking de‐ vices can be gleaned from the table in the ⇒ operating instruc‐ tions of -VAS 1978/35- .

r i o rt a n n ot g uar ante e

or a c c ep t

a ny li a b li i y t

w ith

r s e p c e t th o

t

c e

2.2

2.2.1

Tool descriptions

c e m m o r

c

o t e

Special pliers with insert

iv pr r

fo

The special pliers without insert -VAS 1978/1- with insert for spe‐ cial pliers -VAS 1978/2- is part of the wiring harness repair set -

VAS 1978- and is used to crimp connectors during wiring harness repairs.

Colour of crimp connector

Colour of crimp re‐ cess

C h t. y rig

Wiring cross section y

co

b c t ed te

Yellow

Red

Blue

Yellow.

Yellow.

Red.

Blue

Yellow.

0.35 mm 2

0.5 mm 2 - 1.0 mm 2

1.5 mm 2 - 2.5 mm 2

4.0 mm 2 - 6.0 mm 2

Pro

Note

♦ As an alternative, the connectors can also be crimped with crimping pliers (base tool) -VAS 1978/1-2- in conjunction with head adapters -VAS 1978/1-1- or -VAS 1978/2A-

⇒ page 84

.

♦ Ensure without fail that the correct crimp recess is chosen for the crimp connectors being used.

♦ The insulation on the wires must not be crimped.

G.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

82

Rep. gr.97 - Wiring

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2.2.2

Release tools for contacts

The various release tools serve as a means of detaching the dif‐ ferent contacts from the contact housings without damage.

A selection of release tools is included in wiring harness repair set -VAS 1978- and wiring harness repair set -VAS 1978A- . The complete set of release tools is included in release tool set -VAS

1978/35-

⇒ page 82 .

WARNING

Some tools are equipped with a tool safety device. This must be pushed over the tip of the tool after use in order to protect the tip and prevent personal injury.

s

a ut ho r i s ed

b n l e s

Releasing and dismantling contact housings ⇒ page 102 .

n ot g uar ante e

or a c

2.2.3

Assembly tools for single wire seals

w h o le

, is

n o t

p e r m it t e d

u

The assembly tools serve as a means of sliding the single wire seals fully into the contact housing without damage and thereby assure complete sealing between single wire and contact hous‐ ing.

a r i o n

Four assembly tools for single wire seals are included in each wiring harness repair set -VAS 1978 B- and previous versions.

c ep t a ny li a b li i y t

w ith

r s e p c e t th o

t

c e

Assembling single wire seals ⇒ page 99

.

2.2.4

c e m m o r

c

Wire strippers -VAS 1978/3-

pr

Wire strippers -VAS 1978/3- serve as a means of stripping insu‐ lation off wires and cutting wires in the correct manner.

o p

Wire strippers -VAS 1978/3- are included in wiring harness repair set -VAS 1978 B- and previous versions.

The wire strippers have an adjustable limit stop within the pliers jaws, with which the desired length of insulation to be removed can be adjusted.

c t ed te

G.

n A a sw olk

Stripping:

– Adjust the sliding limit stop in the pliers jaws to the desired length of insulation to be removed.

V y ht b rig py o

C t.

en um c o

d

th n a m

– Insert the end of the wire from the front fully into the pliers jaws and squeeze the pliers together completely.

– Open the pliers and removed the stripped wire end.

2. Repairing wiring harnesses and connectors

83

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Electrical System, General Information - Edition 07.2010

– Cut the wire if necessary with the cutting part on the upper side of the wire strippers.

2.2.5

Hot air blower, 220 V / 50 Hz -VAS

1978/14-

s

a ut ho r i s ed

b y V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c n l e s

w h o le

, is

n o t

p e r m it t e d

u

Caution r i o rt a n

When shrink-fitting, take care not to damage any other wiring, plastic parts or insulating material with the hot air blower.

c ep t

a ny li a b li i y t

w ith

r s e p c e t th o

t

c e

Observe the operating instructions of the hot air blower without fail!

c e m m

c shrink fit the crimp connectors. After crimping, the crimp connec‐ a t e

o r o tor has to be shrink fitted using the hot air blower in order to pr r g

fo in y p

C o t. h y rig

co

Shrink fitting crimp connectors using hot air blower, 220 V / 50 Hz

-VAS 1978/14- ⇒ page 94

, or ⇒ page 96 .

te

G.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

2.2.6

Crimping pliers -VAS 1978/1A-

Crimping pliers -VAS 1978/1A- or crimping pliers (base tool) -VAS

1978/1-2- together with head adapter 0.35 - 2.5 mm² -VAS

1978/1-1- or head adapter 4.0 - 6.0 mm² -VAS 1978/2A- are used to squeeze together crimp connectors from the wiring harness repair sets.

Crimping connectors using crimping pliers -VAS 1978/1A-

⇒ page 96 .

The following heads adapters are available for crimping pliers

(base tool) -VAS 1978/1-2- :

♦ Head adapter 0.35 mm 2 - 2.5 mm 2 -VAS 1978/1-1-

♦ Head adapter 4.0 mm 2 - 6.0 mm 2 -VAS 1978/2A-

♦ Head adapter for JPT contacts -VAS 1978/9-1-

In conjunction with head adapter for JPT contacts -VAS

1978/9-1- , the crimping pliers are used to crimp contacts to single wires during repairs to wiring with cross sections up to 0.35

mm 2

⇒ page 91 .

Interchanging head adapter:

– Open up the crimping pliers fully.

84

Rep. gr.97 - Wiring

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Electrical System, General Information - Edition 07.2010

– Unclip both locking pins -arrows- from the body of the crimping pliers.

– Insert the required head adapter from above -arrow- in the body of the crimping pliers.

n o t

p e r m it t e d

u n l e s s

b y

V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t a is

,

a ut ho r i s ed o h le r i o rt a

w n ny li a i b li t y

w ith

r s e c e p o t

t e th

c

– Lock the head adapter by engaging the pins -arrows- in the body of the crimping pliers.

m m c o r

c

o a t e iv r pr g

fo y in o p

C h t. rig p y y co

b c t ed te

Pro

2.3

General notes concerning repairs to ve‐ hicle electrical system

Caution

When batteries are disconnected and reconnected, the proce‐ dure described in the workshop manual must be strictly ob‐ served.

WARNING

Some tools are equipped with a tool safety device. This must be pushed over the tip of the tool after use in order to protect the tip and prevent personal injury.

G.

n A ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

2. Repairing wiring harnesses and connectors

85

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Electrical System, General Information - Edition 07.2010

r i o rt a n

w h o le

, is

n o t

p e r m it t e d

u n l e s s

a ut ho r i s ed

b y V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t

a ny li a b li i y t

w ith

r s e p c e t th o

t

c e e m c m

c r o e t

o a iv pr r

fo g in y p o

C t. h rig y p

co y

b c t ed te

Pro G.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

86

Rep. gr.97 - Wiring

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Electrical System, General Information - Edition 07.2010

♦ Observe the latest notes in the respective workshop manual when carrying out repairs.

♦ Observe country-specific regulations.

♦ Always disconnect the battery earth strap before working on the electrical system. Disconnecting the battery earth strap

(open circuit) provides a safe working environment for repairs to the electrical system. The battery positive wire need only be disconnected for removal of the battery.

♦ Before starting a repair, it is important to identify and rectify the cause of damage (e.g. sharp edges on body panels, de‐ fective electrical components, corrosion, etc.).

♦ For additional information, e.g. removal and installation of in‐ dividual components, please refer to the relevant workshop manual.

♦ Soldering is not permitted for repairs to vehicle wiring.

♦ Wiring harness and connector repairs to vehicle electrical sys‐ tem should be carried out using wiring harness repair set -VAS

1978 B- and previous versions only. Only use yellow wires from wiring harness repair set -VAS 1978 B- .

♦ Wiring harness repairs may not be integrated in the vehicle's own wiring harness and must be marked with the use of yellow adhesive tape. This indicates a previous repair.

♦ Crimp connectors may never be repaired. If necessary, lay wiring parallel to the defective wiring. After crimping, crimp connectors must to be shrink fitted using the hot air blower in order to prevent any ingress of moisture.

y

V olk sw

♦ It is essential that the supplementary information is observed regarding repairs to wiring harnesses in airbag and belt ten‐ n l e s

2 s

a ut ho r i s ed

b

⇒ page 91 .

a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c sioner systems, fibre optic cables, CAN bus lines, aerial cables and wiring with cross sections up to 0.35 mm systems to be reset.

w h o le

, is

n o t

p e r m it t e d

u

♦ Carry out a function test after every repair. It may be necessary for the fault memory to be interrogated, erased and/or for the

♦ If possible, do not loosen any earth wires from the body (dan‐ ger of corrosion).

♦ Wiring harness repair set -VAS 1978 B- and previous versions do not cover all wiring cross sections that occur in the vehicle.

If the required wiring cross section is not available, the next largest one should be used.

c ep t a ny li a b li i y t

w ith

r s e p c e t th o

t

c e

♦ Screened wires must not be repaired. If damaged they must be replaced complete.

♦ Heat resistant wiring can be found in various places in the ve‐

2.4

e m can be identified by its slightly matt and softer insulation. To

c

o r t e iv a

Repairs to wiring harnesses

g

fo in y o p

Note

C t. h rig p y y co

Observe the general notes on repairs to the vehicle electrical system

⇒ page 85

.

b c t ed te

Pro G.

n A ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

Notes on repairs to airbag and belt tensioner wiring

⇒ page 88

Notes on repairs to fibre optic cables

⇒ page 89

2. Repairing wiring harnesses and connectors

87

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Electrical System, General Information - Edition 07.2010

Notes on repairs to CAN bus wiring ⇒ page 90

Notes on replacement of aerial cables

⇒ page 90

Notes on repairs to wiring with cross sections up to 0.35 mm 2

⇒ page 91

Notes on repair of wiring open circuit with one repair position

⇒ page 94

Notes on repairs to airbag and belt ten‐ sioner wiring

b y V olk sw a ge n AG

.

V olk s w a g en AG do

Notes on repair of wiring open circuit with two repair positions

⇒ page 96

2.4.1

t e d

u n l e s s

a ut ho r i s ed

In addition to the general notes on repairs to wiring harnesses, the following instructions must be observed on how to repair wir‐

n o t

p e r m it ing in airbag and belt tensioner systems:

, is o h le

WARNING r i o rt a

w n

♦ Airbag and seat belt tensioner can fail.

es n ot g uar ante e

or a c c ep t

a ny li a b li i t y

w ith

r s e c e p o t

t e th

c

♦ Faulty repairs to the airbag and seat belt tensioning sys‐ tem can cause malfunctions in the passenger protection system.

♦ For repairs to airbag and belt tensioner wiring harnesses, only contacts, connectors and wiring designed specifically

(ETKA) .

c for this purpose may be used ⇒ Electronic parts catalogue r

c o m m e

o t e a iv r pr g

fo in p y

C o h t. rig p y y

co

b c t ed te

Pro G.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

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Electrical System, General Information - Edition 07.2010

Note

♦ Wires from airbag and belt tensioner wiring harness are only allowed to be repaired using wiring harness repair set -VAS

1978 B- and previous versions.

♦ Observe the general notes on repairs to the vehicle electrical

system ⇒ page 85

.

♦ Observe vehicle stickers indicating high voltage components.

Before carrying out repairs, discharge residual voltage ⇒

General body repairs, interior; Rep. gr. 69 ; Occupant safety .

♦ For repairs to wiring in the airbag and belt tensioner system, a maximum of two positions may be repaired. The more the repairs there are in the wiring, the greater the resistance and this can trigger faults in the self-diagnosis of the system.

♦ To avoid corrosion, the crimp connectors are always to be shrink-fitted when performing airbag or belt tensioner wiring harness repairs.

♦ Do not incorporate the repaired wiring back in the vehicle's own wiring harness and mark the area of repair clearly with yellow insulating tape.

r i o rt a

w n o h le is

,

♦

♦ r m it t e d

Repairs in the area of the airbag or belt tensioner should not be more than 30 cm from the next contact housing. Together with the yellow insulating tape, this gives a clear indication of repairs that have already been carried out.

a e

or a c

The wires to the triggering units (airbags) are entwined as standard with a twine spacing of 20 mm ± 5. This spacing is assured for series production via industrial standard numbers for wiring pairs and it is essential that it is adhered to on the repair lengths of entwined wiring.

ny li a b li i t y

w

n o t

p e

♦ During repairs, the wiring to the triggering units (airbags) must have the same length. When wires -1- and -2- are entwined, the twine spacing of A = 20 mm ± 5 must be adhered to without fail.

♦ There must not be any section of wiring, for example in the vicinity of crimp connectors -arrow-, longer than B = 100 mm with the wires not twisted.

ith

r s e c e p o t

t e th

c e m c

2.4.2

Fibre optic cables (FOC)

m o

c r e

o

There is no provision for fibre optic cable repairs at Volkswagen.

In the event of repairs, the entire fibre optic wiring harness must be replaced. To do this, the following safety precautions must be observed: r pr iv

♦ a g

fo y in

Note t. h rig

Avoid sharp bends in the fibre optic cable; the bend radius c t te

G.

n A a ge sw olk y

V ht b rig o py

C t.

en um c o

d

♦ Do not route fibre optic cables over sharp edges.

th

♦ The end pieces (lenses) must not be made dirty or touched with bare hands.

♦ Do not expose fibre optic cables to heat.

♦ Entwining two fibre optic cables or a fibre optic cable with a copper wire is not permissible.

n a m

2. Repairing wiring harnesses and connectors

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2.4.3

Repairs to CAN bus wiring

♦ An unshielded two-wire line -1- and -2- with a cross section of

0.35 mm 2 or 0.5 mm 2 is used for CAN bus wiring.

s

a ut ho r

♦ The colour codes of the CAN bus wiring can be gleaned from the following table:

Powertrain CAN, high wire

Convenience CAN, high wire

Infotainment CAN, high d

u

Orange/black

Orange/green

Orange/violet

w h o le

, is

n o t

p e r m it t e

CAN low wire, (all) Orange/brown

♦ Repairs to CAN bus wiring can be carried out either with sec‐ tions of repair wiring with the correct cross section or with entwined wires „green/yellow“ or „white/yellow“ from the elec‐ tronic parts catalogue (ETKA) ⇒ Electronic parts catalogue

(ETKA) .

r i o rt a n y V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t

a ny li a b li i y t

w ith

r s e p c e t th o

t

c e

♦ When repairs are performed, both bus wires must have the same length. When twisting the wires -1- and -2- together, the e m m c length of each complete twist must be A = 20 mm.

♦ There must not be any section of wiring, for example in the vicinity of crimp connectors -arrow-, longer than B = 50 mm with the wires not twisted.

c o

o a t e iv pr

♦ Mark the area of repair with yellow insulation tape to make it easy to identify.

2.4.4

Renewal of aerial wiring

in p y

C o h t. p y rig

co y

b c t ed te

Pro G.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

A new repair concept has been developed for repair work on aer‐ ial wires. Now connecting wires in different lengths and various adapter cables are available as replacement parts instead of a complete aerial wire.

General description:

♦ Aerial wires must not be repaired, but if repair is required, they must be replaced only by connecting wires and adapter cables offered as genuine parts.

♦ Replacement parts can be found in the ⇒ Parts catalogue

(ETKA): Special catalogue; Electrical connections; Genuine accessories; Subgroup 35 from illustration No. 035-20 .

♦ These genuine parts are suitable for all aerial wires and wire diameters which may need to be replaced.

♦ The connector housings for aerial wires are only available as genuine parts in one colour. However, they can be used for all colours of aerial connector.

♦ No provision has been made for replacement of individual aerial connectors in the event of repair.

♦ The wires can be used retroactively for all VW models, with all installed aerial wire diameters.

♦ All adapter and connection wires are suitable for all transmitter and receiver signals.

♦ This repair method can also be used for testing or retrofitting.

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Electrical System, General Information - Edition 07.2010

Assembly overview of aerial cable:

Example: aerial wire between radio and aerial is defective. The following wires are required for the repair:

1 - Adapter cable, to radio connection. Length approx. 30 cm.

2 - Connecting wire, available in different lengths.

3 - Adapter cable, to aerial connection. Length approx. 30 cm.

Installing a new aerial cable: n l e s s

a ut ho r i s ed

b y V a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c

Note o t

p e r

Note that the total length of an aerial wire, depending on vehicle

w h o le

, is

n m it t e d

u equipment level, can be divided into sections by aerial diversity control unit, traffic information control unit or aerial amplifier. Only the defective section of aerial wire must be replaced.

a r i o n

– Pull defective aerial wire connections off units.

c ep t

a ny li a b li i y t

w ith

r s e p c e t th o

t

c e

– Determine the routing of the defective aerial wire in vehicle and measure the total length of the aerial connecting wire to be replaced.

The total length of aerial connecting wire is the sum of the length of adapter cables required -1- and -3- and the connecting wire

-2-.

e c m o

– To determine the length of connecting wire required, subtract

60 cm from the measured total length of aerial connecting wire

-2-.

e

o r

c t r pr

fo

– Procure the required adapter cables -1- and -3- and connect‐ ing wire -2- at length calculated as genuine part from the

Electronic parts catalogue (ETKA).

y rig

– Cut off connectors of defective aerial wire.

p y

co

b c t ed te

Pro

The remainder of the defective aerial wire remains in the vehicle.

– Connect adapter cables -1- and -3- to equipment in vehicle.

– Route and attach the connection line -2- in the immediate vi‐ cinity of the factory routing.

G.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

Note

Do not kink or excessively bend aerial wires! The bending radius must not be below 50 mm.

– Connect connecting wire to adapter cables.

– Perform functional test.

2.4.5

Repairs to wiring with cross sections up to 0.35 mm

2

Special tools and workshop equipment required

♦ Crimping pliers, complete -VAS 1978/1 A-

2. Repairing wiring harnesses and connectors

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Electrical System, General Information - Edition 07.2010

♦ Head adapter 0.35 mm² - 2.5 mm² -VAS 1978/1-1-

For repairs to wiring with cross sections up to 0.35 mm 2 , it is es‐ sential that contacts are crimped on using crimping pliers for JPT contacts -VAS 1978/9A- or crimping pliers (base tool) -VAS

1978/1-2- with attached head adapter for JPT contacts -VAS

1978/9-1- . Due to the low current strength of these wires in the micro and thousandths range, incorrectly crimped contacts cause electrical resistances and result in faults or failure in the respec‐ tive system. The most common applications of these contacts are:

♦ Lambda probe

♦ Engine speed sender

♦ Air mass meter

With the use of crimping pliers for JPT contacts -VAS 1978/9Aor crimping pliers (base tool) -VAS 1978/1-2- with attached head adapter for JPT contacts -VAS 1978/9-1- , the correct connection between crimp contact, wire and single wire seal is assured. The tool is only to be used for the application described.

Note t e d

u n l e s s

a ut ho r i s ed olk ot g uar ante e

or a c c ep t

a r m it

n o t

p e

Crimped to the repair wiring are normal contacts and gold-plated contacts. The repair contact must always be the same type as the contact installed in the factory.

h le a r i o rt

w

Crimping on new contact with single wire seal

– Insert head adapter for JPT contacts -VAS 1978/9-1- in crimp‐ ing pliers (base tool) -VAS 1978/1-2-

⇒ page 84 .

ny li a b li i t y

w ith

r s e c e p o t

t e th

c

– Attach the single wire seal to the repair wire.

Note c e m

When doing this, the small diameter of the single wire seal must

c r r pr iv a t e

o g

fo in p y

C o h t. rig p y y

co

b c t ed te

Pro G.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

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Electrical System, General Information - Edition 07.2010

– Open the crimping pliers and insert the end of the repair wire in the opening of the crimping pliers for wire stripping.

– Close the crimping pliers fully.

– Open the crimping pliers again and removed the stripped wire end.

– Push the single wire seal towards the stripped wire end until it is flush with the wiring insulation.

n l e s s

a ut ho r i s ed

b y

V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c

w h o le

, is

n o t

p e r m it t e d

u r i o rt a n

– Insert the new crimp contact in the mounting of the crimping pliers.

c ep t a ny li a b li i y t

w ith

r s e p c e t th o

t

c e e m c m

c r o e t

o a iv pr r

fo g in y p o

C t. h rig y p y co

b c t ed te

Pro G.

n A ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

2. Repairing wiring harnesses and connectors

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Electrical System, General Information - Edition 07.2010

– Insert the stripped wire end with the positioned single wire seal in the crimp contact until it comes into contact with the „wire stop“.

– Crimp the contact, wire and single wire seal by closing the crimping pliers fully.

– Open the crimping pliers again and remove the successfully crimped contact.

Successful crimping can be identified by clean and equal appli‐ cation of pressure on the wire and single wire seal in the contact and by a stamp on the rear that indicates the correct tool was used in the correct manner to carry out the crimping process.

y V es n ot g uar ante e

or a c n l e s s

a ut ho r i s ed

b

2.4.6

Wiring open circuit with one repair posi‐ tion

r i o rt a n

w h o le

, is

n o t

p e r m it t e d

u c ep t

a ny li a b li i y t

w ith

r s e p c e t th o

t

c e

Repair position with single crimp connector

– Place the wire to be repaired to one side (about 20 cm either side of the repair position).

– If necessary, unbind the wiring harness using the folding knife.

e c m m o r

c

o t e a iv r pr g

fo in

VAS 1978/3- .

y p o

C h t. rig

– Cut out the damaged piece of wiring using the wire strippers c t te

Pro G.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

Note

If, after the damaged wire has been cut out, both ends of the ve‐ hicle's own wiring are too short for a repair using single crimp connectors, use a piece of repair wire of the appropriate length with two crimp connectors

⇒ page 96 .

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Electrical System, General Information - Edition 07.2010

– Strip the wire ends of insulation by 6 - 7 mm using the wire strippers.

n l e s s

a ut ho r i s ed

b y V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c

w h o le

, is

n o t

p e r m it t e d

u

– Push the crimp connector on both stripped wire ends of the vehicle's own single wire and crimp it on using the crimping pliers.

r i o rt a n c ep t

a ny li a b li i y t

w ith

r s e p c e t th o

t

c e

Note c

♦ Ensure without fail that the correct crimp recess is chosen for

o m

m e the crimp connectors being used

⇒ page 82 .

r

c

♦ The insulation on the wires must not be crimped.

iv a t e

o r pr

After crimping, the crimp connector has to be shrink fitted using

– Place shrink element for hot air blower -VAS 1978/15- on hot air blower, 220 V / 50 Hz -VAS 1978/14- .

y p

C o h y rig y

co

b c t ed

– Heat up the crimp connector using the hot air blower along a straight line, working from the middle outwards, until it is sealed completely and the adhesive escapes from the ends.

te

Pro

Caution

When shrink-fitting, take care not to damage any other wiring, plastic parts or insulating material with the hot air blower.

Observe the operating instructions of the hot air blower without fail!

G.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

Note

♦ Ensure that, where several wires have to be repaired, the crimp connectors are not directly adjacent to each other. To prevent the circumference of the wiring harness from becom‐ ing to great, position the crimp connectors so they are offset slightly.

♦ If the repair position was already wrapped, this section has to be wrapped again with yellow insulation tape once the repair has been carried out.

♦ Attach the repaired wiring harness with a cable tie, if neces‐ sary, to prevent it from generating noise when the vehicle is in motion.

2. Repairing wiring harnesses and connectors

95

2.4.7

le

, is

n s

Wiring open circuit with two repair posi‐ tions

ut ho

Repair position with interlinked wire.

a r i o n

w h o r i s ed

b

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

o t

p e r m it t e d

u n

a y V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar

– Place the wire to be repaired to the side at two points (about

20 cm to both sides of the relevant repair position).

– If necessary, unbind the wiring harness using the folding knife.

c c ep t

a ny li a b li i y t

w ith

r s e p c e t th o

t

c e c e m wire.

m o r

c

o

– Place the yellow repair wire next to the damage wiring harness and, using wire strippers -VAS 1978/3- , cut the repair wire to the required length.

y in p

C o h t. rig y p y

co

b c t ed te

Pro G.

A n ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

– Strip the wire ends of insulation by 6 - 7 mm using the wire strippers.

– Push the crimp connector onto one side of the vehicle's own single wire and on the other side onto the repair wire.

– Crimp the connector using the crimping pliers to both wire ends.

– Repeat this procedure on the other end of the repair wire.

Note

♦ Ensure without fail that the correct crimp recess is chosen for the crimp connectors being used

⇒ page 82

.

♦ The insulation on the wires must not be crimped.

After crimping, the crimp connector has to be shrink fitted using the hot air blower in order to prevent any ingress of moisture.

– Place shrink element for hot air blower -VAS 1978/15- on hot air blower, 220 V / 50 Hz -VAS 1978/14- .

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– Heat up the crimp connector using the hot air blower along a straight line, working from the middle outwards, until it is sealed completely and the adhesive escapes from the ends.

Caution

When shrink-fitting, take care not to damage any other wiring, plastic parts or insulating material with the hot air blower.

Observe the operating instructions of the hot air blower without fail!

n l e s s

a ut ho r i s ed

b y V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c

♦

Note

w h o le

, is

n o t

p e r m it t e d

u

Ensure that, where several wires have to be repaired, the crimp connectors are not directly adjacent to each other. To prevent the circumference of the wiring harness from becom‐ ing to great, position the crimp connectors so they are offset slightly.

r i o rt a n

♦ If the repair position was already wrapped, this section has to be wrapped again with yellow insulation tape once the repair has been carried out.

c ep t

a ny li a b li i y t

w ith

r s e p c e t th o

t

c e

♦ Attach the repaired wiring harness with a cable tie, if neces‐ sary, to prevent it from generating noise when the vehicle is in motion.

m e m o

2.5

2.5.1

c

Repairs to contact housings and con‐ nectors

g

fo in p y o

Notes on repairs to contact housings and connectors

y

co

b c t ed te

Pro G.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

Note

♦ Observe the general notes on repairs to the vehicle electrical

system ⇒ page 85

.

♦ Allocation of the appropriate crimp contacts to the contact housings is by way of the part number stamped on the contact housing. Listed in illustration 198 (electrical connecting ele‐ ments) in ⇒ Electronic parts catalogue (ETKA) are the part numbers for the contact housings in conjunction with the as‐ sociated crimp contacts.

♦ Damaged contact housings must always be replaced.

♦ New contact housings can be ordered from the OTC in Kassel.

2.5.2

Repairs to contacts in contact housings

– If necessary, first open or disengage the secondary locking

mechanism of the contact housing ⇒ page 102 .

2. Repairing wiring harnesses and connectors

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– Disengage the contact (primary locking mechanism) using the appropriate release tool

⇒ page 102

.

– Pull the contact by the single wire out of the contact housing.

– Select the yellow repair wire with the correct contact from the wiring harness repair set .

– Place the wire to be repaired from the vehicle's own wiring harness to one side (about 20 cm either side of the repair po‐ sition).

– If necessary, unbind the wiring harness using the folding knife.

– Push the new contact of the repair wire into the contact hous‐ ing until it engages.

– Slide the single wire seal onto the repair wire.

Note

The small diameter of the single wire seal must face the contact housing.

– Slide the single wire seal into the contact housing using the correct assembly tool

⇒ page 99

.

– Trim the repair wire and the single wire of the vehicle's own wiring harness accordingly using wire strippers -VAS 1978/3- .

s

a ut ho r i s ed

b y V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c

– Strip the 6 - 7 mm of insulation from the end of the repair wire and the vehicle's own single wire using the wire strippers.

w h o le

, is

n m it t e d

u n l e s

– Crimp the stripped ends of the repair wire and single wire of the vehicle's own wiring harness using the crimping pliers and a crimp connector, as described in the chapter entitled „Wiring open circuits with one repair position“ rt a

⇒ page 94 .

c ep t

a ny li a b li i y t

w ith

r s e p c e t th o

t

c e e m c m

c r o e t

o a iv pr r

fo g in y p o

C t. h rig y p

co y

b c t ed te

98

Rep. gr.97 - Wiring

Pro G.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

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Electrical System, General Information - Edition 07.2010

Note

♦ Ensure that, where several wires have to be repaired, the crimp connectors are not directly adjacent to each other. To prevent the circumference of the wiring harness from becom‐ ing to great, position the crimp connectors so they are offset slightly.

♦ If the repair position was already wrapped, this section has to be wrapped again with yellow insulation tape once the repair has been carried out.

♦ Attach the repaired wiring harness with a cable tie, if neces‐ sary, to prevent it from generating noise when the vehicle is in motion.

2.5.3

Fitting single wire seals

Note

♦

♦

Single wire seals prevent the ingress of moisture and dirt in the contact housing. They are installed, for example, in the engine compartment and must always be reinstalled following repairs.

As standard, the single wire seal is crimped together with the contact on the wire; this is not the case with the repair wires.

n l e s s

a ut ho r i s ed

b y

V olk sw a ge es n ot g uar ante e

or a c

♦

Before crimping the repair line, the single wire seal must there‐ fore first be pushed onto the wire.

It is essential that the single wire seals are of the correct size to fit the cross section of the repair wire. The outer diameter of the single wire seal is based on the socket diameter of the contact housing. Only carry out the repair using the correct assembly tool.

a n r i

Assembling single wire seal:

– Disengage the contact locking mechanism using the appro‐ priate release tool -A- and then pull the wire with the single wire seal backwards -arrow- out of the contact housing.

c ep t a ny li a b li i y t

w ith

r s e p c e t th o

t

c e e m c m

c r o e t

o a iv pr r

fo g in y p o

C t. h rig y p y co

b c t ed te

Pro G.

n A ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

2. Repairing wiring harnesses and connectors

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– Cut off the old contact with the single wire seal from the vehi‐ cle's own wiring harness.

– Slide the repair wire with the new contact in the respective socket of the contact housing until it engages.

t e d

u n l e s s

b y

V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t a r m it

a ut ho r i s ed

n o t

p e r i o rt a

w n is

, o h le

– Place the single wire seal -A- on the free end of the repair wire.

Note ny li a i b li t y

w ith

r s e c e p o t

t e th

c

The small diameter of the single wire seal must face the contact housing.

– Slide the single wire seal -A- on the repair wire until it reaches m r

c o m e the contact housing.

o a t e iv pr r

– Slide the single wire seal -A- using the respective assembly tool -B- fully into the contact housing.

h t. rig p y y co

b c t ed te

Pro G.

n A ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

100

Rep. gr.97 - Wiring

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Electrical System, General Information - Edition 07.2010

– Trim the repair wire and the single wire of the vehicle's own wiring harness accordingly using wire strippers -VAS 1978/3- .

– Crimp the stripped ends of the repair wire and single wire of the vehicle's own wiring harness using the crimping pliers and a crimp connector, as described in the chapter entitled „Wiring

open circuits with one repair position“ ⇒ page 94

.

2.5.4

Repairs to contact housings using cut and clamp technique

Note

♦ For technical reasons, the contact housings for cut and clamp technique can only be supplied with the cut and clamp con‐

♦ tacts inserted.

These contacts can be removed just like any other contact housing if they are not needed.

y

V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c

♦ Repair wires can be supplied that already have the appropriate contacts crimped on ⇒ Electronics parts catalogue (ETKA) .

w h o le

, is

n o t

p e r m it t e d

u r i o rt a n n l e s s

a ut ho r i s ed

b c ep t a ny li a b li i y t

w ith

r s e p c e t th o

t

c e e m c m

c r o e t

o a iv pr r

fo g in y p o

C t. h rig y p y co

b c t ed te

Pro G.

n A ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

2. Repairing wiring harnesses and connectors

101

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

2.6

2.6.1

Releasing and dismantling contact housings

Notes on releasing and dismantling con‐ tact housings

t e d

u n l e s s

a ut ho r i s ed

b y V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t

a

Note r m it

♦ Observe the general notes on repairs to the vehicle electrical system

⇒ page 85 .

is

,

n o t

p e

♦ To release, always use the correct release tools. Under no housings with force.

r i o rt a

w n o h le circumstances should the contacts be pulled out of the contact

♦ Damaged contact housings must always be replaced. New contact housings can be ordered from the OTC in Kassel.

ny li a b li i t y

w ith

r s e c e p o t

t e th

c

♦ As an aid to disengage the secondary locking mechanisms, a small screwdriver can be used.

♦ The socket/pin assignment can be found stamped on the sec‐ ondary locking mechanism or on the rear of the contact hous‐ ing.

c m e

c o m

♦ For more detailed information about the locations of connec‐ tors, see ⇒ Current flow diagrams, Electrical fault finding and

Fitting locations.

iv a t e

o r pr

fo g

C o p y in

Allocation of the correct release tool to the respective locking de‐ vices can be gleaned from the table in the ⇒ operating instruc‐ tions of -VAS 1978/35- .

y

b c t ed te

Pro

2.6.2

Secondary locking element

G.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

The secondary locking mechanism is a housing catch (second line locking mechanism) that secures all the wires in one contact housing. If a secondary locking mechanism is fitted to a contact housing, this must always be opened or removed using the ap‐ propriate tool before releasing and pulling out individual crimp contacts.

The secondary locking mechanism is different in colour from the rest of the contact housing. This makes it easier to identify the secondary locking mechanism and clarifies its intended function.

The types of contact housing shown here are just a few examples to show the different functions of secondary locking mechanism.

Example 1:

The housing catch is disengaged by removing a „toothed ele‐ ment“ -arrow-.

102

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Electrical System, General Information - Edition 07.2010

Example 2:

The housing catch is disengaged by opening a „flap“ -arrow-.

Example 3:

The housing catch can be disengaged by detaching a „slide“

-arrow-.

r i o rt a n

w h o le

, is

n o t

p e r m it t e d

u

2.6.3

n l e s s

a ut ho r i s ed

b y

V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c

Primary locking element

contact in the contact housing.

c ep t a ny li a b

The primary locking mechanism is what fixes an individual crimp

If necessary, any housing catches in place (secondary locking mechanisms) must be released or removed prior to disengaging the contacts using the prescribed tool

⇒ page 102

.

li i y t

w ith

r s e p c e t th o

t

c e

The types of primary locking mechanisms shown as follows are just a few examples to show the different functions of primary locking mechanism.

e m c m

♦ Round connector systems ⇒ page 103

♦ Flat connector systems

⇒ page 104

o r

c

♦ Special connector systems

e a t pr of -VAS 1978/35- .

2.6.4

y o p

Note

C h t. rig

⇒ page 106

Round connector systems

p y y co

b c t ed te

Pro G.

n A a ge sw olk

V y ht b rig o py

C t.

en o c um

d

th n a m

If necessary, any housing catches in place (secondary locking mechanisms) must be released or removed prior to disengaging the contacts using the prescribed tool

⇒ page 102

.

2. Repairing wiring harnesses and connectors

103

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Electrical System, General Information - Edition 07.2010

– Insert the release tool appropriate for the contact housing in the release port of the contact housing.

– Grab hold of the contact by the wire and push it lightly into the contact housing -arrow-.

Note

By pushing the contact in the direction of the contact housing, the locking tabs of the contact are lifted up by the housing edge and disengaged using the release tool.

– At the same time, push the release tool in the direction of the contact housing -arrow- and pull out the released contact from the contact housing.

– The release tool can be pulled out of the contact housing again once the contact has been removed.

2.6.5

Note

Flat connector systems

r m

it t e d

u n l e s s

a ut ho r i s ed

b y V olk sw a ge n AG

.

V olk s w a g en AG do

If necessary, any housing catches in place (secondary locking mechanisms) must be released or removed prior to disengaging

the contacts using the prescribed tool

Flat connector with one locking tab:

⇒ page 102

n o t

p

.

is

, o h le

– Insert the release tool appropriate for the contact housing in the release port of the contact housing.

– Grab hold of the contact by the wire and push it lightly into the contact housing -arrow-.

r i o rt a

w n es n ot g uar ante e

or a c c ep t

a ny li a b li i t y

w ith

r s e c e p o t

t e th

c

Note

By pushing the contact in the direction of the contact housing, the be disengaged using the release tool.

e r

c o m m c locking tab of the contact is lifted up by the housing edge and can

o t e a iv r pr g

fo in p y

C o h t. rig p y y

co

b c t ed te

Pro G.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

104

Rep. gr.97 - Wiring

a ut ho r i s ed

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

– At the same time, push the release tool in the direction of the contact housing and pull out the released contact from the contact housing -arrow-.

n o t

p e r m it t e d

u n l e s s

b y V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t

a ny li a b li i t y

w

– The release tool can be pulled out of the contact housing again once the contact has been removed.

r i o rt a

w n ith

r s e c e p o t

t e th

c

Flat connector with two locking tabs: m e c m

c o the release port of the contact housing.

a

– Grab hold of the contact by the wire and push it fully into the contact housing -arrow-.

Note

fo g in p y

C o h t. y rig p

co y

b t ed

By pushing the contact in the direction of the contact housing, the locking tabs of the contact are lifted up by the housing edge and disengaged using the release tool.

Pro

– At the same time, push the release tool in the direction of the contact housing and pull out the released contact from the contact housing -arrow-.

– The release tool can be pulled out of the contact housing again once the contact has been removed.

G.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

Asymmetrical:

– Insert the release tool appropriate for the contact housing in the release port of the contact housing.

– Grab hold of the contact by the wire and push it lightly into the contact housing -arrow-.

Note

By pushing the contact in the direction of the contact housing, the locking tabs of the contact are lifted up by the housing edge and disengaged using the release tool.

2. Repairing wiring harnesses and connectors

105

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Electrical System, General Information - Edition 07.2010

– At the same time, push the release tool in the direction of the contact housing and pull out the released contact from the contact housing -arrow-.

– The release tool can be pulled out of the contact housing again once the contact has been removed.

2.6.6

Special connector systems

Note ed

b

If necessary, any housing catches in place (secondary locking mechanisms) must be released or removed prior to disengaging

the contacts using the prescribed tool

y V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar

⇒ page 102 .

ante e

or a c

Faston contacts:

w h o le

, is

n o t

p e r m it t e d

u

– Insert the release tool appropriate for the contact housing in the release port of the contact housing.

– Grab hold of the contact by the wire and push it lightly into the contact housing.

r i o rt a n

Note c ep t

a ny li a b li i y t

w ith

r s e p c e t th o

t

c e

By pushing the contact in the direction of the contact housing, the locking tabs of the contact are lifted up by the housing edge and disengaged using the release tool.

c e m o m contact housing and pull out the released contact from the contact housing -arrow-.

iv a pr – The release tool can be pulled out of the contact housing again once the contact has been removed.

p

C o h t. rig p y y

co

b c t ed te

Pro G.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

106

Rep. gr.97 - Wiring

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

GT 150/280 contacts:

– Insert the release tool appropriate for the contact housing un‐ der the locking tab into the contact housing.

– Push the tool onto the limit stop -arrow- in the contact housing.

The contact is ejected from the contact housing.

– The release tool can be pulled out of the contact housing again once the contact has been ejected.

n l e s

w h o le

, is

n o t

p e r m it t e d

u r i o rt a n s

a ut ho r i s ed

b y

V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t a ny li a b li i y t

w ith

r s e p c e t th o

t

c e

Contacts without locking tabs:

– Insert the release tool under the locking tab of the contact housing.

– Push through the release tool with a light upward movement e o m m c

-arrow- onto the limit stop.

r

c

o a t e iv r pr g

fo y in o p

C h t. rig p y y co c t ed te

Pro G.

n A ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

2. Repairing wiring harnesses and connectors

107

3

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Electrical System, General Information - Edition 07.2010

Contact surface cleaning set -VAS

6410-

3.1

Using contact surface cleaning set -VAS

6410-

The contact surface cleaning set -VAS 6410- allows optimal repair quality to be achieved in the area of vehicle electrics. The tools allow performing repair work in the area of the sensor in wiring harnesses for threaded connections in the high-current circuit

(starting and charging current). The contact surface cleaning set

-VAS 6410- is adapted to the structural conditions of vehicles and ensures the process security of repair work as well as a comfort‐ able procedure.

Note l e s s

a ut ho r i s ed

b ante e

or a c c ep t

a ny li a b The illustrations shown here are just a few examples of repair work.

r i o rt a n

w h o le

, is

n o t

p e r m it t e d

u

Contact surface cleaning set VAS 6410 li i y t

w ith

r s e p c e t th o

t

c e

3.1.1

Repairing ring terminals

Special tools and workshop equipment required m e c

♦ VAG 1331 r

c o m

o t e a iv r pr g

fo in p y

C o h t. rig p y y

co

b c t ed te

Pro G.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

Note

♦ The use of penetrating fluid, contact spray or grease etc. is prohibited since the missing adhesion in the threads may cause a torque excess and, therefore, the break of the threa‐ ded connection.

♦ The grey sanding pads are suitable for light dirt and "soft sur‐ faces". The red sanding pads are suitable for heavy dirt and

"hard surfaces".

108

Rep. gr.97 - Wiring

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Electrical System, General Information - Edition 07.2010

WARNING

Danger of injury! Observe warning notices and safety regula‐

tions ⇒ page 2 !

– Disconnect battery.

– Loosen cap nut and remove ring terminal from threaded con‐ nection.

– Check ring terminal for corrosion, dirt etc.

– Select suitable adapter and suitable sanding pad.

Note

As an alternative, the sanding block may also be used.

Caution

Take care not to abrade excessively the tin coating and ensure that the copper does not appear. This could produce a galvanic cell which destroys metal and causes faulty repair.

Note sign, the cleaning process must be performed step by step and a t e d

u n l e s s

a ut ho r i s ed

As the thickness of the tin coating may differ according to the de‐ visual check of the ring terminal is necessary between the steps.

r m it

n o t

p e

b y

V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t a

– Insert adapter into ring terminal and grind off corrosion and dirt with circular movements.

o h le

– Check ring terminal and regrind if necessary.

r i o rt a

w n ny li a i b li t y

w ith

r s e c e p o t

t e th

c e m c m

c r o e t

o a iv pr r

fo g in y p o

C t. h rig y p y co

b c t ed te

Pro G.

n A ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

3. Contact surface cleaning set VAS 6410

109

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Electrical System, General Information - Edition 07.2010

– If necessary, remove punching burr on ring terminal using the deburrer.

– Tighten ring terminal to specified torque ⇒ Current flow dia‐ grams, Electrical fault finding and Fitting locations.

Note

Optimum contact is ensured when the components to be secured are tightened to the specified torque after cleaning.

– Apply suitable anti-corrosion treatment to connection

⇒ page 113

.

– Reconnect battery.

WARNING

Danger of injury! Observe warning notices and safety regula‐ tions

⇒ page 2

!

r m it t e d

u n l e s s

a ut ho r i s ed

b y

V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t a

– Teach in electric windows again, enter radio code, set clock and, if necessary, recode control units which emit code sig‐ nals.

o h le is

,

n o t

p e

3.1.2

r i o rt a

w n

Repairing threaded connections

Special tools and workshop equipment required ny li a i b li t y

w ith

r s e c e p o t

t e th

c

♦ VAG 1331 e m c m

c r o e t

o a iv pr r

fo g in y p o

C t. h rig y p y co

b c t ed te

Pro

Note

♦ The use of penetrating fluid, contact spray or grease etc. is prohibited since the missing adhesion in the threads may cause a torque excess and, therefore, the break of the threa‐ ded connection.

♦ The grey sanding pads are suitable for light dirt and "soft sur‐ faces". The red sanding pads are suitable for heavy dirt and

"hard surfaces".

WARNING

Danger of injury! Observe warning notices and safety regula‐ tions

⇒ page 2

!

– Disconnect battery.

110

Rep. gr.97 - Wiring

G.

n A ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

– Loosen cap nut and remove ring terminal from threaded con‐ nection.

– Check threaded connection for corrosion, dirt etc.

– Select suitable adapter and suitable sanding pad for threaded connection.

Caution

Take care not to abrade excessively the tin coating and ensure that the copper does not appear. This could produce a galvanic cell which destroys metal and causes faulty repair.

Note

As the thickness of the tin coating may differ according to the de‐ sign, the cleaning process must be performed step by step and a visual check of the ring terminal is necessary between the steps.

– Set adapter on threaded connection and grind off corrosion and dirt with circular movements.

– Check threaded connection and regrind if necessary.

– Tighten connection and, if necessary, locating element again to specified torque ⇒ Current flow diagrams, Electrical fault finding and Fitting locations.

Note

Optimum contact is ensured when the components to be secured are tightened to the specified torque after cleaning.

– Apply suitable anti-corrosion treatment to threaded connection

⇒ page 113 .

– Reconnect battery.

a ut ho r i s ed

b y

V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t a

WARNING t e d

u n l e s s r m it

Danger of injury! Observe warning notices and safety regula‐

tions ⇒ page 2 !

is

,

n o t

p e nals.

r i o rt a

w n o h le

– Teach in electric windows again, enter radio code, set clock and, if necessary, recode control units which emit code sig‐ ny li a i b li t y

w ith

r s e c e p o t

t e th

c

3.1.3

Cleaning battery clamp and battery ter‐ minal

Special tools and workshop equipment required e c m m o r

c

o a t e iv r pr

fo g in y o p

C t. h rig p y y co

b c t ed te

Pro n

th

d o c t.

en rig

C o py y ht b olk

V a ge sw

G.

n A

3. Contact surface cleaning set VAS 6410 um

111 a m

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

♦ VAG 1331

Note

The use of penetrating fluid, contact spray or grease etc. is pro‐ hibited since the missing adhesion in the threads may cause a torque excess and, therefore, the break of the threaded connec‐ tion.

WARNING r m it t e d

u n l e s s

a ut ho r i s ed

b y

V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t a

Danger of injury! Observe warning notices and safety regula‐ tions

⇒ page 2

!

is

, o h le

n o t

p e

– Disconnect battery.

r i o rt a

w n

– Check battery clamp and battery terminal for corrosion or dirt.

ny li a i b li t y

w ith

r s e c e p o t

t e th

c

– Clean battery clamp using wire brush of battery terminal clean‐ er with circular movements.

e m c m

c r o e t

o a iv pr r

fo g in y p o

C t. h rig y p y co

b c t ed te

Pro G.

n A ge a sw olk

V y ht b rig py o

C t.

en um c o

d

th n a m

112

Rep. gr.97 - Wiring

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

– Clean battery terminal using underside of battery terminal cleaner with circular movements.

WARNING r i o rt a n

w h o le

, is

n

Danger of injury! Observe warning notices and safety regula‐

tions ⇒ page 2 !

s

a ut ho r i s ed

b

– Reconnect battery and tighten battery terminals to specified torque.

n y

V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t a ny li a b o t

p e r m it t e d

u

Note

Optimum contact is ensured when the components to be secured are tightened to the specified torque after cleaning.

3.1.4

Anti-corrosion treatment

li i y t

w ith

r s e p c e t th o

t

c e

Caution

Missing anti-corrosion treatment results in damage to the on‐ board supply.

e m c m o r

c

♦

♦

♦

o e t a iv pr

fo

Note que.

in p y o

C h t. rig

Use protection wax for cold area.

G.

n A

♦ Use cavity sealing agent for warm area.

ge a sw olk

V o py

C um

♦ The sealing agent independently reaches the respective points through capillary action.

c o

d

th n a m

– Hold injector below ring terminal and spray pin all around.

3. Contact surface cleaning set VAS 6410

113

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Electrical System, General Information - Edition 07.2010

– Hold injector above ring terminal and spray pin and wiring eye all around.

r i o rt a n

w h o le

, is

n o t

p e r m it t e d

u n l e s s

a ut ho r i s ed

b y V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t

a ny li a b li i y t

w ith

r s e p c e t th o

t

c e e m c m

c r o e t

o a iv pr r

fo g in y p o

C t. h rig y p

co y

b c t ed te

114

Rep. gr.97 - Wiring

Pro G.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

4

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

Renewing Lambda probe

Note

♦ Do not repair lambda probe wires, since this can result in mal‐ functions.

♦ If necessary, replace attachment parts, cable ties or marking rings to match the uniform probe to the defective probe as specified.

♦ Identify the lambda probe by way of the protective tube as re‐

quired ⇒ page 117 .

4.1

Renewing LSF Lambda probe (4-pin)

Note

♦ If necessary, replace attachment parts, cable ties or marking rings to match the uniform probe to the defective probe as specified.

♦ Do not repair lambda probe wires, since this can result in mal‐ functions.

– Remove the defective Lambda probe.

– Place both Lambda probes next to each other so that the sen‐ sor housings are at the same height.

r i o rt a

w n o h le is

,

n o t

p e r m it t e d

u n l e s s

a ut ho r i s ed

b y V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t

a ny li a b li i t y

w ith

r s e c e p o t

t e th

c e m c m

c r o e t

o a iv pr r

fo g in y p o

C t. h rig y p

co y

b c t ed te

Pro G.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

4. Renewing Lambda probe

115

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Electrical System, General Information - Edition 07.2010

– Tie back any excess in the uniform probe length (approx. 50 -

250 mm) to the size of the defective probe and secure with cable ties -1-.

– Check that the connector housing of the Lambda probe is compatible with the onboard supply side.

– If necessary, replace the onboard supply system connector with the Lambda probe connector housing supplied

⇒ page 97

Note

♦ The connector housing should only be replaced on older ve‐ hicles. On new vehicles, the connector housing coding match‐ es.

♦ Observe pin assignment. For reasons of clarity, respective pins in new connector housing have a colour marking.

♦ Further notes can be found in the leaflet of the new lambda probe.

– Install the new Lambda probe in the vehicle.

4.2

Renewing LSU Lambda probe (6-pin)

Note

♦

♦

b y V olk sw a ge n AG

.

V olk s w a g en

If necessary, replace attachment parts, cable ties or marking rings to match the uniform probe to the defective probe as specified.

The wires should not be crimped or cut as otherwise the func‐ t e d

u n l e s s

a ut ho r i s ed tion of the Lambda probe will be impaired.

es n ot g uar ante e

or a c c ep t

a

– Remove the old Lambda probe.

n o t

p e r m it

– Place both Lambda probes next to each other so that the sen‐ sor housings are at the same height.

o h le r i o rt a

w n ny li a b li i t y

w ith

r s e c e p o t

t e th

c e m c m

c r o e t

o a iv pr r

fo g in y p o

C t. h rig y p

co y

b c t ed te

Pro G.

n A ge a sw olk y

V ht b rig py o

C t.

en um c o

d

th n a m

116

Rep. gr.97 - Wiring

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Electrical System, General Information - Edition 07.2010

– Tie back any excess in the uniform probe length (approx. 50 -

250 mm) to the size of the defective probe and secure with cable ties -1-.

– Install the new Lambda probe in the vehicle.

4.3

is

,

n o t

p e r m it t e d

u n l e s s

a ut ho r i s ed

b y

V olk sw a ge n AG

.

V olk s w a g en AG do es n ot g uar ante e

or a c c ep t a

Types of protective tube on uniform

Lambda probes

o h le r i o rt a

w n

Note

In addition to identifying by way of the part number, the protective tube can also be used as a means of identification.

ny li a i b li t y

w ith

r s e c e p o t

t e th

c

Type D1, 6 openings at 3.5 mm each

Only used on 4-pin LSF Lambda probes.

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Only used on 4-pin LSF Lambda probes and 6-pin LSU Lambda probes.

Type D4, 12 openings at 1.4 mm each

4. Renewing Lambda probe

117

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

Only used on 4-pin LSF Lambda probes and 6-pin LSU Lambda probes.

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118

Rep. gr.97 - Wiring e m c m

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