Volkswagen Polo 1995 - 2010 Workshop Manual - Electrical System

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 ➤ , wTouaregagen
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Electrical System, General Information
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Service Department. Technical Information
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Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
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27 - Starter, current supply, CCS rised ara
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90 - Gauges, instruments ss a ra
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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

olkswagen AG
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Contents
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27 - Starter, current supply, CCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.1 Fundamentals for batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.2 Types of batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
spec
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1.3 Warning notices and safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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1.4 Battery terminal connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Checking battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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2.1 Checking the various types of batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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2.3 Checking colour display of magic eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.4 Battery tester with printer VAS 5097 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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2.5 Battery tester with printer VAS 6161 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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2.6 Midtronics MCR340V battery tester only for USA/Canada vehicles . . . . . . . . . . . . . . . . . . 18
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2.7 Current draw test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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

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3 Charging battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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3.1 Battery charger VAS 5095 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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3.2 Battery charger VAS 5900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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3.3 Battery charger VAS 5903 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
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3.4 Battery charger VAS 5906 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Prote
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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
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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ii Contents
27 – Starter, current
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Caution
To prevent damage to the battery and vehicle, the following
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1.1 Fundamentals for batteries
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1.2 Types of batteries
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Caution
The description for the following batteries is for maintenance-

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

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1.3 Warning notices and safety regulations
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1.3.1 Dangers when handling vehicle batter‐
ies
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Recognition and avoidance of dangers
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2 Rep. gr.27 - Starter, current supply, CCS

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.
♦ The gas which forms when charging and the gas which
may escape through vent valves is explosive. In extreme
cases a battery may explode if the battery is not handled
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♦ Batteriesemust y V be renewed where the magic geye
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♦ It is prohibited to cause sparks through grinding, welding, an
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cutting operations and use naked lights in the vicinity of
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batteries. Smoking is also prohibited. Sparks generated
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♦ Only work on batteries in well ventilated and suitable

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1.3.2 Safety markings on battery

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Safety markings on battery

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handling batteries. Avoid sparks as well as electrostatic discharge

when working with cables and electrical units. Avoid short circuits.
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Therefore never lay a tool on a battery.

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2. - Wear eye protection before commencing work on battery.

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3. - Keep children away from acid and batteries.

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

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5. - Never dispose of old batteries in household waste system!
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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.
1. Battery 3
1.4 Battery terminal connection
Caution
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♦ Battery terminals should not be coated with grease.
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♦ The battery clamps should be fitted so that the battery ter‐
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♦ Once the battery clamps have been tightened to the speci‐
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2 Checking battery
WARNING

tions ⇒ page 2 !
Caution

2.1 Checking the various types of batteries
2.1.1 Checking battery with magic eye
WARNING

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
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3. Perform a battery load test using battery tester with printer

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

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⇒ page 14 .
4. Depending on the result of the battery test, „perform current
draw test“ ⇒ page 22 .
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2.1.2 Absorbent glass mat battery

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1. Visual check ⇒ page 6

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2. Perform a battery load test using battery tester with printer

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⇒ page 14
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3. Depending on the result of the battery test, „perform current

draw test“ ⇒ page 22 .
2.2 Visual check
WARNING

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 Acan
G. Voleak out
lkswagen AifGthe
housing is damaged. If battery acid s wagen out, serious damage
leaks does
olk no
to the vehicle could be caused. d by Treat
V components affected by t guara
leaked battery acid immediately
ris
e
with acid neutraliser or a soap nte
solution. utho eo
ra
a c
ss
♦ Check whether the battery terminals (battery wire connec‐
ce
e
nl
pt
du
tions) are damaged. The necessary contact on the battery

an
itte
clamps cannot be guaranteed if the battery terminals are dam‐

y li
erm
ab
aged. When connecting the battery clamps, tighten the battery

ility
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clamps to torque specified in this workshop manual „Electrical

wit
, is n
system“ for the respective vehicle. If the battery clamps are

h re
not correctly seated and tightened, the wiring may burn. Which
hole
spec
will cause malfunctions in the electrical system. Therefore it

es, in part or in w
can no longer be guaranteed that the vehicle will function cor‐

t to the co
rectly.
2.3 Checking colour display of magic eye

rrectness of i
l purpos
2.3.1 Checking colour display of „3-colour“

nform
ercia
magic eye
m
at
om
ion
c
WARNING
in t
or
his
ate
do
riv

p
cum
or
tions ⇒ page 2 !
f
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t.
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Cop py
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Prote AG.

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‐
tery. AG. Volkswagen AG d
agen oes
olksw not
V gu
Three different colour d b displays are possible:
y ara
rise nte
o eo
♦ »Green«, abattery
ut
h
is charged sufficiently. ra
ss c
♦ »Black«, battery partly discharged, charge state < 65 % or
ce
le
un
pt
completely discharged
an
d
itte
y li
erm
♦ »Colourless or light yellow«, battery must be renewed.

ab
ility
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wit
is n
WARNING
h re
ole,
spec

t to the co

jump starting
rrectne

ss o
cial p
f inform
2.3.2 Checking colour display of „2-colour“

mer
atio
magic eye
om
n
c
i
or
n thi
te
sd
a
WARNING
iv
o
pr
cum
r
fo
en
ng

t.
yi Co
op
tions ⇒ page 2 ! C py
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pyri by
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by
cted agen
Prote AG.
2. Checking battery 7
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‐ olkswage es n
ot g
tery. d byV ua
ran
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tho
u or
Three different colour displays are possible: ss
a ac
ce
e
♦ »Black«, electrolyte level is OK.

nl
pt
du
an
itte
y li
♦ »Colourless or light yellow«, electrolyte level too low. The bat‐
erm
ab
tery must be renewed.
ility
ot p
wit
, is n
h re
WARNING
hole
spec
es, in part or in w
t to the co
Danger of explosion when checking and charging or slave/ rrectness of i
jump starting
l purpos

nf
ercia
or
2.4 Battery tester with printer -VAS 5097 A-

m
m
atio
om
n in
or c
thi
WARNING
te
sd
iva
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r
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cu

o
m
f
en
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tions ⇒ page 2 !
t.
yi Co
Cop py
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It is not necessary to remove or disconnect battery when using
c by lksw
cted agen
battery tester with printer -VAS 5097 A- . Prote AG.
Battery tester with printer -VAS 5097 A- can be used to test 12 V

starter batteries.

♦ 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. AG. Volkswagen AG d
agen oes
lksw not
For test purposes the battery is loaded with a current which by V is
o gu
ara
similar to the starting current required to start the vehicle. rised
The nte
battery is assessed on this loading and the resultauis th printed out.
o eo
ra
ss c
ce
e
nl
pt
du
Note
an
itte
y li
erm
ab
Observe the ⇒ instruction manual of Battery tester with printer -
ility
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VAS 5097 A- or the sticker ⇒ Brief instructions for battery tester
wit
, is n
with printer -VAS 5097 A- on the unit or table: Cold cranking cur‐
h re
hole
rent ⇒ page 11 .
spec
es, in part or in w
t to the co
2.4.1 Description of battery tester with printer
-VAS 5097 A-
rrectness of i
Battery tester with printer -VAS 5097 A-
l purpos
1 - Green LED, „unit operating“
nform
ercia
2 - Red LED, „unit reverse-polarity connected“

m
at
3 - Red LED, „battery cannot be tested“, recharge battery.
om
ion
c
in t
4 - Start button
or
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ate
do
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5 - Cold cranking current selection switch

p
cum
for
6 - ON/OFF and functions switch
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ng
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7 - Selection switch (battery tester to pick-off point on battery/
C py
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external test point in engine compartment)
rig ht
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8 - Paper feed button
agen
Prote AG.
9 - Printer
2.4.2 Performing battery load test using bat‐

tery tester with printer -VAS 5097 A-
WARNING

tions ⇒ page 2 !
Special tools and workshop equipment required
♦ Battery tester with printer -VAS 5097 A-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
Note
itte
y li
erm
ab
ility
ot p
Observe technical product information TPI 2012182 for battery
wit
tester with printer -VAS 5097 A- .
, is n
h re
hole
spec
Performing battery load test:
es, in part or in w
t to the co
WARNING
rrectness of i
l purpos

nform
ercia
jump starting
m

at
om
ion
c
in t
or
his
ate
do
priv
cum
or
Note
f
en
ng
t.
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op
The battery must have a temperature of at least 10 °C.
C py
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pyri by
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– Switch off ignition and all electrical consumers. cted agen
Prote AG.
– Check magic eye on batteries with magic eye ⇒ page 5 .

– 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 .
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 .

lkswage es n
o ot g
byV ua
ed ran
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Bora
oris 1999 ➤ , Bora Variant 1999 ➤ , CC 2010
tee ➤ , Eos 2006 ➤ , Golf 199 ...
t or
au Electrical System, General aInformation
c - Edition 07.2010
ss
ce
le
un
pt
an
d
itte
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Note
erm
ab
ility
Batteries with cold cranking current higher than 499 A according ot p
wit
is n
to DIN (e.g. 520 A, 580 A or 600 A) can be temporarily tested
h re
ole,
using setting for 499 A according to DIN.
spec
t to the co
– Connect red terminal „+“ of tester to positive terminal.
– Connect black terminal „-“ of tester to negative terminal.
rrectne
Note
ss o
cial p
f in
♦ Ensure test clamps have a good contact!
form
mer
atio
♦ Observe technical product information TPI 2012182 for battery
om
tester with printer -VAS 5097 A- .
n
c
i
or
n thi
te
sd
va
– Select point of connection of test terminals with selection

i
o
pr
cum
switch ⇒ page 9 .
r
fo
en
ng
t.
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1- Connected directly to battery
Co
Cop py
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gh
2- Connected to external test points in engine compartment
ht
pyri by
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by
cted
– Check that the figures given on the battery are correct for the
agen
Prote AG.
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.
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 Table: cold cranking current

Cold cranking current in A
EN/ SAE IEC ⇒ DIN
136 – 17 95 – 124 ⇒ 80 – 104
178 – 219 125 – 154 ⇒ 105 – 129
220 – 261 155 – 184 ⇒ 130 – 154
262 – 303 185 – 214 ⇒ 155 – 179
304 – 345 215 – 244 ⇒ 180 – 204
346 – 387 245 – 274 ⇒ 204 – 229
388 – 429 275 – 304 ⇒ 230 – 254
430 – 471 305 – 334 ⇒ 255 – 279
472 – 513 335 – 364 ⇒ 280 – 304
Cold cranking current in A

EN/ SAE IEC ⇒ DIN
514 – 555 365 – 394 ⇒ 305 –329
556 – 597 395 – 424 ⇒ 330 – 354
598 – 639 425 – 454 ⇒ 355 – 379
640 – 657 455 – 464 ⇒ 380 – 389
658 – 675 465 – 474 ⇒ 390 – 399
676 – 693 475 – 484 ⇒ 400 – 409
694 – 711 485 – 494 ⇒ 410 – 419
712 – 729 495 – 504 ⇒ 420 – 429
730 – 747 505 – 514 ⇒ 430 – 439
748 – 765 515 – 524 ⇒ 440 – 449
766 – 783 525 – 534 ⇒ 450 – 459
784 – 801 535 – 544 ⇒ 460 – 469
802 – 819 545 – 554 ⇒ 470 – 479
820 – 837 555 – 564 ⇒ 480 – 489
838 – 855 565 – 574 ⇒ 490 – 4992) 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.
AG. Volkswagen AG d
agen oes
olksw not
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is nte
2.4.4 Evaluating test result of battery load test
or eo
h
aut ra
ss c
Because of the high load on the battery during this test (a high
ce
e
nl
pt
current flows) the battery voltage drops.
du
an
itte
y li
♦ If the battery is OK, the voltage value drops only to the mini‐
erm
ab
ility
mum voltage.
ot p
wit
, is n
♦ If the battery is defective or has a low charge, the battery volt‐

h re
hole
age quickly drops below the minimum voltage.

spec
es, in part or in w
♦ After the test is completed, this low voltage value remains over t to the co
a longer period, and the voltage increases very slowly again.
♦ Perform test once only. Repeating the test falsifies the result.
rrectness of i
♦ The tester requires approx. 30 minutes to cool down before

l purpos
carrying out another test or testing another battery to ensure

the results are not falsified.
nf
ercia
orm
m
atio
om
n in
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thi
te
sd
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f
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ng
t.
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Cop py
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rig ht
py by
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by lksw
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Prote AG.

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
wage
Note yV
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d b ua
ran
ir se tee
♦ The test printout is urequired
tho for warranty claims. or
a ac
ss
♦ Perform test once only. Repeating immediately the test falsi‐
ce
e
nl
fies the result.
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
2.4.6 Assessing test results
spec
es, in part or in w
t to the co
Printout from battery tester Measure to be performed
Starting capability very good Battery OK.
rrectness of i
Starting capability good Battery OK.
l purpos
Starting capability sufficient Evaluation by carrying out a

current draw test when charg‐
ing ⇒ page 22
nf
ercia
o
Starting capability poor Evaluation by carrying out a
rm
m
atio
om
ing ⇒ page 22
n in
or c
thi
e
Starting capability very poor Evaluation by carrying out a

t
sd
iva

o
r
rp
cu
ing ⇒ page 22
o
m
f
en
ng
t.
yi
Cannot be tested Perform battery charging
Co
op py
⇒ page 25 and repeat test.
t. C rig
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pyri by
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co lksw
by
cted agen
Prote AG.
2.5 Battery tester with printer -VAS 6161-

General description
WARNING

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

agen
AG. Volkswagen AG d
oes
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-VAS 6161- db
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gu
ar
e an
ris tee
1 - Integrated printer tho or
s au ac
2 - Operating lever for paper compartments
ce
e
nl
pt
du
an
3 - Paper slot
itte
y li
erm
ab
4 - LCD screen with main menu

ility
ot p
wit
5 - Control panel with On/Off button

, is n
h re
hole
6 - Connection for battery test cable

spec
es, in part or in w
7 - Memory card slot

t to the co
8 - Infrared temperature sensor

rrectness of i
9 - Data transmitter for PC

l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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Vo
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by c lksw
cted
14
agen
Prote AG.
Rep. gr.27 - Starter, current supply, CCS
2.5.2 Perform battery test with battery tester

with printer -VAS 6161- .
WARNING

tions ⇒ page 2 !

♦ Battery tester with printer -VAS 6161-
Performing battery test: AG. Volkswagen AG d

agen oes
olksw not
V gu
d by ara
WARNING orise nte
eo
h
aut ra
s c
Batteries where the magic eye is colourless or light yellow must s
ce
le

un
pt
an
d
itte
y li

rm
ab
jump starting
pe
ility
ot
wit
, is n

h re
hole
spec
es, in part or in w
– Switch off ignition and all electrical consumers.

t to the co

rrectness of i
– Switch on unit.
l purpos

nform
mercia
a
com
Note
ion in
r
te o
thi
Ensure test clamps have a good contact!

s
iva
do
r
rp
cum
fo
– Select one of the following functions.

en
ng
t.
yi Co
op
♦ Maintenance test (only in new cars before registration, in sta‐
C py
t. rig
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tionary and stock maintenance programme ⇒ page 16 )
ht
pyri by
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by c lksw
♦ Service test ⇒ page 16
cted agen
Prote AG.
♦ Guarantee test ⇒ page 17
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.
AG. Volkswagen AG d
2.5.3 Performing maintenance test y Volksw
agen oes
not
gu
d b ara
rise nte
ho eo
WARNING aut ra
c
ss
ce
le
un
pt
an
d

itte
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erm
ab
ility
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jump starting
wit
is n
h re
ole,
spec
t to the co
– Select „Maintenance test“ in the menu.
– Connect scanner.
rrectnes
Note
s o
cial p
f inform
If no scanner is available, write vehicle identification number on
mer
test printout by hand.
atio
om
n
c
i
or
n
– Scan in vehicle identification number.
thi
te
sd
iva
o
– Select „On battery terminal“ or „On jump-start point“.
pr
cum
r
fo
en
ng
– Scan in barcode or select type and manufacturer manually in

t.
yi Co
op
menu. C py
t. rig
gh ht
yri
– Measure temperature. Hold temperature sensor about 5 cm
p by
co Vo
by lksw
above terminal connection until temperature stabilises. Prote
cted AG.
agen
– Start test.
– Print out test log if necessary.
2.5.4 Perform service test
WARNING

jump starting
– Select „Service test“ in the menu.

– Select vehicle type.
above one battery terminal until temperature stabilises.

– 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

jump starting
– Select „Guarantee test“ in the menu.

– Select „In vehicle“ or „Outside vehicle“.
– Select vehicle type.
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.
AG. Volkswagen AG d
agen oes
– Print out test log if necessary. olksw not
byV gu
ara
ed
2.5.6 Comments concerning test print out ris nte
ho eo
aut ra
s c
1- Check type. s
ce
le
un
pt
2- Battery test result

an
d
itte
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erm
ab
3- Measured voltage
ility
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wit
4- Measured cold start value of battery.

is n
h re
ole,
5- Nominal cold start value of battery selected on tester.

spec
6- Measured temperature of battery.

t to the co
7- Fitting location of battery

rrectne
8- Position of battery clamp selected on tester

9- Selected battery technology.
ss o
cial p
f inform
Note
mer
atio
om
The test printout is required for warranty claims.

n
c
i
or
n thi
te
sd
iva
o
pr

um
r
fo
en
ng
t.
yi Co
Evaluating battery test results for guarantee and service tests ht. Cop py
rig
rig ht
Battery test results Measures
py by
co Vo
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Battery OK No measures on battery
Prote AG.

Battery OK - recharge. Charge battery ⇒ page 25 . In
case of discharging, look for
fault
Perform current draw test Perform current draw test
⇒ page 22 . Fully charge bat‐
tery ⇒ page 25 and repeat
test. swagen AG. Volkswagen AG does
olk not
Renew battery. Disconnect
edb
yV battery and repeat gu
ara
ristest. The result „Renew battery“ nte
ho eo
aut may be caused by a weak cable ra
s c
s contact.
ce
le
un
pt
Battery cell defective - renew. Renew battery.
an
d
itte
y li
Check connection. Connect cable directly to bat‐
rm
ab
tery and not to jump start termi‐
pe
ility
ot
nal.
wit
, is n
h re
hole
Evaluating battery test results for maintenance test
spec
es, in part or in w
t to the co
Battery OK No measure
Charge battery immediately. Charge battery fully
rrectness of i
⇒ page 25 .
l purpos
Mark as defective. Mark as defective.

Check tester connection. Disconnect battery and repeat
nform
ercia
test. The result „Check tester

connection“ may be caused by
m
a
com
ti
a weak cable contact.
on in
r
te o
Check connection. Connect cable directly to bat‐ thi

s
iva
tery and not to jump start termi‐

do
r
nal.
rp
cum
fo
en
g
Noises Wait until measured value ap‐

n
t.
yi Co
op
pears on display.
C py
t. rig
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2.6 Midtronics -MCR340V- battery tester
op Vo
by c lksw
cted agen
Prote
only for USA/Canada vehicles
AG.
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.

WARNING

jump starting
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.
AG. Volkswagen A
gen G do
swa es
Refer to ⇒ Self-study bprogramme
yV
olk No. ; Vehicle batteries
not
gufor more
information. ir se
d ara
nte
tho eo
The followings acharging
u and analysis procedures apply to all bat‐
ra
c
s
teries, all battery installation locations (engine compartment or
ce
le
luggage compartment) and battery purposes (starter battery or

un
pt
an
d
second/convenience battery).
itte
y li
erm
ab
Always comply with the safety regulations, the regulations for

ility
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setting up the battery tester, the display menu/display buttons,

wit
is n
LEDs and the operating procedures described in the ⇒ operating

h re
ole,
manual MCR340V .
spec
t to the co
Note
rrectne
Observe and comply with all subsections, remarks and referen‐

ces to the vehicle and battery type, etc. to be tested.
ss o
cial p
2.6.2 Performing battery test with Midtronics -

inform
mer
MCR340V- battery tester

atio
om
Prerequisites:
c
i
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WARNING
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Before working on the battery, read through the warning and
Co
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safety regulations carefully, and comply with them ⇒ page 2 .
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jump starting
– Read general description ⇒ page 18 .

– Perform visual check ⇒ page 6 .
– 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. n AG. Volkswagen AG do

kswage es n
♦ For additional information, refer to the ⇒ operating y Vmanual
ol ot g
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INC 940 . o
ir se
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tee
th or
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Perform test: ss
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WARNING
erm
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es, in part or in w
jump starting
t to the co
rrectness of i
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nf
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– Switch on tester.
rm
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or c

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Ensure test clamps have a good contact!
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– Select „In vehicle“ or „Outside vehicle“.
AG.
– Select „Warranty test“.
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 .

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

Results of battery test:
Battery OK None
Good - charge Charge battery ⇒ page 55 .
Use Incharge Charge battery ⇒ page 55 .
Renew battery. Renew battery ⇒ Electrical sys‐
tem; Rep. gr. 27 ; Removing
and installing battery
Battery cell defective 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 . AG. Volkswagen AG d
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olksw not
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Display message Measures hor eo
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No display – Check whether terminals of ss c
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battery tester are firmly con‐

un
nected to battery terminals. pt

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itte
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ab
– Check battery terminals are ility
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tightened according to reg‐

wit
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ulations and do not have

h re
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corrosion.
spec
t to the co
– Charge battery
⇒ page 55 .
System noise – Switch off all electrical con‐
rrectne
sumers.
– Wait until all electrical loads

ss o
monitored by onboard sup‐

cial p
f in
ply control unit have switch‐

form
mer
ed off.
atio
om
– Remove ignition key.

n
c
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– Disconnect any suspect

iv
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electrical equipment not

p
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connected to onboard sup‐

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ply as standard.
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21
Prote AG.
2. Checking battery
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

not be checked or charged. Do not slave/jumpestart the vehicle!
n AG. Volkswagen AG ag does
ksw
Danger of explosion when checking y Vand charging or slave/
ol not
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Note
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♦ Ensure that the correct charging mode is set on the charger
hole
so that the current draw test is not falsified.
spec
es, in part or in w
t to the co
♦ VAS 5095 A ⇒ page 26
♦ VAS 5900 ⇒ page 30
rrectness of i
♦ VAS 5903 ⇒ page 41
l purpos
To quickly ascertain the state of discharged batteries, the battery

current draw test whilst charging helps to determine whether the
nform
ercia
battery must be replaced or fully recharged.

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Note
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For battery tester with printer -VAS 6161- , the current draw test
r
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must always be performed when the test result „Perform current

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t.
draw test“ appears on the display.
yi Co
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The current draw test must be carried out when the test result with cop Vo
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battery tester with printer -VAS 5097A- is as follows: cted agen
Prote AG.
1 - Starting output sufficient

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.

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Electrical System, nteGeneral Information - Edition 07.2010
ho eo
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Test requirements
ss c
ce
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un
pt
♦ When charging a battery, battery temperature must be at least
an
d
itte
≥ +10 °C.
y li
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ab
ility
♦ The charger must be capable of outputting a charge current of
ot p
wit
at least 30 A, as for example with VAS 5095A, VAS 5900, VAS
is n
h re
5903
ole,
spec
♦ The battery's current draw must be measured with a current
t to the co
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.
rrectne
– Connect battery to battery charger and start charging se‐
quence.
ss o
– Measure charging current of battery after 5 minutes.
cial p
f inform
Test result:
mer
atio
m
If the current draw A is higher than 10 % of the nominal capacity

o
n
c
(e.g. > 6.1 A for a 61 Ah battery), fully charge battery and test
i
or
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again.
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Note
t.
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For Eos with two 6V absorbent glass mat batteries, the charge
rig by
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current must only be 5 % higher than the nominal capacity of the
by c lksw
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battery. Example for Eos: the 50 Ah battery must have a charge
Prote AG.
current higher than 2.5 A after 5 minutes of starting the charging

sequence.
– 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

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“ .
♦ 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 Charge Condition of battery
11.60 V 0% Discharged, no capacity Heavily discharged ⇒ page 59 .
AG. Volkswagen AG d
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Measured value edMeasure
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No-load voltage ≥ 12.5 V autho
No-load voltage OK eo
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No-load voltage < 12.5 V s Charging battery ⇒ page 25
ce
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ab
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3 Charging battery
WARNING
AG. Volkswagen AG d
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Danger of injury! Observe warning notices and safety regula‐ byV
ol not
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tions ⇒ page 2 ! rised ara
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WARNING
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3.1 Battery charger -VAS 5095 A-
thi
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This chapter describes the basic functions of the battery charger

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-VAS 5095 A- . For additional information refer to ⇒ operating
f
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t.
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instructions for battery charger -VAS 5095 A- .
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Note Prote
cted AG.
agen
♦ 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
The battery charger charges without peaks in amperage or volt‐ . Volkswagen AG

age. This will not adversely effect the onboard electronics. The kswagen AG does
not
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battery can remain in the vehicle while it is being charged and byV
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Battery charger -VAS 5095 A- s au ra
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1 - ON / OFF switch (0 = charger OFF)
nl
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2 - Charging current indicator (I > 12 A)
erm
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3 - Charging current indicator, battery partially charged > 90 %
wit
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4 - Maintaining charge; lights up green when battery is fully charg‐
hole
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spec
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5 - Malfunction indicator
6 - Support mode indicator
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7 - Support mode/normal mode changer-over switch
l purpos
8 - Charger cable, red terminal „+“, black terminal „-“

9 - Battery type change-over switch (on base of charger unit)
nform
mercia
3.1.2 Charging battery with battery charger -
at
om
ion
c
VAS 5095 A-
in t
or
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ate
do
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WARNING
for
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op
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tions ⇒ page 2 !
rig ht
py by
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♦ 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

WARNING

jump starting
– Switch off ignition and all w

electrical
agen
AG. Vconsumers.
olkswagen AG
doe
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Vol t
– Check setting for ebattery
db
y type on type of battery switchgu
ara
⇒ page 25 . Must
thoris
be set to 2.4 V/C (volts/battery cell). nte
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– Connect red
ss terminal clamp „+“ of charger unit to positive ter‐ c
ce
le
minal on battery.
un
pt
an
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itte
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erm
ab
Note
ility
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wit
is n
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In vehicles with start/stop function and battery monitor control unit
ole,
-J367- fitted, black terminal clamp „-“ must be connected to body
spec
earth. Connecting it to battery negative terminal will cause start/
t to the co
stop system to malfunction.
– Connect black terminal clamp „-“ of battery charger to negative
rrectne
terminal.
– Switch on battery charger ⇒ page 25 .
ss o
cial p
f
The charging current indicators ⇒ page 26 -2- and -3- light up
inform
yellow. When only the light emitting diode (LED) -3- lights up yel‐
mer
low, battery is partially discharged (approx. 90 %).

atio
om
n
c
If the LED lights up green ⇒ page 26 -4- the charger has switched
i
or
n thi
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to "maintaining charge". The battery is fully charged.

t
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– Switch off charging unit ⇒ page 25 .

um
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– Remove charger unit terminals from battery terminals.
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3.1.3 Charging totally discharged battery with
gh ht
pyri by
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battery charger -VAS 5095 A-
cted agen
Prote AG.
WARNING

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.
WARNING

jump starting olksw AG. V agen AG
agen does
These batteries must be
Vol renewed.
ksw not
gu
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db ara
rise nte
tho eo
– Charge battery ⇒ page 26 . au ra
c
ss
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3.1.4 Charging battery in support mode with

un
pt
an
d
itte
y li
battery charger -VAS 5095A-
rm
ab
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ility
ot
General notes:
wit
, is n
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The support mode provides the onboard supply with power when
hole
spec
the battery is removed or disconnected.
es, in part or in w
t to the co
For further information, refer to the ⇒ operating manual VAS
5095A .
rrectness of i
The support mode is suitable in the following situations:
♦ Support mode of onboard supplies without installed battery
l purpos
♦ Power conservation when renewing the battery

nform
ercia
♦ Ancillaries test without battery

m
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com
tion in
WARNING
r
te o
thi
s
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do

r
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cum
tions ⇒ page 2 !
fo
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t.
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Cop py
t. rig
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pyri by
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WARNING
lksw
cted agen
Prote AG.

jump starting

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.
AG. Volkswagen AG d
agen oes
♦ Danger of explosion yV
olksw not
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♦ Ensure charger terminal clamps are seated
horis securely. nte
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♦ Do not press START / STOP button
s when charger unit
s c
ce
cables are connected incorrectly. The charger unit may be nl
e
pt
du
damaged.
an
itte
y li
erm
ab
ility
ot p
– Remove battery.
wit
, is n
h re
hole
spec
Caution
es, in part or in w
t to the co
When battery is removed, ensure there is no contact between
terminal clamp connected to positive clamp and body earth.
rrectness of i
Also ensure there is no contact between battery clamps.
l purpos
– Connect red terminal clamp „+“ to positive terminal of vehicle.
nform
mercia
at
Note
om
ion
c
in t
or
his
ate
-J367- fitted, black terminal clamp „-“ must be connected to body
do
priv
c
um
for
en
g

n
t.
yi Co
Cop py
ht. rig
– Connect black terminal clamp „+“ to negative terminal of ve‐
rig ht
py by
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hicle. by c lksw
cted agen
Prote AG.
– Check setting for battery type on normal/support mode switch
⇒ page 25 . It must be switched on support mode.
– 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.
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ e,nEos AG. V2006
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Electrical System, General Information - Edition
V olksw 07.2010 es n
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3.1.5 Charging battery in maintenance mode s au
tho or
ac
with battery charger -VAS 5095 A- s
ce
e
nl
pt
du
an
itte
y li
WARNING
erm
ab
ility
ot p
wit
, is n
h re
tions ⇒ page 2 !
hole
spec
es, in part or in w
t to the co
WARNING
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ercia
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m
at
om
ion
c
in t
or
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ate
In maintenance mode the battery charger -VAS 5095 A- ensures
do
priv
c
that the battery is charged correctly and is maintained in fully
um
for
en
charged condition.
ng
t.
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– Proceed as for charging battery ⇒ page 26 . t. C rig
gh ht
pyri by
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Note
AG.
♦ 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.
3.2 Battery charger -VAS 5900-
WARNING

tions ⇒ page 2 !
WARNING

jump starting

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

Note
♦ The effective charging current can be read directly on these

charging units.
♦ Observe ⇒ operating instructions for battery charger -VAS
5900- .
. Volkswagen AG
gen AG
3.2.1 Description of battery ycharger -VAS
a does
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Vol gu
5900- db ara
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The battery charger -VAS 5900-ssisa suitable for charging all 12V c
ce
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un
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an
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Battery charger -VAS 5900-

itte
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1 - Display
ility
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2 - Adjustment button „Up“ ↑
h re
hole
spec
3 - Adjustment button „Down“ ↓
es, in part or in w
t to the co
4 - START / STOP
5 - INFO
rrectness of i
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VAS 5900-
nform
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a
com
tio
WARNING
n in
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iva

do
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tions ⇒ page 2 ! cum

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jump starting

♦ Battery charger -VAS 5900-
Note

– 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

-J367- fitted, black terminal clamp must be connected to body
– 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.
AG. Volkswagen AG d
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is n
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t to the co
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Rep. gr.27 - Starter, current supply, CCS cted agen
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At a charge condition of 100 % all bars appear in display.
Note
AG. Volkswagen AG d
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♦ In the battery type „standard by
V charge“ the parallel use of con‐
ol not
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longer. tho eo
s au ra
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♦ The battery charger will switch to maintenance mode after
s
ce
e
nl
about 1-7 hours, depending on type of battery. To achieve a
pt
du
an
100 % charge the battery should remain connected for this
itte
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period.
ab
ility
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Possible faults and fault rectification
h re
hole
spec
1- Displayed battery voltage is not as per nominal voltage:
es, in part or in w
t to the co
– Press respective button „Up“ ↑ or „Down“ ↓ until charging
sequence starts.
2- Displayed battery voltage is not as per nominal voltage –
rrectness of i
charging sequence already started:
l purpos
– Press START / STOP twice.
nf
ercia
or
sequence starts again.
m
m
atio
om
3- Battery charger does not detect a battery, when battery volt‐
n in
or c
age is less than 2 V:
thi
te
sd
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Display remains unchanged. o

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

t.
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Ending battery charging sequence:
t. C rig
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pyri by
Vo
o
– Press START / STOP . by c lksw
cted agen
Prote AG.
– Disconnect black terminal clamp „-“ of charger from negative
terminal.
– Disconnect red terminal clamp „+“ of charger from positive
terminal on battery.
3.2.3 Charging battery in service mode with

battery charger -VAS 5900-
WARNING

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.
WARNING

jump starting
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 .
olkswagen AG
en AG. V
olks
wag does
not
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♦ Battery charger -VAS 5900- rise nte
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Note
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te o
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operating mode will appear on display ⇒ page 31 .

r
rp
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en
ng
t.
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– 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.
Note
AG. Volkswagen AG d
agen oes
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In vehicles with start/stop
d b yV
o
function and battery monitor gcontrol
ua unit
-J367- fitted, black
oris terminal clamp „-“ must be connectedanto
e r
teebody
earth. Connecting
au
th it to battery negative terminal will cause start/ or
ac
stop system ss to malfunction.
ce
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spec
At a charge condition of approx. 80 - 85 % of the battery voltage,
es, in part or in w
the battery charger switches to the „final charge“ mode. The fourth
t to the co
bar appears in display -1-. The battery is ready for use.
rrectness of i
Note
l purpos
The success of the „service charge“ depends on the severity of

the sulphation of the battery
nform
mercia
Possible faults and fault rectification:

a
com
tion in

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sequence starts.
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t.
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rig by
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– Press START / STOP twice. by c lksw
cted agen
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sequence starts.
Display remains unchanged.
The operating mode and ampere hours (Ah) as set are displayed.
– Press START / STOP .
terminal.
3.2.4 Charging totally discharged batteries

with battery charger -VAS 5900-
WARNING

tions ⇒ page 2 !
WARNING

gen AG
. Volkswagen AG
d a oes
lksw not
Danger of explosion when checking and charging
db
y V or slave/
o gu
ara
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ise nte
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These batteries must be renewed. s au ra
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e
nl
pt
du
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itte
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erm
ab
Caution
ility
ot p
wit
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hole
spec
es, in part or in w
t to the co
battery terminals.
♦ When charging always set the battery charger to the cor‐
rect type of battery ⇒ operating instructions for battery
rrectness of i
charger -VAS 5900- !
l purpos
♦ Totally discharged battery is not recognised by battery

charger ⇒ page 59 .
nform
ercia
♦ Do not press START / STOP button when charger unit

m
cables are connected incorrectly. The charger unit may be

at
om
io
damaged. n
c
in t
or
his
ate
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priv
Batteries with a voltage of less than 2 volts will not be recognised

um
for
automatically by battery charger -VAS 5900- .

en
ng
t.
yi Co
op py
Special tools and workshop equipment required t. C rig
gh ht
pyri by
co Vo
by lksw
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Note

not be excluded.
♦ The battery must have a temperature of at least 10 °C.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
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rise nte
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is n
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
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or
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te
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t.
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Cop py
t. rig
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pyri by
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by
cted agen
Prote AG.
– Set battery to respective battery type with INFO .

Note


– 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 STARTen / . agen AG

. Volksw
AGSTOP
ag does
olksw not
Then follows the enquiry for "is charger cable
d by V terminal polarity gu
ara
correct". orise nte
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ut or
– Check polarity of charger unitsscables.
a ac
ce
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nl
– Confirm polarity of charger unit cables with START / STOP .

pt
du
an
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Charger will start charging sequence for totally discharged bat‐

erm
ab
tery.
ility
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terminal.
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General notes:
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WARNING

tions ⇒ page 2 !
WARNING

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agen do
Danger of explosion when checking
yV
olksand charging or slave/ s not g
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d b ua
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These batteries must be srenewed.
au
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e
nl
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Caution
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battery terminals.
rrectness of i
♦ Danger of explosion
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♦ Ensure charger terminal clamps are seated securely.

nf
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atio
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– Remove battery.
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– Connect charger plug to battery charger. The last selected op
yi Co
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pyri by
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Caution
cted agen
Prote AG.

Note

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

hicle.
activated.
Note

– Confirm the selected battery voltage with START / STOP .

Then follows the enquiry for "is charger cable terminal polarity
correct".
End battery support mode:
G. Volkswagen A AG do
agen es n
ksw
3.2.6 Charging battery in maintenance mode
db
yV
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ua
ran
ise
tho
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or
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s
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nl
pt
Note
du
an
itte
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ab
♦ When a battery is being charged in the maintenance mode and

ility
ot p
an electrical consumer draws current from the battery, the

wit
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battery charger -VAS 5900- automatically compensates the

h re
hole
charge.
spec
es, in part or in w

t to the co
riod.
rrectness of i
♦ Observe battery manufacture's maintenance instructions!

l purpos
nform
WARNING
mercia
at

om
ion
tions ⇒ page 2 !
c
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or
his
ate
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priv
cum
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t.
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Cop py
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

WARNING

jump starting
When the battery is fully charged the battery charger -VAS 5900-
switches to maintenance mode.
– Proceed as for charging battery ⇒ page 31 . olkswage es n
ot g
byV ua
At a charge condition of 100 % all bars appearrisin
ed display. ran
tee
tho
u or
a ac
ss
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e
nl
pt
du
an
itte
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erm
ab
ility
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WARNING
nf
ercia
orm
m
atio
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tions ⇒ page 2 !
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or c
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WARNING
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not be checked or charged. Do not slave/jump start the vehicle! cop Vo
by lksw
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AG.
jump starting

-VAS 5903- . For additional information refer to ⇒ operating in‐
structions for battery charger -VAS 5903- .
Note
Observe ⇒ operating instructions for battery charger -VAS 5903- .
3.3.1 Description of battery charger -VAS

5903-
The battery charger -VAS 5903- is suitable for charging all 12V
Battery charger -VAS 5903-
1 - Display
2 - Adjustment button „Up“ ↑
3 - Adjustment button „Down“ ↓
4 - START / STOP
5 - INFO

VAS 5903-
WARNING
AG. Volkswagen AG d
agen oes
lksw not
Danger of injury! Observe
d by Vo
warning notices and safety gregula‐
ua
ran
tions ⇒ page 2 !orise tee
h
aut or
ac
ss
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un
pt
an
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WARNING
itte
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rm
ab
pe
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ot
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, is n
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spec
jump starting
es, in part or in w
t to the co

rrectness of i

l purpos

nform
mercia
a
com
tion in
r
te o
thi
s
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cum
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t.
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Cop py
t. rig
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pyri by
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by
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Note



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.
Note


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.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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ris nte
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aut ra
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nl
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du
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ility
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es, in part or in w
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rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
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t.
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Cop py
ht. rig
rig ht
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by lksw
cted agen
Prote AG.
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.

sequence starts.
2- Displayed battery voltage is not as per nominal voltage -
sequence starts again.
Display remains unchanged. agen
AG. Volkswagen AG d
oes
olksw not
The battery type and ampere hours (Ah) as set is displayed. d by V gu
ara
rise nte
Ending battery charging sequence: utho eo
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s a c
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nl
pt
du
an
itte
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terminal.
erm
ab
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t to the co
3.3.3 Charging battery in refresh charge
mode with battery charger -VAS 5903-
rrectness of i
l purpos
WARNING
nf
ercia

orm
tions ⇒ page 2 !
m
atio
om
n in
or c
thi
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sd
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WARNING
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f
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t.
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t. C rig
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agen oes
olksw not
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Caution rise nte
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The operating mode „refresh charge“ is not
s permitted on VW
ce
le
vehicles as the voltage peaks will damage the onboard elec‐
un
pt
an
d
tronics.
itte
y li
erm
ab
If there is a requirement to use „refresh charge“ mode the bat‐
ility
ot p
tery must be disconnected from the onboard supply.
wit
is n
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ole,
spec
t to the co
Caution
When charging always set the battery charger to the correct
rrectne
type of battery ⇒ operating instructions for battery charger -
VAS 5903- !
ss
The „refresh charge“ mode is suitable for:
o
cial p
f in
♦ Wet batteries, where distilled water can be replenished.
form
mer
atio
Do not use operating mode „refresh charge“ with maintenance-
om
free wet batteries.
n
c
i
or
n thi
te
sd
iva
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pr
c
The „refresh charge (refr)“ operating mode is only used on sus‐
um
r
fo
en
ng
pect defective batteries (e.g. sulphation). The battery will be

t.
yi Co
charged to maximum specific gravity and the plates will be reac‐ Cop py
t. rig
tivated (dissipation of sulphur layer). opyri
gh by
Vo
ht
c
by lksw
cted agen
Prote AG.
Note


In the display the symbol -1- for „refresh charge for wet batteries“
or symbol -2- for „refresh charge for gel/absorbent glass mat bat‐
– Connect red terminal clamp „+“ to positive terminal on battery. agen
AG. Volkswagen AG d
oes
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ara
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Note ut
ho eo
ra
s a c
s
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un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
At a charge condition of approx. 80 - 85 % of the battery voltage,
rrectne
the battery charger switches to the „final charge“ mode. The fourth
bar appears in display -1-. The battery is ready for use.
ss o
cial p
f in
Note
form
mer
atio
m
The success of the „refresh charge“ depends on the severity of

o
n
c
the sulphation of the battery.
i
or
n thi
te
sd
iva
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pr
cum
r
fo
en
ng

t.
yi Co
Cop py
– Press respective button „Up“ ↑ or „Down“ ↓ until charging ht. rig
rig ht
py by
sequence starts. co Vo
by lksw
cted agen
Prote
AG.

sequence starts.
Display remains unchanged.
The operating mode and ampere hours (Ah) as set are displayed.
terminal.

3.3.4 Charging totally discharged battery with

WARNING

tions ⇒ page 2 !
WARNING

Volkswagen AG
Danger of explosion when checking and charging
ksw
agor slave/
en AG. does
jump starting by
Vol not
gu
ara
ed nte
These batteries must be renewed. oris eo
th
au ra
c
ss
ce
le
un
pt
an
d
itte
Caution
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
battery terminals.
t to the co
♦ When charging always set the battery charger to the cor‐
rect type of battery ⇒ operating instructions for battery
charger -VAS 5903- !
rrectne
♦ Totally discharged battery is not recognised by battery
charger ⇒ page 59 .
ss o
cial p
f
inform
mer
damaged.
atio
om
n
c
i
or
n thi
te
Batteries with a voltage of less than 2 volts will not be recognised

sd
iva
o
r
automatically by battery charger -VAS 5903- .

p
cum
r
fo
en
ng

t.
yi Co
Cop py
t. rig
♦ Battery charger -VAS 5903- opyri
gh by
Vo
ht
c by lksw
cted agen
Prote AG.
Note

not be excluded.
♦ The battery must have a temperature of at least 10 °C.

en AG. V
olkswagen AG
ag does
lksw not
– Connect charger plug to battery charger.
yV
o The last selected gu
db ara
operating mode will appear onris display ⇒ page 42 .
e nte
tho eo
s au ra
c
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
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t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


Note


activated.
wage es n
battery voltage (6 V, 12 V or 24 V). yV
olks ot g
b ua
ed ran
oris tee
th or
Note au ac
ss
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un
pt
an
d
itte
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ab
pe
ility
ot
wit
, is n
h re
hole
spec
correct".
es, in part or in w
t to the co
rrectness of i
Charger will start charging sequence for totally discharged bat‐
l purpos
tery.
nform
ercia

m
a
com
tio

n in
r
te o
terminal.
thi
s
iva
do

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t.
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op
– Pull charger plug out of battery charger. C py
t. rig
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pyri by
Vo
co
by lksw
cted agen
Prote AG.
General notes:
5903 .

WARNING

tions ⇒ page 2 !
WARNING

n AG. Volkswagen A
Danger of explosion when checking
olks
wage and charging ordoslave/
G
es n
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jump starting d by V ua
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ris
These batteries mustuthbe
o
renewed. eo
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e
nl
pt
du
an
itte
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erm
ab
ility
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Caution
wit
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hole
ing totally discharged batteries/support mode“ is not ac‐ spec

es, in part or in w
tive. Connect battery charger terminal clamps correctly to t to the co

battery terminals.
rrectness of i
♦ Danger of explosion
l purpos
♦ Ensure charger terminal clamps are seated securely.

nform
ercia

m
at
om
damaged.
ion
c
in t
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ate
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– Remove battery.
p
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en
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n
t.
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operating mode will appear on display ⇒ page 31 . Cop py
t. rig
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pyri by
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co
Caution
by lksw
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Prote AG.

Note


AG. Volkswagen AG d
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Bora 1999 by
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d ara
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h eo
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– Connect black terminal clamp „+“ to negative terminal of ve‐ ss
ce
le
hicle.
un
pt
an
d
itte
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ab
ility
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activated.
wit
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t to the co
Note
rrectne
ss o
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form
mer
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correct".
n
c
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t
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fo
en
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t.
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Co
Cop py
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End battery support mode: yri
p by
o Vo
by c lksw
cted
agen
Prote AG.

3.3.6 Charging battery in maintenance mode

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.
riod.
♦ Observe battery manufacture's maintenance instructions!
WARNING

tions ⇒ page 2 !
WARNING

jump starting
When the battery is fully charged the battery charger -VAS 5903-
switches to maintenance mode.
– Proceed as for charging battery ⇒ page 42 .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
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or c
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t.
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52
Prote AG.
Rep. gr.27 - Starter, current supply, CCS

3.4.1 General description
Battery charger - VAS 5906-
WARNING

tions ⇒ page 2 ! olksw n AG. V agen AG
wage does
Volks not
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WARNING
au
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nl
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Battery charger -VAS 5906- has been specially developed for
charging in vehicle onboard supply during vehicle presentation.
rrectness of i
It has an automatic charging characteristic for starter batteries, 3
- 300 AH.
l purpos
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.
nf
ercia
orm
For sustained operation, battery charger -VAS 5906- changes to

m
atio
m
trickle charging once battery is fully charged.

o
n in
or c
Tester starts fully automatically and does not require any settings.
thi
te
sd
a
All that is required is to connect crocodile clips and mains cable.

iv
o
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rp
cu
o

f
en
ng
t.
5906 .
yi Co
Cop py
t. rig
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cop Vo
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VAS 5906-
Prote AG.
WARNING

tions ⇒ page 2 !
WARNING

jump starting
Overview of operating panel:

1- Charge condition display 25 %.
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

tions ⇒ page 2 !
– Switch off ignition.

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

earth. Connecting it to battery negative terminal willswcause
agen start/
AG. Volkswagen AG d
oes
stop system to malfunction. by
Volk not
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ara
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ris
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– Connect black charging cable to negative
au
t terminal „-“ on bat‐ or
ac
tery. ss
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pt
Charging starts after about 2 seconds.

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Number of LEDs lit indicates charge condition of battery. Battery

ab
ility
has been charged up once all lights are lit.

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When battery is fully charged, battery charger -VAS 5906- auto‐

h re
hole
matically switches over to trickle charging.

spec
es, in part or in w
t to the co
Caution
Danger of sparking if charging terminals are removed too soon.

rrectness of i
Terminate charging by pressing start/stop button.

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– Press start/stop button to terminate charging.

nform
ercia
– Disconnect black charging cable from negative terminal „-“ on

m
at
om
battery.
on
c
in t
or
– Disconnect red charging cable from positive terminal „+“ on

his
ate
battery.
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3.5 Midtronics -INC 940- battery charger on‐

ly for USA/Canada
Warning and safety regulations ⇒ page 2
General description ⇒ page 55
AG. Volkswagen AG d
Charge battery ⇒ page 56 . lksw
agen oes
not
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Dealing with problems with Midtronics
rised b
-INC 940- battery tester ara
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⇒ page 58 ut
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3.5.1 General description of Midtronics -INC
s
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nl
pt
du
940- battery tester
an
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erm
ab
Batteries in VW vehicles are only allowed to be charged with bat‐
ility
ot p
tery chargers approved by VW. In the USA/Canada, it is permitted
wit
, is n
for the Midtronics -INC 940- battery charger to be used.
h re
hole
spec
Midtronics -INC 940- battery charger combines battery charging
es, in part or in w
with a charge condition checks and a battery test.
t to the co
The following charging and analysis procedures apply to all bat‐
teries, all battery installation locations (engine compartment or
rrectness of i
luggage compartment) and battery application purposes (starter
battery or second/convenience battery).
l purpos
Always comply with the safety regulations, the regulations for

setting up the battery charger, the display menu/display buttons,
nf
ercia
o
LEDs and the operating procedures described in the ⇒ operating
rm
m
manual INC 940 .
atio
om
n in
c
Read through ⇒ operating manual INC 940 carefully.

or
thi
te
sd
a
Refer to ⇒ Self-study programme No. ; Vehicle batteries for more

iv
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information.
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WARNING
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Prote
tions ⇒ page 2 !
AG.
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.
WARNING

jump starting
3.5.2 Charging battery

Prerequisites:
WARNING

jump starting
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.
olks
wage⇒ page 6 .
– Perform visual check of battery es n
ot g
V
by ua
– Determine whetherrisbattery
ed
type is „Standard“ (wet battery) ror an
tee
„AGM“ (absorbent
autho glass mat battery). or
ac
ss
– Close all vehicle doors.
ce
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nl
pt
du
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itte
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erm
ab
Note
ility
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♦ Battery temperature must be at least 10 °C.

h re
hole
spec
♦ For additional information, refer to the ⇒ operating manual

es, in part or in w
INC 940 .
t to the co
Perform charging procedure:

rrectness of i
– Switch off all electrical consumers.

l purpos
– Switch off ignition and remove ignition key.

– Connect red terminal clamp „+“ of charger unit to positive ter‐
nform
ercia
minal on battery.
m
at
om
ion
c
in t
r
Note
o
his
ate
do
riv

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or

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cted
– Connect black terminal clamp „-“ of battery charger to negative
agen
Prote AG.
terminal.
– 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).

– 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: Measures:
Battery OK Battery can be returned to op‐
eration.
Charging required ♦ 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.
Renew battery. Battery defective. Charging

agen procedure
AG. Volkswagen AG
does is interrupted.
Re‐
y Volksw new battery.
not
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un
pt
In case Midtronics -INC 940- shows fault messages or text dis‐

an
d
itte
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plays other than those listed above, please refer to

rm
ab
⇒ page 58 .
pe
ility
ot
wit
, is n
h re
hole
spec
WARNING
es, in part or in w
t to the co
Stop charging if battery is liberating a lot of gas. Press „Stop“

button on front.
rrectness of i
l purpos
When charging and testing procedure has finished, Midtronics -

INC 940- battery charger displays „Battery good“ or „Renew
battery“ and total charging time.
nform
ercia
There are three possible messages depending on individual cir‐

m
cumstance (printout for warranty, repair job, evaluation and filing):

com
tion in
r
♦ Generate test code (only possible after automatic charging

te o
thi
and test).
s
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♦ Print last test result (for warranty).

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♦ Display last test results. Cop py
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cted agen
Prote AG.
For additional information, refer to the ⇒ operating manual INC

940 .
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 Measures

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

tightened according to reg‐
ulations and do not have
corrosion.
Terminals connected? Safety function of tester.
– Connect terminals n AG. Volkswagen AG do
s wage to battery es n
before starting
byV
olk
charging pro‐ ot g
ua
cedure.
ir se
d ran
tee
ho
System noise – s Switch
au
t
off all electrical con‐ or
ac
s sumers.
ce
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nl
pt
du
an
– Wait until all electrical loads
itte
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monitored by onboard sup‐
erm
ab
ply control unit have switch‐
ility
ot p
ed off.
wit
, is n
h re
hole
– Remove ignition key.

spec
es, in part or in w
t to the co
– Disconnect any suspect

electrical equipment not
connected to onboard sup‐
rrectness of i
ply as standard.
l purpos
Wait a few minutes and repeat charging procedure ⇒ page 56 .

nf
ercia
orm
m
atio
om
n in
or c
thi
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iva
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o
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t.
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Prote AG.

Electrical System, General Information
. Volkswage
- Edition 07.2010
AG n AG d
agen oes
olksw not
3.6 Solar panel -VAS 6102A- ise
db
yV gu
ara
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tho eo
3.6.1 Charging battery in maintenance mode ss au ra
c
with solar panel -VAS 6102A-
ce
le
un
pt
an
d
itte
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Solar panel VAS 6102A
erm
ab
ility
ot p
General description:
wit
is n
h re
Solar panel -VAS 6102A- supports onboard supply and prevents
ole,
spontaneous battery discharging.
spec
t to the co
Solar panel -VAS 6102A- achieves max. voltage of 14.3 V and a
charging current of max. 255 mA.
Solar panel -VAS 6102A- is allowed to be used for charging all
rrectne
rechargeable lead or lead gel batteries.
Solar panel -VAS 6102A- is connected to diagnostic connection
ss o
in vehicle.
cial p
f inform
A green LED is integrated in the frame to indicate its function. The
mer
brighter the LED, the higher the charging current.
atio
om
n
c
Integrated electronics prevent battery overcharging.
i
or
n thi
te
sd
iva
o
– Secure solar panel -VAS 6102A- on interior mirror -1-.
pr
cum
r
fo
en
ng
– Place underside on dash panel -2-.

t.
yi Co
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t. rig
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pyri by
Note
co Vo
by lksw
cted agen
Prote AG.
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

tions ⇒ page 2 !
A battery is designated „totally discharged“ when the no-load volt‐

age is less than 11.6 V.
WARNING

jump starting
Caution
♦ Totally discharged batteries freeze prematurely.

♦ Frozen batteries should no longer be used.
Note
AG. Volkswagen AG d
agen oes
ksw
♦ Totally discharged by
Vbatteries in vehicles before registration
ol not
gu
must be exchanged
rised prior to delivery. Preliminary damageara
nte can‐
not be excluded.
tho eo
s au ra
c
♦ Batteries that have not been used for a long period of time
s
ce
le
discharge themselves, e.g. those fitted in stored vehicles.

un
pt
an
d
itte
y li
♦ In totally discharged batteries, the electrolyte is comprised al‐

rm
ab
most entirely of water because the acid content is so low.

pe
ility
ot
wit
, is n
♦ Totally discharged batteries sulphate, that means, the entire

h re
plate surfaces of the battery harden.

hole
spec
es, in part or in w
♦ If a battery is recharged shortly after it has totally lost its

t to the co
charge, the sulphation will mostly dissipate.

♦ If these batteries are not recharged, the plates continue to
rrectness of i
harden and the ability to recharge is reduced. The result of

which is a reduction in the battery output.
l purpos
– Check battery no-load voltage ⇒ page 25 .

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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Cop py
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pyri by
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Prote AG.

4 Cruise control system (CCS)

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
AG. Volkswagen AG d
agen oes
Faults on the CCS are output via the engine control unit.
Vol
ksw not
gu
by ara
ed
For fault finding, use vehicle diagnosis, testinghoand
ris information nte
eo
system in „Guided fault finding“ mode. au
t ra
c
ss
4.1 Activating and deactivating cruise con‐
ce
le
un
pt
an
d
trol system (CCS)

itte
y li
rm
ab
pe
ility
– Connect vehicle diagnostic tester ⇒ page 78 .
ot
wit
, is n
h re
hole
– Select „Guided fault finding“ mode in vehicle diagnostic tester .
spec
es, in part or in w
– Using „GoTo“ button, select „Functions/component“ and the
t to the co
following menu options in succession:
♦ Drive
rrectness of i
♦ Engine code
l purpos
♦ 01 - On Board Diagnostic capable systems

♦ Engine management/diesel direct injection and glow plug sys‐
nform
ercia
tem
m
a
com
ti
♦ Functions
on in
r
te o
thi
♦ Activating and deactivating cruise control system (CCS)
s
iva
do
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rp
cum
fo
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ng
t.
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4. Cruise control system (CCS) 61

90 – Gauges, instruments
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
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by c lksw
cted agen
Prote AG.
62 Rep. gr.90 - Gauges, instruments

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.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
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un
pt
– To loosen the connection, rotate the lock ring -1- through 90°
an
d
itte
y li
-arrow- and pull off the hose connection.
rm
ab
pe
ility
– To secure the connection, push on the hose connection and
ot
wit
, is n
rotate the lock ring -1- -arrow- until it engages.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– To loosen the connection, pull up the lock ring -1- by approx.

1 mm -arrow- and pull off the hose connection.
m
a
com
tion in
– To secure connection, attach hose connection and press in

r
te o
thi
clip -1- until it engages.

s
iva
do
r

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cum
fo

en
ng
t.
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t. rig
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co lksw
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cted agen
Prote AG.
1. Washer fluid line hose couplings 63

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

– To loosen the connection, push the lock ring -1- -arrow- and
pull off the hose connection. . Volkswag AG en AG
w agen doe
– To secure the connection, yV
push
olks and hold the lock ring s not g
-arrow- and push on ithe se
d bhose connection. Check that the se‐ ua
ran
curing clip has correctly
h or
engaged by depressing and trying to tee
ut or
pull off without the
ss
a clip. ac
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
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co lksw
by
cted agen
Prote AG.
64 Rep. gr.92 - Windscreen wash/wipe system

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-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
2.3 Repairing corrugated pipe

hole
spec
es, in part or in w

t to the co
♦ Hot air blower -VAS 5179- or

rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
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t.
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Cop py
♦ Hot air blower -V.A.G 1416/- or ht. rig
rig ht
py by
o Vo
♦ Hot air blower -VAS 1978/14- by c lksw
cted agen
Prote AG.
2. Hose repair 65
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 shrink-
fit 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.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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t. rig
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pyri by
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o
by c lksw
cted agen
Prote AG.
66 Rep. gr.92 - Windscreen wash/wipe system

lkswageBora 1999 ➤ , Bora esVariant
not 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...
o
byV Electrical
gu
ara System, General Information - Edition 07.2010
ed
ris nte
utho eo
ra
a c
ss
3 Distinguishing features of jointless
ce
le
un
pt
wiper blades
an
d
itte
y li
erm
ab
Distinguishing features from Bosch and Federal Mogul.
ility
ot p
wit
is n
When renewing wiper rubbers, note the make. When renewing
h re
ole,
wiper blades, the same make must be used.
spec
Wiper blades can be identified according to wiper arm fastening.
t to the co
Bosch wiper blades -1 and 2-:
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
op
Federal Mogul wiper blades -1-:
C py
t. rig
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pyri by
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co lksw
by
cted agen
Prote AG.
3. Distinguishing features of jointless wiper blades 67

94 – Lights, bulbs, switches - exterior

age G do n AG. Volkswagen A
ksw es n
y Vol ot g
ua
b
ed ran
oris tee
1 Operation and safety notes for gas
th or
au ac
ss
discharge bulbs
ce
le
un
pt
an
d
itte
y li
– If repairs are to be made to the headlight with gas discharge rm
ab
bulbs, observe the following:
pe
ility
ot
wit
, is n
♦ Notes on dangerous high voltage/currents ⇒ page 68
h re
hole
♦ Notes on pressure, temperature, radiation/arcs ⇒ page 69
spec
es, in part or in w
t to the co
♦ Assembly notes for gas discharge bulbs ⇒ page 70
♦ Disposal regulations for gas discharge bulbs ⇒ page 70
rrectness of i
l purpos
♦ Protective goggles
♦ Gloves
nform
mercia
a
WARNING
com
tion in
r
te o
thi
It is absolutely necessary to disconnect the battery earth strap
s
iva
before working on parts of the gas discharge headlights
do
r
rp
c
marked with yellow high voltage symbols.
um
fo
en
ng
t.
yi
Then switch dipped beam on and off again. This will eliminate
Co
op py
any possible residual voltage.
t. C rig
gh ht
pyri by
Vo
The gas discharge lamp control unit must never be operated
o
by c lksw
cted agen
without a gas discharge lamp. Prote AG.
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.
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

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
o eo
aut
h
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC r a2010
➤ , Eos 2006 ➤ , Golf 199 ...
s c
s Electrical System, General Information - Edition 07.2010
ce
e
nl
pt
du
an
itte
y li
erm
WARNING
ab
ility
ot p
wit
, is n
• Switch off ignition and all electrical consumers and re‐
h re
move ignition key.
hole
spec
es, in part or in w
• When working on headlight system, ensure that there is
t to the co
no voltage in any components, including the dissipation of
residual voltage after the headlights are switched off.
• Residual voltage can be dissipated by turning the dipped
rrectness of i
beams on and then off again after withdrawing the ignition
l purpos
key.
• When working on the headlight system, ensure that the
nform
ercia
lights cannot be switched on.

m
at
om
ion
c
Notes on pressure, temperature, radiation/arcs
in t
or
his
ate
do
priv
c
WARNING
um
for
en
ng
t.
yi Co
op
• The bulbs may be operated in the headlight housing only C py
ht. rig
(protection against contact due to very hot bulbs, absorp‐ rig ht
py by
tion of UV radiation, avoidance of dazzling light, protection
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against explosion).
agen
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• 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.
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

Repair notes for gas discharge bulbs
Caution
♦ Before exchanging a bulb, always switch off the affected

consumers. gen AG
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♦ Switch off ignition and all electrical
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♦ Do not touch the bulb sglass
sa with bare fingers; use clean c
cloth gloves. When the light bulb is switched on, the heat
ce
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would vaporise the oil of the finger prints which would then
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settle on the reflector, impairing the brightness of the
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same sort. The designation appears on the base of the
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♦ Properly engage connectors during installation and en‐
sure tight seating of the connection.
rrectne
Disposal regulations for gas discharge bulbs
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WARNING
inform
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• Gas discharge bulbs must be disposed of as hazardous
atio
m
waste; never dispose of gas discharge bulbs as conven‐

o
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tional waste.
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• Gas discharge bulbs contain metallic mercury (Hg) and

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• Dispose of only in containers intended for this purpose at
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an authorised collection point.
Prote AG.
70 Rep. gr.94 - Lights, bulbs, switches - exterior

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

agen
AG.lighter
Volkswa-U1-
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⇒ page 72 . olksw not
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1.2 Removingaut
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and installing socket illumi‐ e or
ac
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s bulb -L42-
s
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The removal of the socket illumination bulb -L42- is performed in

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the same way as the removal of the cigarette lighter illumination

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ab
bulb -L28- ⇒ page 76 .

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1. 12 V socket 71
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. AG. Volkswagen n AG do
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Caution ris
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2.1 General description
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Caution
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with the puller T 40148. sd

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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.
72 Rep. gr.96 - Lights, bulbs, switches - interior

2.2 Assembly overview
Caution
If excessive force is exertedeon

n AGsockets
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en AG illumination,
the retaining sleeve may
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Only illuminated rissockets (cigarette lighter) can be removed
ed ran
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with the puller T
o
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th 40148. or
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1 - Cigarette lighter socket with
t to the co
wiring tail
2 - Cigarette lighter
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3 - Socket
s
4 - Cigarette lighter socket
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5 - Retaining sleeve
form
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6 - Light bulb W 5 12 V 1.2 watt

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7 - Bulb carrier
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2. Cigarette lighter U1 73
2.3 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

out being damaged.

♦ Puller -T 40148-
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Removing s
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– Remove cigarette lighter, dummy cigarette lighter etc. from

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socket if necessary.
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Note
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For reasons of clarity, the socket is removed in the illustration.

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Caution
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The socket or the retaining sleeve can be damaged.

Ensure that the puller is seated correctly, otherwise the retain‐
nf
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ing lugs of the retaining sleeve will not be released.

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Rep. gr.96 - Lights, bulbs, switches - interior Prote
cted AG.
agen
– Push puller -arrow- into socket so that locking lugs -1- engage
in recesses -2-.
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– Pull grip -3- in direction of -arrow- to release locking lugs of
retaining sleeve.
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– Pull socket out of retaining sleeve using puller.
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Caution
ss
The socket wiring can be damaged.
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Take care not to stretch the wiring when pulling out the socket.
form
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thrust piece 40148/1 -2- with the knurled nut -1-.
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When using the thrust piece, ensure that no surrounding com‐
Prote AG.
ponents are damaged.
– 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.
– 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. wage
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When the puller is mounted, the socket retaining springs areed by ua
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pressed apart and the retaining force is reduced. tho
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After removing the socket, carefully press the retaining springs ss
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together and check if the cigarette lighter remains in the re‐ e
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moval position after the heating phase.
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– Carefully press socket retaining springs together -arrows-.
h re
hole
spec
– Check if cigarette lighter remains in removal position after
es, in part or in w
heating phase and ensure it is not ejected in vehicle interior.
t to the co
Installing
Install in reverse order of removal.
rrectness of i
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2.4 Removing and installing cigarette lighter

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illumination bulb -L28-

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♦ On some vehicles, the illumination is not provided by a light
Prote AG.
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.
Removing:
– Remove socket ⇒ page 74 .
76 Rep. gr.96 - Lights, bulbs, switches - interior

– 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.
AG. Volkswagen AG d
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– Remove light bulb in direction of -arrow-.
e
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Installing:
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Installation is carried out in reverse order of removal.
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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.
AG. Volkswagen A
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♦ All the operations described, e.g. adaptation, coding, etc. can

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be performed using the vehicle diagnostic tester .

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♦ All work procedures can be found in „guided fault finding“ and

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„guided functions“ modes.

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♦ Additional information
spec
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t to the co
⇒ Self-study programme No. 202 ; Vehicle diagnostic, testing

and information system VAS 5051
rrectness of i
⇒ Self-study programme No. 256 ; VAS 5052

l purpos
⇒ Self-study programme No. 294 ; Online connection of VAS

5051
nf
ercia
– Connecting vehicle diagnostic tester ⇒ page 78

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1.1 Connecting vehicle diagnostic tester

om
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Observe the latest operating instructions for vehicle diagnostic
Co
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tester , which are displayed after selecting the „Administration“ t. C rig
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78 Rep. gr.97 - Wiring

♦ Vehicle diagnostic tester
♦ Diagnostic cable -VAS 5051/6A- (5 m)
♦ Diagnostic cable -VASAG

5051/5A-
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Only these cables are to be used for diagnosis, as they are the
ce
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only ones fitted with CAN wiring and therefore allowing CAN di‐
un
pt
an
d
agnosis and/or CAN communication.

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Connecting vehicle diagnostic tester :

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– Apply handbrake.
ole,
spec
– Vehicles with automatic gearbox, move selector lever to posi‐

t to the co
tion „P“ or „N“.

– Vehicles with manual gearbox, move gearstick to neutral po‐
sition.
rrectne
– With ignition switched off, connect vehicle diagnostic tester

s
using diagnostic cable -VAS 5051/6A- to diagnostic interface

s o
-arrow- in vehicle.
cial p
f inform
– Switch on ignition.
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Note
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All other and the following vehicle diagnostic, testing and infor‐
Co
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mation systems or vehicle diagnostic and service information
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systems are connected accordingly in the sequence described
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1. Vehicle diagnostic, testing and information systems 79

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.
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.
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2 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.waUsinggen AGthe tools, n AG doe
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repairs to connectors and wiring open circuits yV
olks can be carried out. s no
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To do this, complete repair wire sectionsised b with contacts already ara
nte
crimped on are used and joined to ut
h the vehicle's own wiring har‐
o r eo
ness with the aid of crimp connectors.
ss a A special set of pliers with ra
c
three different crimp recesses and a hot air blower for shrinking
ce
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un
the crimp connectors make a perfect electrical connection.
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Note
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Additional information:
spec
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⇒ Operating instructions Wiring harness repair set -VAS 1978-
2.1.2 Upgrade kit -VAS 1978/50-
rrectne
Upgrade kit -VAS 1978/50- is required to bring the „old“ wiring
ss
harness repair set -VAS 1978- up to the latest standard of wiring
o
cial p
f
harness repair set -VAS 1978A- . The upgrade kit comprises of 4
inform
assembly and 10 release tools, a new set of crimping pliers for
mer
crimp connectors with head adapter 0.35 - 2.5 mm2 -VAS
atio
m
1978/1-1- , 4.0 - 6.0 mm2 -VAS 1978/2 A- and head adapter for
o
n
c
i
or
JPT contacts -VAS 1978/9-1- . Also included are new stickers, a n thi
e
new set of operating instructions, crimp connectors for 0.35

t
sd
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mm2 cable cross-section and a roll of black felt adhesive tape.

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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.
Note
Additional information:
⇒ Operating instructions Wiring harness repair set -VAS 1978A-
2. Repairing wiring harnesses and connectors 81

AG. Volkswagen AG d
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Electrical System, General Information - Edition
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2.1.4 Release tool set -VAS 1978/35-
ce
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Release tool set -VAS 1978/35- serves as a means of releasing
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various primary and secondary locking devices in Group vehicles.
ility
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The set comprises of 26 different tools with which, for example,
wit
is n
round connector systems, flat contacts with one or two fasteners
h re
ole,
and also single wire seals can be released or fitted.
spec
Allocation of the correct release tool to the respective locking de‐
t to the co
vices can be gleaned from the table in the ⇒ operating instruc‐
tions of -VAS 1978/35- .
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f inform
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2.2 Tool descriptions
atio
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2.2.1 Special pliers with insert
iva
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The special pliers without insert -VAS 1978/1- with insert for spe‐
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cial pliers -VAS 1978/2- is part of the wiring harness repair set - Cop py
VAS 1978- and is used to crimp connectors during wiring harness
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Colour of crimp Colour of crimp re‐ Wiring cross section
AG.
connector cess
Yellow Yellow. 0.35 mm2
Red Red. 0.5 mm2 - 1.0 mm2
Blue Blue 1.5 mm2 - 2.5 mm2
Yellow. Yellow. 4.0 mm2 - 6.0 mm2
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.

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

agen device. This
AG. Volkswagen AGmust
does
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be pushed over the tip of the tool
by V after use in order to protect t gua
ol no
the tip and prevent personal
ris
einjury.
d ran
te
tho eo
s au ra
c
s
Releasing and dismantling contact housings ⇒ page 102 .
ce
le
un
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rm
2.2.3 Assembly tools for single wire seals
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The assembly tools serve as a means of sliding the single wire
, is n
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seals fully into the contact housing without damage and thereby
hole
spec
assure complete sealing between single wire and contact hous‐
es, in part or in w
ing.
t to the co
Four assembly tools for single wire seals are included in each
wiring harness repair set -VAS 1978 B- and previous versions.
rrectness of i
Assembling single wire seals ⇒ page 99 .
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tion in
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2.2.4 Wire strippers -VAS 1978/3-

thi
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Wire strippers -VAS 1978/3- serve as a means of stripping insu‐

um
fo
en
lation off wires and cutting wires in the correct manner.

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Wire strippers -VAS 1978/3- are included in wiring harness repair
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The wire strippers have an adjustable limit stop within the pliers Prote AG.
jaws, with which the desired length of insulation to be removed
can be adjusted.
Stripping:
– Adjust the sliding limit stop in the pliers jaws to the desired
length of insulation to be removed.
– 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.

– Cut the wire if necessary with the cutting part on the upper side
of the wire strippers.
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2.2.5 Hot air blower, 220 V / 50 Hz -VAS
ot p
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1978/14-
h re
ole,
spec
t to the co
Caution
When shrink-fitting, take care not to damage any other wiring,
rrectne
plastic parts or insulating material with the hot air blower.
Observe the operating instructions of the hot air blower without
ss
fail!
o
cial p
f inform
mer
The hot air blower, 220 V / 50 Hz -VAS 1978/14- is used in con‐
atio
m
junction with shrink element for hot air blower -VAS 1978/15- to
o
n
c
i
or
n
shrink fit the crimp connectors. After crimping, the crimp connec‐
thi
te
tor has to be shrink fitted using the hot air blower in order to
sd
iva
o
prevent any ingress of moisture.
pr
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ng
t.
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Hot air blower, 220 V/50 Hz -VAS 1978/14- is included in wiring Cop py
harness repair set -VAS 1978 B- and previous versions.
t. rig
gh ht
pyri by
Vo
co
Shrink fitting crimp connectors using hot air blower, 220 V / 50 Hz
by lksw
cted agen
Prote
-VAS 1978/14- ⇒ page 94 , or ⇒ page 96 .
AG.
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 mm2 - 2.5 mm2 -VAS 1978/1-1-
♦ Head adapter 4.0 mm2 - 6.0 mm2 -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
mm2 ⇒ page 91 .
Interchanging head adapter:
– Open up the crimping pliers fully.

– Unclip both locking pins -arrows- from the body of the crimping
pliers.
AG. Volkswagen AG d
agen oes
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ed
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pt
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– Insert the required head adapter from above -arrow- in the
an
itte
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body of the crimping pliers.
erm
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ility
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wit
, is n
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spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
– Lock the head adapter by engaging the pins -arrows- in the
orm
body of the crimping pliers.
m
atio
om
n in
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thi
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Cop py
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rig ht
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by lksw
cted agen
Prote AG.
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.

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ot
wit
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spec
es, in part or in w
t to the co
rrectness of i
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nform
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a
com
tion in
r
te o
thi
s
iva
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fo
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t.
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Cop py
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pyri by
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co lksw
by
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Prote AG.

♦ 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 gen AG. Volkswagen AG
does
order to prevent any ingress of moisture. Vol
ksw
a
not
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db ara
♦ It is essential that the supplementary information isor
isobserved
e nte
regarding repairs to wiring harnesses in airbag aand
uth belt ten‐ eo
ra
sioner systems, fibre optic cables, CAN bus lines,
ss aerial cables c
ce
and wiring with cross sections up to 0.35 mm2 ⇒ page 91 .
le
un
pt
an
d
itte
♦ Carry out a function test after every repair. It may be necessary
y li
erm
ab
for the fault memory to be interrogated, erased and/or for the
ility
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systems to be reset.
wit
is n
h re
♦ If possible, do not loosen any earth wires from the body (dan‐
ole,
spec
ger of corrosion).
t to the co
♦ 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
rrectne
largest one should be used.
♦ Screened wires must not be repaired. If damaged they must
s
be replaced complete.
s o
cial p
f in
♦ Heat resistant wiring can be found in various places in the ve‐

form
mer
hicle, mainly in the engine compartment. Heat resistant wiring

atio
can be identified by its slightly matt and softer insulation. To

om
repair these wires, only heat resistant wiring may be used.

c
i
or
n thi
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sd
va
2.4 Repairs to wiring harnesses

i
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Cop py
Note ht. rig
rig ht
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by lksw
Observe the general notes on repairs to the vehicle electrical
cted agen
Prote AG.
system ⇒ page 85 .
Notes on repairs to airbag and belt tensioner wiring ⇒ page 88

Notes on repairs to fibre optic cables ⇒ page 89

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 mm2
⇒ page 91
Notes on repair of wiring open circuit with one repair position
⇒ page 94 en AG. V
olkswagen AG
ag does
lksw not
Notes on repair of wiring open circuit with two repair positions
yV
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⇒ page 96 o
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2.4.1 Notes on repairs to airbag
ss and belt ten‐ c
ce
sioner wiring e
nl
pt
du
an
itte
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In addition to the general notes on repairs to wiring harnesses,
erm
ab
ility
the following instructions must be observed on how to repair wir‐
ot p
ing in airbag and belt tensioner systems:
wit
, is n
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hole
spec
WARNING
es, in part or in w
t to the co
♦ Airbag and seat belt tensioner can fail.
♦ Faulty repairs to the airbag and seat belt tensioning sys‐
rrectness of i
tem can cause malfunctions in the passenger protection
l purpos
system.
♦ For repairs to airbag and belt tensioner wiring harnesses,
nform
ercia
only contacts, connectors and wiring designed specifically

for this purpose may be used ⇒ Electronic parts catalogue
m
at
(ETKA) .
om
ion
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in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

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
♦ 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.
G. Volkswage
♦ Repairs in the area
lksw
ofenthe
ag
A
airbag ornbelt
AG dotensioner should not
es n
be more than y V30 cm from the next contact housing.
o ot g
ua Together
db
with theoryellow
ise insulating tape, this gives a clearraindication
nte of
repairs
auth that have already been carried out. eo
r a
ss c
♦ The wires to the triggering units (airbags) are entwined as
ce
e
nl
standard with a twine spacing of 20 mm ± 5. This spacing is

pt
du
an
assured for series production via industrial standard numbers

itte
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erm
for wiring pairs and it is essential that it is adhered to on the

ab
ility
repair lengths of entwined wiring.

ot p
wit
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♦ During repairs, the wiring to the triggering units (airbags) must

h re
hole
have the same length. When wires -1- and -2- are entwined,
spec
the twine spacing of A = 20 mm ± 5 must be adhered to without

es, in part or in w
t to the co
fail.
♦ There must not be any section of wiring, for example in the
vicinity of crimp connectors -arrow-, longer than B = 100 mm
rrectness of i
with the wires not twisted.

l purpos
2.4.2 Fibre optic cables (FOC)

nf
ercia
orm
m
There is no provision for fibre optic cable repairs at Volkswagen.

atio
m
In the event of repairs, the entire fibre optic wiring harness must
o
n in
or c
be replaced. To do this, the following safety precautions must be

thi
e
observed:
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Note
Co
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♦ Avoid sharp bends in the fibre optic cable; the bend radius
p by
co Vo
by lksw
should be no tighter than 25 mm. Prote
cted AG.
agen
♦ Do not route fibre optic cables over sharp edges.

♦ 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.

2.4.3 Repairs to CAN bus wiring lksw

agen
AG. Volkswagen AG d
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♦ An unshielded two-wire line -1- and -2- with a cross section isedof
b ara
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2 2
0.35 mm or 0.5 mm is used for CAN bus wiring. hor eo
aut ra
s c
♦ The colour codes of the CAN bus wiring can be gleaned from
s
ce
le
the following table:
un
pt
an
d
itte
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Powertrain CAN, high wire Orange/black
erm
ab
ility
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Convenience CAN, high wire Orange/green
wit
is n
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Infotainment CAN, high Orange/violet
ole,
spec
CAN low wire, (all) Orange/brown
t to the co
♦ 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‐
rrectne
tronic parts catalogue (ETKA) ⇒ Electronic parts catalogue
(ETKA) .
ss
♦ When repairs are performed, both bus wires must have the
o
cial p
f i
same length. When twisting the wires -1- and -2- together, the
nform
length of each complete twist must be A = 20 mm.
mer
atio
m
♦ There must not be any section of wiring, for example in the

o
n
c
i
vicinity of crimp connectors -arrow-, longer than B = 50 mm
or
n thi
e
with the wires not twisted.

t
sd
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pr
c
♦ Mark the area of repair with yellow insulation tape to make it
um
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fo
en
ng
easy to identify.
t.
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Cop py
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2.4.4 Renewal of aerial wiring
ht
pyri by
Vo
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by c lksw
cted agen
Prote
A new repair concept has been developed for repair work on aer‐
AG.
ial wires. Now connecting wires in different lengths and various

adapter cables are available as replacement parts instead of a
complete aerial wire.
♦ 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.

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.
olks
wage es n
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3- Adapter cable, to aerial connection. rLength
ise
d approx. 30 cm. ran
tee
tho
or
Installing a new aerial cable: ss
au ac
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Note
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ility
Note that the total length of an aerial wire, depending on vehicle
ot
wit
, is n
equipment level, can be divided into sections by aerial diversity
h re
control unit, traffic information control unit or aerial amplifier. Only
hole
spec
the defective section of aerial wire must be replaced.
es, in part or in w
t to the co
– Pull defective aerial wire connections off units.
– Determine the routing of the defective aerial wire in vehicle
rrectness of i
and measure the total length of the aerial connecting wire to
l purpos
be replaced.
The total length of aerial connecting wire is the sum of the length
nform
ercia
of adapter cables required -1- and -3- and the connecting wire
m
-2-.
a
com
tion in
– To determine the length of connecting wire required, subtract
r
te o
thi
60 cm from the measured total length of aerial connecting wire
s
iva
do
-2-.
r
rp
cum
fo
en
g
– Procure the required adapter cables -1- and -3- and connect‐
n
t.
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ing wire -2- at length calculated as genuine part from the . Cop py
Electronic parts catalogue (ETKA).
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gh ht
pyri by
Vo
co
– Cut off connectors of defective aerial wire.
by lksw
cted agen
Prote AG.
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.
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 mm2
♦ Crimping pliers, complete -VAS 1978/1 A-

♦ Head adapter 0.35 mm² - 2.5 mm² -VAS 1978/1-1-
For repairs to wiring with cross sections up to 0.35 mm2, 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 1978/9A-
AG. Volkswagen AG d
or crimping pliers (base tool) -VAS lksw1978/1-2-
agen with attachedoeshead
not
adapter for JPT contacts -VAS d by 1978/9-1-
Vo , the correct connection gu
ara
between crimp contact, wireoris and single wire seal is assured. The ntee
e
tool is only to be usedafor
u the application described.
th or
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ss c
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Note
an
itte
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erm
ab
ility
Crimped to the repair wiring are normal contacts and gold-plated

ot p
contacts. The repair contact must always be the same type as the
wit
, is n
h re
contact installed in the factory.

hole
spec
es, in part or in w
Crimping on new contact with single wire seal

t to the co
– Insert head adapter for JPT contacts -VAS 1978/9-1- in crimp‐

ing pliers (base tool) -VAS 1978/1-2- ⇒ page 84 .
rrectness of i
– Attach the single wire seal to the repair wire.

l purpos
Note
nform
mercia
at
When doing this, the small diameter of the single wire seal must
om
io
face the contact to be crimped on.

n
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– 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.
olkswagen AG
en AG. V
– Push the single wire seal towardsolkthe
swastripped wire end until
g does
itnot
is flush with the wiring insulation.
ed by V gu
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ab
ility
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ole,
spec
t to the co
– Insert the new crimp contact in the mounting of the crimping

rrectne
pliers.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
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fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– 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 toolowas
lkswaused
en AG. V gen AG
in the correct manner to carry out the crimping
olks
wagprocess. does
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erm
ab
ility
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wit
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ole,
spec
2.4.6 Wiring open circuit with one repair posi‐
t to the co
tion
Repair position with single crimp connector
rrectne
– Place the wire to be repaired to one side (about 20 cm either
side of the repair position). ss o
cial p
– If necessary, unbind the wiring harness using the folding knife.

inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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yri
– Cut out the damaged piece of wiring using the wire strippers -
p by
o Vo
by c lksw
VAS 1978/3- . Prote
cted AG.
agen
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 .

– Strip the wire ends of insulation by 6 - 7 mm using the wire wagen AG. Volkswagen AG doe
strippers. yV
olks s no
t gu
b ara
ed nte
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th or
au ac
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un
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Push the crimp connector on both stripped wire ends of the
vehicle's own single wire and crimp it on using the crimping
rrectne
pliers.
ss o
Note
cial p
f inform
mer
atio
m
the crimp connectors being used ⇒ page 82 .

o
n
c
i
or
n
thi
te
sd
iva
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pr
cum
After crimping, the crimp connector has to be shrink fitted using
r
fo
en
ng
the hot air blower in order to prevent any ingress of moisture.

t.
yi Co
Cop py
– Place shrink element for hot air blower -VAS 1978/15- on hot
t. rig
gh ht
yri
air blower, 220 V / 50 Hz -VAS 1978/14- .
p by
co Vo
by lksw
cted agen
Prote AG.
– 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

Observe the operating instructions of the hot air blower without
fail!
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.

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byV ua
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Bora 1999au➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006
th or
ac ➤ , Golf 199 ...
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2.4.7 Wiring open circuit with two repair posi‐
itte
y li
erm
ab
tions
ility
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is n
Repair position with interlinked wire.
h re
ole,
spec
– Place the wire to be repaired to the side at two points (about
20 cm to both sides of the relevant repair position).
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
e
– Place the yellow repair wire next to the damage wiring harness
t
sd
va
and, using wire strippers -VAS 1978/3- , cut the repair wire to
i
o
pr
cum
the required length.
r
fo
en
ng
t.
yi Co
– Cut the damaged section of wire out of the vehicle's own single Cop py
wire.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– 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
the crimp connectors being used ⇒ page 82 .
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- .

– 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

AG. Volkswagen n AG do
wage e
Observe the operating instructionsVol of the hot air blower withoutot gu
ks sn
by
fail! ris
ed ara
nt ee
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s au ac
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un
pt
an
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Note
erm
ab
ility
ot p
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ole,
spec
t to the co
slightly.
rrectne
s
s o
cial p
f
inform
motion.
mer
atio
om
n
c
2.5 Repairs to contact housings and con‐ i

or
n thi
te
sd
a
nectors
iv
o
pr
cum
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fo
en
ng
t.
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op py
2.5.1 Notes on repairs to contact housings
t. C rig
gh ht
yri by
and connectors
op Vo
by c lksw
cted agen
Prote AG.
Note

♦ 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 .

– 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).
– 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- .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
– Strip the 6 - 7 mm of insulation from the end of the repair wire

pe
ility
and the vehicle's own single wire using the wire strippers.
ot
wit
, is n
h re
– Crimp the stripped ends of the repair wire and single wire of
hole
spec
the vehicle's own wiring harness using the crimping pliers and
es, in part or in w
a crimp connector, as described in the chapter entitled „Wiring

t to the co
open circuits with one repair position“ ⇒ page 94 .

rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Note

slightly.
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,
n AG. Vfor
olksexample,
wagen AG in the
engine compartment and must olksalways
wage be reinstalled dfollowing
oes
not
repairs. ed
byV gu
ara
is nte
or
♦ As standard, the single
au
th wire seal is crimped together with the eo
ra
contact on the wire;
ss this is not the case with the repair wires. c
Before crimping the repair line, the single wire seal must there‐
ce
le
un
pt
fore first be pushed onto the wire.
an
d
itte
y li
erm
ab
♦ It is essential that the single wire seals are of the correct size
ility
to fit the cross section of the repair wire. The outer diameter
ot p
wit
of the single wire seal is based on the socket diameter of the

is n
h re
contact housing. Only carry out the repair using the correct
ole,
spec
assembly tool.
t to the co
Assembling single wire seal:

– Disengage the contact locking mechanism using the appro‐
rrectne
priate release tool -A- and then pull the wire with the single
wire seal backwards -arrow- out of the contact housing.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– 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.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
– Place the single wire seal -A- on the free end of the repair wire.
t to the co
Note
rrectness of i
The small diameter of the single wire seal must face the contact
l purpos
housing.
nf
ercia
– Slide the single wire seal -A- on the repair wire until it reaches
rm
m
the contact housing.

atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
– Slide the single wire seal -A- using the respective assembly
m
f
en
ng
t.
tool -B- fully into the contact housing.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– 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
AG. Volkswagen
technique can only be supplied with the cut
kswand clamp con‐
agen AG do
es n
tacts inserted. y Vol ot g
ua
db e ran
ris tee
♦ These contacts can be removed
ut just like any other contact
ho or
housing if they are not needed.
ss
a ac
ce
le
♦ Repair wires can be supplied that already have the appropriate

un
pt
an
d
contacts crimped on ⇒ Electronics parts catalogue (ETKA) .

itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2.6 Releasing and dismantling contact

housings
AG. Volkswagen AG d
agen oes
olksw not
V gu
by ara
2.6.1 Notes on releasing and dismantling con‐ ed
ris nte
ho eo
ut
tact housings ss a ra
c
ce
e
nl
pt
du
an
itte
y li
Note
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
♦ To release, always use the correct release tools. Under no
es, in part or in w
circumstances should the contacts be pulled out of the contact
t to the co
housings with force.
♦ Damaged contact housings must always be replaced. New
rrectness of i
contact housings can be ordered from the OTC in Kassel.
l purpos
♦ As an aid to disengage the secondary locking mechanisms, a

small screwdriver can be used.
nform
ercia
♦ The socket/pin assignment can be found stamped on the sec‐

ondary locking mechanism or on the rear of the contact hous‐
m
at
om
ing.
ion
c
in t
or
♦ For more detailed information about the locations of connec‐
his
ate
tors, see ⇒ Current flow diagrams, Electrical fault finding and
do
priv
c
Fitting locations.
um
for
en
ng
t.
yi Co
op
Allocation of the correct release tool to the respective locking de‐ C py
t. rig
vices can be gleaned from the table in the ⇒ operating instruc‐
gh ht
pyri by
tions of -VAS 1978/35- .
o Vo
by c lksw
cted agen
Prote AG.
2.6.2 Secondary locking element
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-.

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-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
2.6.3 Primary locking element

pe
ility
ot
wit
, is n
The primary locking mechanism is what fixes an individual crimp

h re
hole
contact in the contact housing.

spec
es, in part or in w
If necessary, any housing catches in place (secondary locking

t to the co
mechanisms) must be released or removed prior to disengaging

the contacts using the prescribed tool ⇒ page 102 .
rrectness of i
The types of primary locking mechanisms shown as follows are

just a few examples to show the different functions of primary
l purpos
locking mechanism.
♦ Round connector systems ⇒ page 103
nform
ercia
♦ Flat connector systems ⇒ page 104

m
a
com
tio
♦ Special connector systems ⇒ page 106

n in
r
te o
thi
Allocation of the correct release tool to the respective locking de‐

s
iva
do
vice can be gleaned from the table in the ⇒ operating instructions

r
rp
cum
fo
of -VAS 1978/35- .
en
ng
t.
yi Co
op
2.6.4 Round connector systems
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
Note
AG.

mechanisms) must be released or removed prior to disengaging

– 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 Flat connector systems lksw

agen
AG. Volkswagen AG d
oes
not
Vo gu
d by ara
ise nte
or eo
Note aut
h
ra
ss c
ce
e

nl
pt
du
mechanisms) must be released or removed prior to disengaging an

itte
the contacts using the prescribed tool ⇒ page 102 . y li

erm
ab
ility
ot p
wit
, is n
Flat connector with one locking tab:

h re
hole
spec

es, in part or in w

t to the co
rrectness of i
l purpos
Note
nf

ercia
locking tab of the contact is lifted up by the housing edge and can
rm
m
atio
be disengaged using the release tool.

om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

lkswage es n
o ot g
byV ua
d ran
ir se te
o
Bora 1999 ➤ , Bora Variant
auth 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golfe199
... or
ac
ss
ce
e
nl
pt
du
an
itte
y li
contact housing and pull out the released contact from the
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Flat connector with two locking tabs:
m
at
om
i
on
c
in t
or
his
ate
– Grab hold of the contact by the wire and push it fully into the
do
priv
c
um
for
en
ng
t.
yi Co
Cop py
. rig
Note
t
gh ht
pyri by
Vo
co lksw
by
cted
agen
Prote AG.
Asymmetrical:
Note


2.6.6 Special connector systems
Note lks wage es n
o ot g
byV ua
d ran
ir se
If necessary, any housing catches tho in place (secondary locking tee
or
mechanisms) must be released ss
auor removed prior to disengaging ac
ce
le
un
pt
an
d
itte
y li
Faston contacts:
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
contact housing.
es, in part or in w
t to the co
Note
By pushing the contact in the direction of the contact housing, the rrectness of i
l purpos
nform
mercia
com
tion in
r
te o
thi

s
iva
do
r
rp
cum
fo

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

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.
AG. Volkswagen AG d
agen oes
olksw not
The contact is ejected from the contact housing.
d by V gu
ara
rise nte
o
– The release tool can be pulled outauof
t the contact housing again
h eo
ra
once the contact has been ejected.
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Contacts without locking tabs:
l purpos
– Insert the release tool under the locking tab of the contact
housing.
nform
ercia
– Push through the release tool with a light upward movement

-arrow- onto the limit stop.
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
The contact is ejected from the contact housing.
co lksw
by
cted agen
Prote AG.

3 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).n AThe ocontact
lkswagensurface cleaning set
e G. V AG do
-VAS 6410- is adapted to olksthe
wagstructural conditions eof
s nvehicles
o
and
ensures the process d bsecurity
yV of repair work as well ast gauacomfort‐
r
able procedure.orise ante
eth or
au ac
ss
ce
le
Note
un
pt
an
d
itte
y li
erm
The illustrations shown here are just a few examples of repair
ab
ility
work.
ot p
wit
is n
h re
ole,
Contact surface cleaning set VAS 6410

spec
t to the co
rrectnes
3.1.1 Repairing ring terminals

s o
cial p
f inform

mer
atio
♦ VAG 1331
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
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

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.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
Note ise
d b ara
nte
or eo
th
u ra
As the thickness
ss a
of the tin coating may differ according to the de‐ c
sign, the cleaning process must be performed step by step and a
ce
e
nl
pt
du
visual check of the ring terminal is necessary between the steps.

an
itte
y li
erm
ab
ility
ot p
– Insert adapter into ring terminal and grind off corrosion and dirt
wit
, is n
with circular movements.

h re
hole
spec
– Check ring terminal and regrind if necessary.

es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Contact surface cleaning set VAS 6410 109

– 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. agen
AG. Volkswagen AG d
oes
olksw not
byV gu
ara
ed
nte
WARNING horis
eo
aut ra
ss c
ce
e
nl
pt
tions ⇒ page 2 !
du
an
itte
y li
erm
ab
ility
ot p
– Teach in electric windows again, enter radio code, set clock
wit
, is n
and, if necessary, recode control units which emit code sig‐
h re
nals.
hole
spec
es, in part or in w
t to the co
3.1.2 Repairing threaded connections
rrectness of i
♦ VAG 1331
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
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

tions ⇒ page 2 !

– 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

AG. Volkswagen AG d
agen oes
– Apply suitable anti-corrosion treatment to threaded connection
olks
w not
yV gu
⇒ page 113 . se
d b ara
nte
ri
ho eo
– Reconnect battery. aut ra
c
ss
ce
e
nl
pt
du
WARNING
an
itte
y li
erm
ab

ility
ot p
tions ⇒ page 2 !
wit
, is n
h re
hole
spec
– Teach in electric windows again, enter radio code, set clock

es, in part or in w
t to the co
and, if necessary, recode control units which emit code sig‐

nals.
rrectness of i
3.1.3 Cleaning battery clamp and battery ter‐

l purpos
minal
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
111
cted agen
Prote AG.
3. Contact surface cleaning set VAS 6410
♦ VAG 1331
Note
The use of penetrating fluid, contact spray or grease etc. is pro‐ swagen AG. Vo
lkswagen AG
does
hibited since the missing adhesion in the threads may causebyaVolk not
gu
torque excess and, therefore, the break of the threaded connec‐
ris
ed
ara
nte
tion. ut
ho eo
ra
a c
ss
ce
e
nl
pt
du
WARNING
an
itte
y li
erm
ab
ility
ot p
tions ⇒ page 2 !
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Check battery clamp and battery terminal for corrosion or dirt.
– Clean battery clamp using wire brush of battery terminal clean‐
rrectness of i
er with circular movements.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Clean battery terminal using underside of battery terminal

cleaner with circular movements.
WARNING

. Volkswagen AG
tions ⇒ page 2 ! kswagen AG does
n
ol ot g
yV ua
edb ran
ris tee
ho
– Reconnect
aut battery and tighten battery terminals to specified
or
ac
torque.
ss
ce
le
un
pt
an
d
itte
y li
Note
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
3.1.4 Anti-corrosion treatment
rrectness of i
Caution
l purpos
Missing anti-corrosion treatment results in damage to the on‐

board supply.
nform
mercia
a
com
tion in
r
te o
Note
thi
s
iva
do
r
rp
cum
♦ All threaded connections must be tightened to specified tor‐

fo
en
g
que.
n
t.
yi Co
Cop py
♦ Always use hose supplied with anticorrosive agent tin.
ht. rig
rig ht
py by
o Vo
♦ Use protection wax for cold area.
by c lksw
cted agen
Prote AG.
♦ Use cavity sealing agent for warm area.
♦ The sealing agent independently reaches the respective
points through capillary action.
– Hold injector below ring terminal and spray pin all around.
3. Contact surface cleaning set VAS 6410 113

– Hold injector above ring terminal and spray pin and wiring eye
all around.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

4 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.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4. Renewing Lambda probe 115

– 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
AG. Volkswagen AG d
agen oes
♦ If necessary, replace attachment parts,
yV
olkcable
sw ties or marking not
gu
rings to match the uniform probeiseto
d b the defective probe as ara
nte
specified. thor eo
u ra
sa c
♦ The wires should not be crimped
s or cut as otherwise the func‐
ce
e
tion of the Lambda probe will be impaired.

nl
pt
du
an
itte
y li
erm
ab
– Remove the old Lambda probe.

ility
ot p
– Place both Lambda probes next to each other so that the sen‐
wit
, is n
h re
sor housings are at the same height.

hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– 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.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
4.3 Types of protective tube on uniform
ility
ot p
wit
Lambda probes
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
In addition to identifying by way of the part number, the protective
rrectness of i
tube can also be used as a means of identification.
l purpos
Type D1, 6 openings at 3.5 mm each
nf
ercia
Only used on 4-pin LSF Lambda probes.
orm
m
Type D2, 6 openings at 2 mm each

atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
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

Only used on 4-pin LSF Lambda probes and 6-pin LSU Lambda
probes.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
118
cop Vo
by lksw
Rep. gr.97 - Wiring Prote
cted AG.
agen

Volkswagen Polo 1995 - 2010 Workshop Manual - Electrical System

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Volkswagen Polo 1995 - 2010 Workshop Manual - Electrical System

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Service

92 - Windscreen wash/wipe system

94 - Lights, bulbs, switches - exterior

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Copyright © 2010 Volkswagen AG, Wolfsburg K0059101320

2.3 Checking colour display of magic eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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

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

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

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

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

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

To prevent damage to the battery and vehicle, the following

To ensure long use of the battery, the battery must be checked,

has other tasks: it acts as a buffer and supplies electrical energy

to the complete electrical onboard supply of the vehicle.

The description for the following batteries is for maintenance-

1.2.1 Battery with magic eye

No stickers may be removed and do not replenish with distilled

Batteries where the magic eye is colourless or light yellow must

1.2.2 Absorbent glass mat battery

Always replace an absorbent glass mat battery with another ab‐

1.3 Warning notices and safety regulations

the warnings on the battery, in the operating manual and in ELSA

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

♦ Untrained personnel e.g. apprentices, trainees etc. may

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

1.3.2 Safety markings on battery

Safety markings on battery

handling batteries. Avoid sparks as well as electrostatic discharge

Therefore never lay a tool on a battery.

2. - Wear eye protection before commencing work on battery.

3. - Keep children away from acid and batteries.

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

1.4 Battery terminal connection

ened any further.

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

Danger of injury! Observe warning notices and safety regula‐

To prevent damage to the battery and vehicle, the following

2.1 Checking the various types of batteries

2.1.1 Checking battery with magic eye

Danger of injury! Observe warning notices and safety regula‐

Carry out procedure in sequence as follows:

These batteries must be renewed.

3. Perform a battery load test using battery tester with printer

-VAS 5097 A- ⇒ page 9 .

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

2.1.2 Absorbent glass mat battery

Carry out procedure in sequence as follows:

1. Visual check ⇒ page 6

2. Perform a battery load test using battery tester with printer

-VAS 5097 A- ⇒ page 9 .

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

2.2 Visual check

Danger of injury! Observe warning notices and safety regula‐

It is essential to visually inspect the external condition, to check

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

Performing this test establishes:

tions) are damaged. The necessary contact on the battery

clamps cannot be guaranteed if the battery terminals are dam‐

aged. When connecting the battery clamps, tighten the battery

clamps to torque specified in this workshop manual „Electrical