2003 Volkswagen Touran 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 ➤ , wTouareg ➤, AG. Volkswagen2003 AG do agen es n ks l o o V , Touareg 2010sed➤ Touran 2003t gua➤ by ran un le

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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

27 - Starter, current supply,

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90 - Gauges, instruments

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92 - Windscreen wash/wipe system

94 - Lights, bulbs, switches - exterior

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97 - Wiring

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96 - Lights, bulbs, switches - interior

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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

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Contents

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

1 1 1 2 4 5 5 6 6 8 14 18 22 23 25 25 30 41 53 55 59 59 61 61

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Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fundamentals for batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Types of batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warning notices and safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery terminal connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the various types of batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking colour display of magic eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery tester with printer VAS 5097 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery tester with printer VAS 6161 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Midtronics MCR340V battery tester only for USA/Canada vehicles . . . . . . . . . . . . . . . . . . Current draw test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking no-load voltage of battery on stock and stored vehicles . . . . . . . . . . . . . . . . . . Charging battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery charger VAS 5095 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery charger VAS 5900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery charger VAS 5903 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery charger VAS 5906 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Midtronics INC 940 battery charger only for USA/Canada . . . . . . . . . . . . . . . . . . . . . . . . . . Solar panel VAS 6102A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Totally discharged batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cruise control system (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activating and deactivating cruise control system (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . .

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1 1.1 1.2 1.3 1.4 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 4 4.1

1

90 - Gauges, instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 92 - Windscreen wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 1 1.1 1.2 2 2.1 2.2 2.3 3

Washer fluid line hose couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Windscreen and rear window washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hose repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairing smooth pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairing corrugated pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Distinguishing features of jointless wiper blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63 63 64 65 65 65 65 67

94 - Lights, bulbs, switches - exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 1

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

68

96 - Lights, bulbs, switches - interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 1 1.1 1.2 2 2.1 2.2 2.3 2.4

12 V socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing 12 V socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing socket illumination bulb L42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cigarette lighter U1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing cigarette lighter socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing cigarette lighter illumination bulb L28 . . . . . . . . . . . . . . . . . . . . . .

71 71 71 72 72 73 74 76

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

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Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 1 1.1 1.2 2 2.1 2.2 2.3 2.4 2.5 2.6 3 3.1 4 4.1 4.2 4.3

Vehicle diagnostic, testing and information systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting vehicle diagnostic tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting vehicle diagnostic tester Golf Model Year 1998 - 2003 . . . . . . . . . . . . . . . . . . Repairing wiring harnesses and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring harness repair set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tool descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General notes concerning repairs to vehicle electrical system . . . . . . . . . . . . . . . . . . . . . . Repairs to wiring harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairs to contact housings and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Releasing and dismantling contact housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact surface cleaning set VAS 6410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Using contact surface cleaning set VAS 6410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing LSF Lambda probe (4-pin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Renewing LSU Lambda probe (6-pin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Types of protective tube on uniform Lambda probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

78 78 80 81 81 82 85 87 97 102 108 108 115 115 116 117

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Contents

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27 –

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Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 !

Caution

To prevent damage to the battery and vehicle, the following should be observed concerning types of battery ⇒ page 1 .

1.1

Fundamentals for batteries

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

Types of batteries

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General notes

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Apart from supplying energy for starting the engine, the battery has other tasks: it acts as a buffer and supplies electrical energy to the complete electrical onboard supply of the vehicle.

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WARNING

Caution

The description for the following batteries is for maintenancefree batteries. No stickers may be removed and do not replen‐ ish with distilled water. Only perform a visual check. Refer to chapter, Checking battery ⇒ page 5 .

1.2.1

Battery with magic eye

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

No stickers may be removed and do not replenish with distilled water. Only perform a visual check. Refer to chapter, Checking battery ⇒ page 5 .

WARNING

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle! Danger of explosion when checking and charging or slave/ jump starting. These batteries must be renewed.

1. Battery

1

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 This battery is equipped with a magic eye. The magic eye pro‐ vides information concerning the level of the electrolyte and the charge state of the battery via a coloured display. Checking colour display of the magic eye ⇒ page 6

1.2.2

Absorbent glass mat battery

Maintenance-free battery with a contained electrolyte and no magic eye. Lead-acid battery where the electrolyte is contained within a mi‐ croscopic glass mat (AGM). The battery is sealed and fitted with valves. AGM is the abbreviation for absorbent glass mat. Due to containment of the electrolyte, this type of battery may not n AG. Volkswagen AG do have a magic eye. Absorbent glass mat batteries are identified es n wage by s k l ot g o the abbreviation AGM on the battery. yV ua b d un le

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

1.3

Warning notices and safety regulations

1.3.1

Dangers when handling vehicle batter‐ ies

Recognition and avoidance of dangers

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

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Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 WARNING

♦ Untrained personnel e.g. apprentices, trainees etc. may only work on batteries when supervised by a vehicle me‐ chanic/foreman or vehicle electrician/foreman. ♦ Acid is highly corrosive. There is a considerable danger of acid burns if personnel do not handle batteries correctly. Therefore suitable measures must be taken to ensure that equipment/solutions etc. are available to neutralize acid burns. A suitable solution is: e.g. a soap solution. ♦ If electrolyte leaks from a battery it may cause skin burns or acid corrosion and rusting on the vehicle. This may damage safety relevant components on the vehicle. ♦ 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 correctly. n AG. Volkswagen AG do e wage s no t

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y V be renewed where the magic geye ua is col‐ ♦ Batteriesemust db ran s light yellow. They must not be checked ior teor r ourless o eo h t u ra charged and do not slave/jump start. Danger of explosion a c s s when checking and charging or slave/jump starting. pe rm itte d es, in part or in w l purpos hole ercia , is n m ot com

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

1.3.2

Safety markings on battery

Safety markings on battery

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1. - Fires, sparks, naked flames and smoking are prohibited when handling batteries. Avoid sparks as well as electrostatic discharge when working with cables and electrical units. Avoid short circuits. Therefore never lay a tool on a battery. 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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♦ It is prohibited to cause sparks through grinding, welding, cutting operations and use naked lights in the vicinity of batteries. Smoking is also prohibited. Sparks generated by electrostatic charging must also be avoided. Always touch the vehicle body before touching the battery.

4. - Disposal: old batteries are classed as hazardous waste. They may only be disposed of through a suitable collection centre and only in accordance with respective legislation. ht rig py Co t.

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5. - Never dispose of old batteries in household waste system! AG.

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

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Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010

1.4

Battery terminal connection Caution

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AG. Volkswagen AG d agen oes ksw not l o To prevent damage to the battery clamps and gu y V battery termi‐ b ara nals, the following should be observed: rised nte o eo th u ra a ♦ The battery clamps should only be fitted by hand and with‐ c s s pe rm itte d

♦ Battery terminals should not be coated with grease.

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

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

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010

2

Checking battery WARNING

Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 !

Caution

To prevent damage to the battery and vehicle, the following should be observed concerning types of battery ⇒ page 1 .

2.1

Checking the various types of batteries

2.1.1

Checking battery with magic eye WARNING

Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 ! Carry out procedure in sequence as follows: 1.

Visual check ⇒ page 6

2.

Check colour display of „3-colour“ magic eye ⇒ page 6 or „2-colour“ magic eye ⇒ page 7 . WARNING

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AG. Volkswagen AG d agen oes ksw not l o V gu Batteries where the magic eye is colourless or light yellow must y b ara d nte not be checked or charged. Do not slave/jumporstart ise the vehicle! eo h t u ra a charging or slave/ c Danger of explosion when checking and s s

These batteries must be renewed.

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3.

Perform a battery load test using battery tester with printer -VAS 5097 A- ⇒ page 9 .

– Battery test with battery tester with printer -VAS 6161⇒ page 14 . 4.

Depending on the result of the battery test, „perform current draw test“ ⇒ page 22 .

2.1.2

Absorbent glass mat battery

Carry out procedure in sequence as follows: 2.

Perform a battery load test using battery tester with printer -VAS 5097 A- ⇒ page 9 .

– Battery load test with battery tester with printer -VAS 6161⇒ page 14

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Depending on the result of the battery test, „perform current draw test“ ⇒ page 22 .

2.2

Visual check WARNING

Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 ! It is essential to visually inspect the external condition, to check the terminals and to ensure proper attachment of the battery be‐ fore performing extensive tests. Caution

♦ The battery will be damaged if the battery is not secured correctly. ♦ Vibrations shorten the life of the battery, there is a danger of an explosion, the cell plates may be damaged and the clamping bracket may damage the battery housing. ♦ Check battery is securely seated, if necessary tighten se‐ curing bolt to specified torque. Performing this test establishes: ♦ If battery housing is damaged Electrolyte out lkswag en AifGthe G. Voleak Acan does agen out, serious damage w housing is damaged. If battery acid leaks s k no ol V y to the vehicle could be caused. Treat components affected by t guara b d e nte leaked battery acid immediately with acid neutraliser or a soap ris eo tho u ra solution. a

Checking colour display of magic eye

2.3.1

Checking colour display of „3-colour“ magic eye

WARNING

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♦ Check whether the battery terminals (battery wire connec‐ 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 system“ for the respective vehicle. If the battery clamps are not correctly seated and tightened, the wiring may burn. Which will cause malfunctions in the electrical system. Therefore it can no longer be guaranteed that the vehicle will function cor‐ rectly.

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 General information on magic eye: Applies for all batteries with „1J0“, „7N0“ and „3B0“ indexes in original equipment and for all replacement batteries 191 915 105 AB and from „000 915 105 AX“ index. The magic eye provides information concerning electrolyte level and the charge state of the battery. Before carrying out a visual check, tap the magic eye lightly and carefully using the handle of a screwdriver. The air bubbles, which can influence the display, will dissipate when doing this. The col‐ our display of the magic eye will therefore be more accurate. Note ♦ Air bubbles can form below the magic eye particularly when

the battery is being charged, including during normal vehicle operation. These distort the colour displayed by the magic eye.

♦ Because the magic eye is located in only one cell, the display

applies only to this cell. An exact determination of the battery condition is only possible through a battery load test ⇒ page 9 or a battery test ⇒ page 14 .

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

tery.

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

2.3.2

Checking colour display of „2-colour“ magic eye

r fo ng

WARNING

Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 !

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♦ »Black«, battery partly discharged, charge state < 65 % or completely discharged

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2. Checking battery

7

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Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 General information on magic eye: For batteries from „5K0“ index in original equipment and for re‐ placement batteries 191 915 105 AC from „000 915 105 DX“ index, the »green« colour display for charge state display has been discontinued. The introduction of the new colour display will take place gradually, i.e. there will be a transition period for both displays. In the future, the only remaining colours will be »black« or »colourless or light yellow«. The magic eye provides information concerning the electrolyte level of the battery. The charge state of the battery can no longer be read from the magic eye, a battery load test must be carried out for this ⇒ page 9 Before carrying out a visual check, tap the magic eye lightly and carefully using the handle of a screwdriver. The air bubbles, which can influence the display, will dissipate when doing this. The col‐ our display of the magic eye will therefore be more accurate. Note ♦ Air bubbles can form below the magic eye particularly when

the battery is being charged, including during normal vehicle operation. These distort the colour displayed by the magic eye.

♦ Because the magic eye is located in only one cell, the display

applies only to this cell. An exact determination of the battery condition is only possible through a battery load test ⇒ page 9 .

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

♦ The magic eye can be located at various positions on the bat‐ Three different colour displays are possible:

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♦ »Black«, electrolyte level is OK.

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tery.

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

rrectness of i t to the co nf o r m spec atio h re n in wit

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.

Battery tester with printer -VAS 5097 A-

Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 !

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

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8

AG.

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

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

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2.4

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 ♦ 80 - 520 A low-temperature test current according to DIN (Deutsche Industrie Norm (German Industrial Standard))1) ♦ 95 - 574 A cold cranking current according to IEC (Interna‐ tional Engineering Consortium) ♦ 136 - 855 A cold cranking current according to EN/ SAE (Eu‐ ropean Norm/Standard of Automotive Engineers)

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Note

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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 ksw not l o gu For test purposes the battery is loaded with a current which y V is b ara d e nte similar to the starting current required to start the vehicle. The is r o eo th printed out. battery is assessed on this loading and the resultauis ra c s s

2.4.1

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Observe the ⇒ instruction manual of Battery tester with printer VAS 5097 A- or the sticker ⇒ Brief instructions for battery tester with printer -VAS 5097 A- on the unit or table: Cold cranking cur‐ rent ⇒ page 11 .

Description of battery tester with printer -VAS 5097 A-

Battery tester with printer -VAS 5097 A1 - Green LED, „unit operating“

2 - Red LED, „unit reverse-polarity connected“

3 - Red LED, „battery cannot be tested“, recharge battery. 4 - Start button

AG.

8 - Paper feed button

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7 - Selection switch (battery tester to pick-off point on battery/ external test point in engine compartment)

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6 - ON/OFF and functions switch

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5 - Cold cranking current selection switch

9 - Printer

2.4.2

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

Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 ! Special tools and workshop equipment required

2. Checking battery

9

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 ♦ Battery tester with printer -VAS 5097 A-

rrectness of i t to the co nform spec at i h re o n wit in t his

Observe technical product information TPI 2012182 for battery tester with printer -VAS 5097 A- . Performing battery load test: WARNING

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle! Danger of explosion when checking and charging or slave/ jump starting These batteries must be renewed.

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

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– Switch off ignition and all electrical consumers.

– 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 .

10

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

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Note

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Note

Batteries with cold cranking current higher than 499 A according to DIN (e.g. 520 A, 580 A or 600 A) can be temporarily tested using setting for 499 A according to DIN. – Connect red terminal „+“ of tester to positive terminal. – Connect black terminal „-“ of tester to negative terminal. Note

♦ Ensure test clamps have a good contact! ♦ Observe technical product information TPI 2012182 for battery

tester with printer -VAS 5097 A- . r fo ng

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1-

Connected directly to battery

2-

Connected to external test points in engine compartment

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– Select point of connection of test terminals with selection switch ⇒ page 9 .

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

– 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 EN/ SAE 136 – 17 178 – 219 220 – 261 262 – 303 304 – 345 346 – 387 388 – 429 430 – 471 472 – 513

Cold cranking current in A IEC ⇒ 95 – 124 125 – 154 155 – 184 185 – 214 215 – 244 245 – 274 275 – 304 305 – 334 335 – 364

⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒

DIN 80 – 104 105 – 129 130 – 154 155 – 179 180 – 204 204 – 229 230 – 254 255 – 279 280 – 304 2. Checking battery

11

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 Cold cranking current in A IEC ⇒

EN/ SAE 514 – 555 556 – 597 598 – 639 640 – 657 658 – 675 676 – 693 694 – 711 712 – 729 730 – 747 748 – 765 766 – 783 784 – 801 802 – 819 820 – 837 838 – 855

365 – 394 395 – 424 425 – 454 455 – 464 465 – 474 475 – 484 485 – 494 495 – 504 505 – 514 515 – 524 525 – 534 535 – 544 545 – 554 555 – 564 565 – 574

DIN

⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒

305 –329 330 – 354 355 – 379 380 – 389 390 – 399 400 – 409 410 – 419 420 – 429 430 – 439 440 – 449 450 – 459 460 – 469 470 – 479 480 – 489 490 – 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 ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

2.4.4

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

rrectness of i t to the co nf o r m spec atio h re n in wit

♦ If the battery is OK, the voltage value drops only to the mini‐ mum voltage. ♦ If the battery is defective or has a low charge, the battery volt‐ age quickly drops below the minimum voltage. ♦ After the test is completed, this low voltage value remains over a longer period, and the voltage increases very slowly again. ♦ Perform test once only. Repeating the test falsifies the result. ♦ The tester requires approx. 30 minutes to cool down before carrying out another test or testing another battery to ensure the results are not falsified.

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

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12

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010

Comments concerning test print out

1-

Measuring range selected on tester

2-

Diagram -arrow- indicates battery condition.

3-

Test result

4-

Battery voltage during load test.

5-

Vehicle data and date Must be completed by test personnel Note

♦ The test

fies the result.

rrectness of i t to the co nf o r m spec atio h re n in wit

2.4.6

Assessing test results

Printout from battery tester

Measure to be performed

Starting capability very good Starting capability good Starting capability sufficient

Battery OK. Battery OK. Evaluation by carrying out a current draw test when charg‐ ing ⇒ page 22 Evaluation by carrying out a current draw test when charg‐ ing ⇒ page 22 Evaluation by carrying out a current draw test when charg‐ ing ⇒ page 22 Perform battery charging ⇒ page 25 and repeat test. Prote cted by

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Cannot be tested

AG.

Starting capability very poor

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Starting capability poor

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

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2.4.5

2. Checking battery

13

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010

2.5

Battery tester with printer -VAS 6161-

General description WARNING

Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 ! It is not necessary to remove or disconnect battery when using battery tester with printer -VAS 6161- . The battery tester with printer -VAS 6161- does not load the bat‐ tery any more. It works on the principle of dynamic conductance acquisition. Every battery type is stored in the tester. Data can be stored on an SD card. The battery tester with printer -VAS 6161- can be updated via an interface or an SD card, so that battery data from Volkswagen are always up to date. The integrated temperature sensor improves measurement qual‐ ity. A 2D scanner is available as an option to read data directly from the bar code of the battery. Note

Observe the ⇒ operating manual of the battery tester with printer -VAS 6161- .

2.5.1

Description of battery tester with printer AG. Volkswagen AG d agen oes ksw not l o gu -VAS 6161yV ar db

1 - Integrated printer s

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3 - Paper slot

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2 - Operating lever for paper compartments

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4 - LCD screen with main menu

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5 - Control panel with On/Off button

6 - Connection for battery test cable 7 - Memory card slot

8 - Infrared temperature sensor

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

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14

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9 - Data transmitter for PC

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010

2.5.2

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

Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 ! Special tools and workshop equipment required ♦ Battery tester with printer -VAS 6161-

Performing battery test: WARNING

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

rrectness of i t to the co nform spec a t i h re o n in wit thi s

es, in part or in w l purpos hole ercia , is n m ot com

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

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These batteries must be renewed. – Switch off ignition and all electrical consumers. – Check magic eye on batteries with magic eye ⇒ page 5 . – Switch on unit.

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

Ensure test clamps have a good contact! Prote cted by c o p yri gh t. C op yi

♦ Maintenance test (only in new cars before registration, in sta‐ tionary and stock maintenance programme ⇒ page 16 )

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♦ Service test ⇒ page 16

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– Select one of the following functions.

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Note

♦ Guarantee test ⇒ page 17

2. Checking battery

15

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 Note ♦ The test is completed after about 10 seconds. ♦ The result of the test is printed out by the printer. ♦ The tester requires no cooling phase before it is ready for the

next measurement.

2.5.3

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

Performing maintenance test

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WARNING

Danger of explosion when checking and charging or slave/ jump starting These batteries must be renewed.

– Select „Maintenance test“ in the menu. – Connect scanner. Note

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

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

– Print out test log if necessary.

2.5.4

Perform service test WARNING

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle! Danger of explosion when checking and charging or slave/ jump starting These batteries must be renewed. – Select „Service test“ in the menu. – Select „On battery terminal“ or „On jump-start point“. – Select vehicle type. – Measure temperature. Hold temperature sensor about 5 cm above one battery terminal until temperature stabilises.

16

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

AG.

– Start test.

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

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

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urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

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

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 – Select battery type „Normal“, „AGM“, „2*6V“ or „Gel“. – Select „CCA“, „JIS“, „DIN“, „SAE“, „IEC“ or „EN“ norm. – Start test. – Print out test log if necessary.

2.5.5

Perform guarantee test WARNING

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle! Danger of explosion when checking and charging or slave/ jump starting These batteries must be renewed. – Select „Guarantee test“ in the menu. – Select „In vehicle“ or „Outside vehicle“. – Select „On battery terminal“ or „On jump-start point“. – Select vehicle type. – Measure temperature. Hold temperature sensor about 5 cm above one battery terminal until temperature stabilises. – Select battery type „Normal“, „AGM“, „2*6V“ or „Gel“ or scan in. – Select battery capacity or scan in. – Start test.

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte is r o eo h ut ra a c s s

– Print out test log if necessary.

2.5.6

Comments concerning test print out

2-

Battery test result

3-

Measured voltage

4-

Measured cold start value of battery.

5-

Nominal cold start value of battery selected on tester.

6-

Measured temperature of battery.

7-

Fitting location of battery

8-

Position of battery clamp selected on tester

9-

Selected battery technology.

urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

The test printout is required for warranty claims. r fo ng

Assessing test results Prote cted by c o py rig ht . C op yi

Evaluating battery test results for guarantee and service tests No measures on battery

AG.

Battery OK

Measures

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Battery test results

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2.5.7

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Note

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Check type.

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1-

2. Checking battery

17

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 Battery test results

Measures

Battery OK - recharge.

Evaluating battery test results for maintenance test Battery OK Charge battery immediately.

No measure Charge battery fully ⇒ page 25 . Mark as defective. Disconnect battery and repeat test. The result „Check tester connection“ may be caused by a weak cable contact. Connect cable directly to bat‐ tery and not to jump start termi‐ nal. Wait until measured value ap‐ pears on display.

r te o iva r rp fo g n

Check connection. Noises

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

2.6

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Mark as defective. Check tester connection.

General description ⇒ page 18 Perform battery test with Midtronics -MCR340V- battery tester ⇒ page 19 . Dealing with problems with Midtronics -MCR340V- battery tester ⇒ page 21

2.6.1

General description WARNING

Danger of injury. Before working on the battery, read through the warning and safety regulations carefully, and comply with them ⇒ page 2 . Dispose of electrolyte (mixture of sulphuric acid and water) safely! Waste electrolyte is only allowed to be disposed of at appropriately indicated collecting points. Comply with the lo‐ cally applicable disposal guidelines. Do not test batteries that are liberating gas. Otherwise, there is a danger of explosion.

18

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

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Measures

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Battery test results

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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 not olk gu yV Renew battery. Disconnect battery and repeat ara db e nte istest. The result „Renew battery“ r o eo h ut may be caused by a weak cable ra a c s s contact. Battery cell defective - renew. Renew battery. Check connection. Connect cable directly to bat‐ tery and not to jump start termi‐ nal.

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 WARNING

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle! Danger of explosion when checking and charging or slave/ jump starting These batteries must be renewed.

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. olkswagen A AG. V gen swa

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not olk Refer to ⇒ Self-study bprogramme No. ; Vehicle batteries gufor more yV ara d information. nte ir se

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Always comply with the safety regulations, the regulations for setting up the battery tester, the display menu/display buttons, LEDs and the operating procedures described in the ⇒ operating manual MCR340V . Note

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

2.6.2

Performing battery test with Midtronics MCR340V- battery tester

Prerequisites:

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WARNING

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u ra The followings acharging and analysis procedures apply to all bat‐ c s teries, all battery installation locations (engine compartment or luggage compartment) and battery purposes (starter battery or second/convenience battery).

c o p yri gh t . C op yi

Before working on the battery, read through the warning and safety regulations carefully, and comply with them ⇒ page 2 . agen lksw Vo by

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

Prote cted by

Danger of explosion when checking and charging or slave/ jump starting These batteries must be renewed. – Read general description ⇒ page 18 . – Perform visual check ⇒ page 6 .

2. Checking battery

19

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 – Open bonnet or cover for other installation location of battery. – Determine whether battery type is „Standard“ or „AGM“. – Remove covers from battery positive and negative terminals. – Use wing covers or other kinds of cover before you use equip‐ ment in engine compartment or interior. – Close all doors. Note ♦ Battery temperature must be at least 10 °C. ♦ For additional information, refer to the

WARNING

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Perform test:

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INC 940 .

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rrectness of i t to the co nf o r m spec atio h re n in wit

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle! Danger of explosion when checking and charging or slave/ jump starting These batteries must be renewed.

– Switch off ignition and all electrical consumers. – Check magic eye on batteries with magic eye ⇒ page 5 . – Switch on tester.

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

Prote cted by

– 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 .

20

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

AG.

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

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Ensure test clamps have a good contact!

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Note

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

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 Note

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

2.6.3

Assessing test results

Results of battery test: Battery test results

Measures

Battery OK Good - charge Use Incharge Renew battery.

None Charge battery ⇒ page 55 . Charge battery ⇒ page 55 . Renew battery ⇒ Electrical sys‐ tem; Rep. gr. 27 ; Removing and installing battery Renew battery ⇒ Electrical sys‐ tem; Rep. gr. 27 ; Removing and installing battery

Battery cell defective

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 . Measures

No display

– Check whether terminals of battery tester are firmly con‐ nected to battery terminals. – Check battery terminals are tightened according to reg‐ ulations and do not have corrosion.

– Wait until all electrical loads monitored by onboard sup‐ ply control unit have switch‐ ed off. – Remove ignition key. r fo ng

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

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System noise

– Charge battery ⇒ page 55 . – Switch off all electrical con‐ sumers.

2. Checking battery

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Display message

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21

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 Wait a few minutes and test again ⇒ page 19 . Note

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

2.7

Current draw test WARNING

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jumpestart the vehicle! n AG. Volkswagen AG ag ksw

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Note

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♦ Ensure that the correct charging mode is set on the charger

so that the current draw test is not falsified.

♦ VAS 5095 A ⇒ page 26 ♦ VAS 5900 ⇒ page 30 ♦ VAS 5903 ⇒ page 41

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The current draw test must be carried out when the test result with battery tester with printer -VAS 5097A- is as follows: AG.

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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.

22

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

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For battery tester with printer -VAS 6161- , the current draw test must always be performed when the test result „Perform current draw test“ appears on the display.

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Note

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

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♦ The charger must be capable of outputting a charge current of at least 30 A, as for example with VAS 5095A, VAS 5900, VAS 5903 ♦ The battery's current draw must be measured with a current 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. – Connect battery to battery charger and start charging se‐ quence. – Measure charging current of battery after 5 minutes. Test result:

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Note

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If the current draw A is higher than 10 % of the nominal capacity (e.g. > 6.1 A for a 61 Ah battery), fully charge battery and test again.

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♦ When charging a battery, battery temperature must be at least ≥ +10 °C.

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Test

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For Eos with two 6V absorbent glass mat batteries, the charge current must only be 5 % higher than the nominal capacity of the battery. Example for Eos: the 50 Ah battery must have a charge current higher than 2.5 A after 5 minutes of starting the charging sequence. agen lksw Vo by

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– Fully charge the battery when the charge current is higher than 10 % of the nominal capacity (observe exception for Eos in above note). – Perform battery test after allowing battery to rest for two hours ⇒ page 9 . If the charge current, in amperes, lies below 10 % of the nominal capacity after 5 minutes of starting the charging sequence (5 % for the 2 x 6 volt batteries in Eos) (example for 50 Ah battery < 5A), renew battery. For Guarantee and ex-gratia cases: complete battery test sheet and keep it with the battery.

2.8

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

Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 !

Note ♦ The no-load voltage test may only be carried out to assess the

condition of the battery on stock and stored vehicles within the framework of prescribed maintenance.

♦ The no-load test serves to determine whether a battery on a

stock or stored vehicle requires recharging ⇒ Maintenance tables „Service for stock and stored vehicles“ .

Special tools and workshop equipment required

2. Checking battery

23

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 ♦ Hand multimeter -V.A.G 1526 B-

Test conditions The battery must not have been charged or discharged within the last 2 days. – Check battery no-load voltage with hand multimeter -V.A.G 1526 B- . No-load voltage

Charge

Condition of battery

11.60 V

0%

Discharged, no capacity Heavily discharged ⇒ page 59 .

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

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24

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Charging battery ⇒ page 25

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No-load voltage ≥ 12.5 No-load voltage < 12.5 V

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Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010

3

Charging battery WARNING

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Danger of injury! Observe warning notices and tions ⇒ page 2 !

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WARNING

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To prevent damage to the battery and vehicle, the following should be observed concerning types of battery ⇒ page 1 .

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.

Battery charger -VAS 5095 A-

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Note

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This chapter describes the basic functions of the battery charger -VAS 5095 A- . For additional information refer to ⇒ operating instructions for battery charger -VAS 5095 A- .

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3.1

♦ 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

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 The battery charger charges without peaks in amperage or volt‐ . Volkswagen AG does age. This will not adversely effect the onboard electronics. The kswagen AG not l o gu battery can remain in the vehicle while it is being charged and yV b ara d e nte need not be disconnected. ris

2 - Charging current indicator (I > 12 A)

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1 - ON / OFF switch (0 = charger OFF)

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Battery charger -VAS 5095 A-

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3 - Charging current indicator, battery partially charged > 90 % 4 - Maintaining charge; lights up green when battery is fully charg‐ ed 5 - Malfunction indicator 6 - Support mode indicator

7 - Support mode/normal mode changer-over switch

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

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

Charging battery with battery charger VAS 5095 A-

♦ Battery charger -VAS 5095 A-

Caution

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

Note

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

26

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

AG.

Special tools and workshop equipment required

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Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 !

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3.1.2

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 WARNING

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle! Danger of explosion when checking and charging or slave/ jump starting These batteries must be renewed. olkswagen AG AG. Vconsumers. – Switch off ignition and all w electrical doe agen

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gu y ara – Check setting for ebattery type on type of battery switch db nte s i r ⇒ page 25 . Must be set to 2.4 V/C (volts/battery cell). o eo h t au

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In vehicles with start/stop function and battery monitor control unit -J367- fitted, black terminal clamp „-“ must be connected to body earth. Connecting it to battery negative terminal will cause start/ stop system to malfunction. – Connect black terminal clamp „-“ of battery charger to negative terminal. – Switch on battery charger ⇒ page 25 . The charging current indicators ⇒ page 26 -2- and -3- light up yellow. When only the light emitting diode (LED) -3- lights up yel‐ low, battery is partially discharged (approx. 90 %). If the LED lights up green ⇒ page 26 -4- the charger has switched to "maintaining charge". The battery is fully charged. Prote cted by c o p yri gh t. C op yi

– Remove charger unit terminals from battery terminals.

Charging totally discharged battery with battery charger -VAS 5095 Aagen lksw Vo by

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3.1.3

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– Switch off charging unit ⇒ page 25 .

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Note

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

WARNING

Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 ! The charger unit automatically recognises totally discharged bat‐ teries and initiates a gentle charging procedure with a low charg‐ ing current. The charging current is automatically adapted to suit the charge condition of the battery. Note ♦ Observe notes in chapter ⇒ page 59 . ♦ Totally discharged batteries in vehicles before registration

must be exchanged prior to delivery. Preliminary damage can‐ not be excluded.

♦ The battery voltage must be at least 0.6 V.

3. Charging battery

27

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 WARNING

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle! Danger of explosion when checking and charging or slave/ jump starting olksw AG. V agen

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

General notes: The support mode provides the onboard supply with power when the battery is removed or disconnected. For further information, refer to the ⇒ operating manual VAS 5095A . The support mode is suitable in the following situations: ♦ Support mode of onboard supplies without installed battery ♦ Power conservation when renewing the battery ♦ Ancillaries test without battery

Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 !

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WARNING

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle! Danger of explosion when checking and charging or slave/ jump starting These batteries must be renewed. – Switch off ignition and all electrical consumers.

28

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

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WARNING

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– Charge battery ⇒ page 26 . ss

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Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 Caution

♦ The terminal polarity protection in operating mode „charg‐ ing totally discharged batteries/support mode“ is not ac‐ tive. Connect battery charger terminal clamps correctly to battery terminals. ♦ It can cause sparks through a short-circuit.

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e nte s i r Ensure charger terminal clamps are seated securely. o eo h ut ra a c s Do not press START / STOP button s when charger unit

♦ Danger of explosion

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♦

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

Caution

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– Remove battery.

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♦

When battery is removed, ensure there is no contact between terminal clamp connected to positive clamp and body earth. Also ensure there is no contact between battery clamps. – Connect red terminal clamp „+“ to positive terminal of vehicle.

AG.

– Check setting for battery type on normal/support mode switch ⇒ page 25 . It must be switched on support mode.

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

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In vehicles with start/stop function and battery monitor control unit -J367- fitted, black terminal clamp „-“ must be connected to body earth. Connecting it to battery negative terminal will cause start/ stop system to malfunction.

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Note

– 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.

3. Charging battery

29

olkswa➤ Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ e,nEos gen, AGolf AG. V2006 G do 199 ... ag es n ksw 07.2010 l Electrical System, General Information - Edition ot g o V

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WARNING

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

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3.1.5

ua ran tee

Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 !

WARNING

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle! Danger of explosion when checking and charging or slave/ jump starting These batteries must be renewed.

Prote cted by

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 5900WARNING

Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 !

WARNING

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle! Danger of explosion when checking and charging or slave/ jump starting These batteries must be renewed. This chapter describes the basic functions of the battery charger -VAS 5900- . For additional information refer to ⇒ operating in‐ structions for battery charger -VAS 5900- .

30

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

AG.

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

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Note

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– Proceed as for charging battery ⇒ page 26 .

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In maintenance mode the battery charger -VAS 5095 A- ensures that the battery is charged correctly and is maintained in fully charged condition.

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 Note ♦ The effective charging current can be read directly on these

charging units.

♦ Observe ⇒ operating instructions for battery charger -VAS

5900- .

3.2.1

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a ksw Description of battery ycharger -VAS Vol db e s 5900i or h ut

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The battery charger -VAS 5900-ssisa suitable for batteries supplied by Volkswagen.

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1 - Display

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Battery charger -VAS 5900-

2 - Adjustment button „Up“ ↑ 3 - Adjustment button „Down“ ↓ 4 - START / STOP

3.2.2

Charging battery with battery charger VAS 5900WARNING

Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 !

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

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5 - INFO

Danger of explosion when checking and charging or slave/ jump starting These batteries must be renewed. Special tools and workshop equipment required ♦ Battery charger -VAS 5900-

3. Charging battery

31

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 Note

The battery must have a temperature of at least 10 °C. – Switch off ignition and all electrical consumers. – Connect charger plug to battery charger. The last selected type of battery will appear on display. – Set battery to respective operating mode with INFO . In the display the symbol -1- for „standard charge for wet batter‐ ies“ or symbol -2- for „standard charge for gel/absorbent glass mat batteries“ will appear. – Set battery capacity (Ah) of battery for charging using respec‐ tive button „Up“ ↑ or „Down“ ↓ . – Connect red terminal clamp „+“ to positive terminal on battery. Note

In vehicles with start/stop function and battery monitor control unit -J367- fitted, black terminal clamp must be connected to body earth. Connecting it to battery negative terminal will cause start/ stop system to malfunction. – Connect black terminal clamp „-“ to negative terminal. The charger unit recognises the voltage required for the connec‐ ted battery (6 V, 12 V or 24 V) and initiates the charging sequence.

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

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32

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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.

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 At a charge condition of 100 % all bars appear in display. Note

♦

AG. Volkswagen AG d agen oes ksw not l o V charge“ the parallel use of con‐ In the battery type „standard gu by d e sumers while charging is possible. The charging period will bearante is r o eo h t longer. ra au c s s

about 1-7 hours, depending on type of battery. To achieve a 100 % charge the battery should remain connected for this period.

1-

Displayed battery voltage is not as per nominal voltage:

– Press respective button „Up“ ↑ or „Down“ ↓ until charging sequence starts. 2-

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

– Press START / STOP twice. – Press respective button „Up“ ↑ or „Down“ ↓ until charging sequence starts again. 3-

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

Display remains unchanged.

– Press START / STOP .

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Ending battery charging sequence:

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

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Possible faults and fault rectification

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♦ The battery charger will switch to maintenance mode after

AG.

– Disconnect black terminal clamp „-“ of charger from negative terminal. – Disconnect red terminal clamp „+“ of charger from positive terminal on battery. – Pull charger plug out of battery charger.

3.2.3

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

Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 !

Caution

The operating mode „service charge“ is not permitted on VW vehicles as the voltage peaks will damage the onboard elec‐ tronics. If there is a requirement to use „service charge“ the battery must be disconnected from the onboard supply.

3. Charging battery

33

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 WARNING

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle! Danger of explosion when checking and charging or slave/ jump starting These batteries must be renewed.

Caution

When charging always set the battery charger to the correct type of battery ⇒ operating instructions for battery charger VAS 5900- ! The „service mode“ is suitable for: ♦ Wet batteries where the magic eye allows charging (magic eye black or green) The operating mode „service charge (SERV)“ is only used on sulphated batteries. The battery is charged at a voltage of > 14.4 V. This can result in a partial reduction of the sulphated layer. After charging, always check the colour of the magic eye before using the battery ⇒ page 6 .

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wag Special tools and workshop equipment required olks

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Note

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♦ Battery charger -VAS 5900-

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

– Connect charger plug to battery charger. The last selected operating mode will appear on display ⇒ page 31 .

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

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34

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– Switch off ignition and all electrical consumers.

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 – Set battery to respective battery type with INFO . In the display, the symbol -1- for „Service charge for wet batteries“ or symbol -2- for „Service charge for gel/absorbent glass mat bat‐ teries“ will appear. – Set battery capacity (Ah) of battery for charging using respec‐ tive button „Up“ ↑ or „Down“ ↓ . – Connect red terminal clamp „+“ to positive terminal on battery. Note

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

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

The success of the „service charge“ depends on the severity of the sulphation of the battery Possible faults and fault rectification: Displayed battery voltage is not as per nominal voltage:

– Press respective button „Up“ ↑ or „Down“ ↓ until charging sequence starts. ht rig py Co t.

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

– Press START / STOP twice.

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1-

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

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– Press respective button „Up“ ↑ or „Down“ ↓ until charging sequence starts. 3-

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

Display remains unchanged. The operating mode and ampere hours (Ah) as set are displayed. Ending battery charging sequence: – Press START / STOP . – Disconnect black terminal clamp „-“ of charger from negative terminal. – Disconnect red terminal clamp „+“ of charger from positive terminal on battery. – Pull charger plug out of battery charger.

3. Charging battery

35

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010

3.2.4

Charging totally discharged batteries with battery charger -VAS 5900WARNING

Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 !

WARNING

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

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Caution

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These batteries must be renewed.

♦ 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. ♦ When charging always set the battery charger to the cor‐ rect type of battery ⇒ operating instructions for battery charger -VAS 5900- ! ♦ Totally discharged battery is not recognised by battery charger ⇒ page 59 . ♦ Do not press START / STOP button when charger unit cables are connected incorrectly. The charger unit may be damaged.

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36

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♦ Battery charger -VAS 5900-

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Batteries with a voltage of less than 2 volts will not be recognised automatically by battery charger -VAS 5900- .

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 Note ♦ Observe notes in chapter ⇒ page 59 . ♦ Totally discharged batteries in vehicles before registration

must be exchanged prior to delivery. Preliminary damage can‐ not be excluded.

♦ The battery must have a temperature of at least 10 °C. – Switch off ignition and all electrical consumers.

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– Connect charger plug to battery charger. The last selected operating mode will appear on display ⇒ page 31 .

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3. Charging battery

37

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Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 – Set battery to respective battery type with INFO . In the display, the symbol -1- for „Service charge for wet batteries“ or symbol -2- for „Service charge for gel/absorbent glass mat bat‐ teries“ will appear. – Set battery capacity (Ah) of battery for charging using respec‐ tive button „Up“ ↑ or „Down“ ↓ . – Connect red terminal clamp „+“ to positive terminal on battery. Note

In vehicles with start/stop function and battery monitor control unit -J367- fitted, black terminal clamp must be connected to body earth. Connecting it to battery negative terminal will cause start/ stop system to malfunction. – Connect black terminal clamp „-“ to negative terminal. – Press START / STOP for approx. 5 seconds. The menu „charging totally discharged batteries/support mode“ will be activated. – Press respective button „Up“ ↑ or „Down“ ↓ to set respective battery voltage (6 V, 12 V or 24 V). Note

If a button is not pressed within 5 seconds the charger will return to the main menu (select operating mode). – Confirm the selected battery voltage with STARTen / . agen AG . Volksw AGSTOP does ag ksw not l o V terminal polarity gu y Then follows the enquiry for "is charger cable b ara d nte ise correct". r o e h ut

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– Confirm polarity of charger unit cables with START / STOP .

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Charger will start charging sequence for totally discharged bat‐ tery. Ending battery charging sequence: – Press START / STOP .

– Disconnect black terminal clamp „-“ of charger from negative terminal. – Disconnect red terminal clamp „+“ of charger from positive terminal on battery. – Pull charger plug out of battery charger.

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

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

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38

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

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The support mode is suitable in the following situations:

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For further information, refer to the ⇒ operating manual VAS 5900 .

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3.2.5

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 ♦ Support mode of onboard supplies without installed battery ♦ Power conservation when renewing the battery ♦ Ancillaries test without battery WARNING

Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 !

WARNING

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

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– Switch off ignition and all electrical consumers.

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Caution

♦ The terminal polarity protection in operating mode „charg‐ ing totally discharged batteries/support mode“ is not ac‐ tive. Connect battery charger terminal clamps correctly to battery terminals. ♦ It can cause sparks through a short-circuit. ♦ Danger of explosion

♦ Ensure charger terminal clamps are seated securely. ♦ Do not press START / STOP button when charger unit cables are connected incorrectly. The charger unit may be damaged. – Remove battery.

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– Connect charger plug to battery charger. The last selected operating mode will appear on display ⇒ page 31 .

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When battery is removed, ensure there is no contact between terminal clamp connected to positive clamp and body earth. Also ensure there is no contact between battery clamps. – Connect red terminal clamp „+“ to positive terminal of vehicle. Note

In vehicles with start/stop function and battery monitor control unit -J367- fitted, black terminal clamp must be connected to body earth. Connecting it to battery negative terminal will cause start/ stop system to malfunction.

3. Charging battery

39

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 – Connect black terminal clamp „+“ to negative terminal of ve‐ hicle. – Press START / STOP for approx. 5 seconds. The menu „charging totally discharged batteries/support mode“ will be activated. – Press respective button „Up“ ↑ or „Down“ ↓ to set respective battery voltage (6 V, 12 V or 24 V). Note

If a button is not pressed within 5 seconds the charger will return to the main menu (select operating mode). – Confirm the selected battery voltage with START / STOP . Then follows the enquiry for "is charger cable terminal polarity correct". – Check polarity of charger unit cables. – Confirm polarity of charger unit cables with START / STOP . The battery charger starts with support mode. End battery support mode: – Press START / STOP . – Disconnect black terminal clamp „-“ of charger unit from neg‐ ative terminal of vehicle. – Disconnect red terminal clamp „+“ of charger unit from positive terminal of vehicle. – Pull charger plug out of battery charger. G. Volkswagen A agen ksw l o yV db ise r tho au s s

Charging battery in maintenance mode with battery charger -VAS 5900ility ab y li an pt ce

Note

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

an electrical consumer draws current from the battery, the battery charger -VAS 5900- automatically compensates the charge.

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

riod.

♦ The battery is always ready for use. ♦ Observe battery manufacture's maintenance instructions! WARNING

Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 !

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40

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3.2.6

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Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 WARNING

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle! Danger of explosion when checking and charging or slave/ jump starting These batteries must be renewed. When the battery is fully charged the battery charger -VAS 5900switches to maintenance mode.

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– Proceed as for charging battery ⇒ page 31 .

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3.3

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

At a charge condition of 100 % all bars

Battery charger -VAS 5903WARNING

Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 !

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

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WARNING

These batteries must be renewed. This chapter describes the basic functions of the battery charger -VAS 5903- . For additional information refer to ⇒ operating in‐ structions for battery charger -VAS 5903- . Note

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

3. Charging battery

41

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010

3.3.1

Description of battery charger -VAS 5903-

The battery charger -VAS 5903- is suitable for charging all 12V batteries supplied by Volkswagen. Battery charger -VAS 59031 - Display 2 - Adjustment button „Up“ ↑ 3 - Adjustment button „Down“ ↓ 4 - START / STOP 5 - INFO

3.3.2

Charging battery with battery charger VAS 5903WARNING

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WARNING

es, in part or in w l purpos hole ercia , is n m ot com

Danger of explosion when checking and charging or slave/ jump starting These batteries must be renewed.

Special tools and workshop equipment required

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Note

The battery must have a temperature of at least 10 °C. – Switch off ignition and all electrical consumers. – Connect charger plug to battery charger. The last selected operating mode will appear on display ⇒ page 42 .

42

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

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♦ Battery charger -VAS 5903-

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

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Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 – Set battery to respective operating mode with INFO . In the display the symbol -1- for „standard charge for wet batter‐ ies“ or symbol -2- for „standard charge for gel/absorbent glass mat batteries“ will appear. – Set battery capacity (Ah) of battery for charging using respec‐ tive button „Up“ ↑ or „Down“ ↓ . – Connect red terminal clamp „+“ to positive terminal on battery. Note

In vehicles with start/stop function and battery monitor control unit -J367- fitted, black terminal clamp must be connected to body earth. Connecting it to battery negative terminal will cause start/ stop system to malfunction. – Connect black terminal clamp „-“ to negative terminal. The charger unit recognises the voltage required for the connec‐ ted battery (6 V, 12 V or 24 V) and initiates the charging sequence. At a charge condition of approx. 80 - 85 % the battery charger switches to the „final charge“ mode. The fourth bar appears in display -1-. The battery is ready for use.

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3. Charging battery

43

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Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 At a charge condition of 100 % all bars appear in display. Note ♦ In the battery type „standard charge“ the parallel use of con‐

sumers while charging is possible. The charging period will be longer.

♦ The battery charger will switch to maintenance mode after

about 1-7 hours, depending on type of battery. To achieve a 100 % charge the battery should remain connected for this period.

Possible faults and fault rectification: 1-

Displayed battery voltage is not as per nominal voltage:

– Press respective button „Up“ ↑ or „Down“ ↓ until charging sequence starts. 2-

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

– Press START / STOP twice. – Press respective button „Up“ ↑ or „Down“ ↓ until charging sequence starts again. 3-

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

Display remains unchanged. The battery type and ampere hours (Ah) as set is

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– Press START / STOP .

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Ending battery charging sequence:

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

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

3.3.3

Charging battery in refresh charge mode with battery charger -VAS 5903WARNING

Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 !

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

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44

AG.

These batteries must be renewed.

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

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

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WARNING

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 . Volkswage Caution

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

Caution

When charging always set the battery charger to the correct type of battery ⇒ operating instructions for battery charger VAS 5903- ! The „refresh charge“ mode is suitable for: ♦ Wet batteries, where distilled water can be replenished. Do not use operating mode „refresh charge“ with maintenancefree wet batteries. r fo ng

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Special tools and workshop equipment required

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

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The operating mode „refresh charge“ is vehicles as the voltage peaks will damage the onboard elec‐ tronics.

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Note

The battery must have a temperature of at least 10 °C. – Switch off ignition and all electrical consumers. – Connect charger plug to battery charger. The last selected operating mode will appear on display ⇒ page 42 .

3. Charging battery

45

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 – Set battery to respective operating mode with INFO . In the display the symbol -1- for „refresh charge for wet batteries“ or symbol -2- for „refresh charge for gel/absorbent glass mat bat‐ teries“ will appear. – Set battery capacity (Ah) of battery for charging using respec‐ tive button „Up“ ↑ or „Down“ ↓ . – Connect red terminal clamp „+“ to positive terminal on battery. Note

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– 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 % of the battery voltage, the battery charger switches to the „final charge“ mode. The fourth bar appears in display -1-. The battery is ready for use. Note

Displayed battery voltage is not as per nominal voltage:

– Press respective button „Up“ ↑ or „Down“ ↓ until charging sequence starts.

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

– Press START / STOP twice. – Press respective button „Up“ ↑ or „Down“ ↓ until charging sequence starts. 3-

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

Display remains unchanged. The operating mode and ampere hours (Ah) as set are displayed. Ending battery charging sequence: – Press START / STOP . – Disconnect black terminal clamp „-“ of charger from negative terminal. – Disconnect red terminal clamp „+“ of charger from positive terminal on battery. – Pull charger plug out of battery charger.

46

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

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Possible faults and fault rectification:

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

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urposes, in part or in wh ole, cial p is n mer m ot p o c erm or e t a itte v i r d p

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In vehicles with start/stop function and battery monitor control unit -J367- fitted, black terminal clamp must be connected to body earth. Connecting it to battery negative terminal will cause start/ stop system to malfunction.

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010

3.3.4

Charging totally discharged battery with battery charger -VAS 5903WARNING

Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 !

WARNING

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle! Volkswagen AG does not gu ara nte eo ra c

G. en A Danger of explosion when checking and charging slave/ agor ksw l o V jump starting by

♦ 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. ♦ When charging always set the battery charger to the cor‐ rect type of battery ⇒ operating instructions for battery charger -VAS 5903- ! ♦ Totally discharged battery is not recognised by battery charger ⇒ page 59 . ♦ Do not press START / STOP button when charger unit cables are connected incorrectly. The charger unit may be damaged.

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♦ Battery charger -VAS 5903-

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

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Caution

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These batteries must be renewed.

3. Charging battery

47

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 Note ♦ Observe notes in chapter ⇒ page 59 . ♦ Totally discharged batteries in vehicles before registration

must be exchanged prior to delivery. Preliminary damage can‐ not be excluded.

♦ The battery must have a temperature of at least 10 °C. – Switch off ignition and all electrical consumers. olkswagen AG en AG. V ag lksw

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o – Connect charger plug to battery charger. The last selected yV db e operating mode will appear onris display ⇒ page 42 .

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 – Set battery to respective operating mode with INFO . In the display, the symbol -1- for „Service charge for wet batteries“ or symbol -2- for „Service charge for gel/absorbent glass mat bat‐ teries“ will appear. – Set battery capacity (Ah) of battery for charging using respec‐ tive button „Up“ ↑ or „Down“ ↓ . – Connect red terminal clamp „+“ to positive terminal on battery. Note

In vehicles with start/stop function and battery monitor control unit -J367- fitted, black terminal clamp must be connected to body earth. Connecting it to battery negative terminal will cause start/ stop system to malfunction. – Connect black terminal clamp „-“ to negative terminal. – Press START / STOP for approx. 5 seconds. The menu „charging totally discharged batteries/support mode“ will be activated. – Press respective button „Up“ ↑ or „Down“ ↓ to set respective n AG. Volkswagen AG do es n wage s k l ot g battery voltage (6 V, 12 V or 24 V). o yV

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

rrectness of i t to the co nform spec a t i h re o n in wit thi s

– Confirm the selected battery voltage with START / STOP . Then follows the enquiry for "is charger cable terminal polarity correct". – Check polarity of charger unit cables. – Confirm polarity of charger unit cables with START / STOP . Charger will start charging sequence for totally discharged bat‐ tery. Ending battery charging sequence: – Press START / STOP .

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

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– Pull charger plug out of battery charger.

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

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

General notes: The support mode provides the onboard supply with power when the battery is removed or disconnected. For further information, refer to the ⇒ operating manual VAS 5903 . The support mode is suitable in the following situations:

3. Charging battery

49

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 ♦ Support mode of onboard supplies without installed battery ♦ Power conservation when renewing the battery ♦ Ancillaries test without battery WARNING

Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 !

WARNING

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

G es n wage and charging ordoslave/ Danger of explosion when checking ot g olks V y ua jump starting b d ra e ris

nte eo ra c

o These batteries mustuthbe renewed.

– Switch off ignition and all electrical consumers.

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Caution

♦ The terminal polarity protection in operating mode „charg‐ ing totally discharged batteries/support mode“ is not ac‐ tive. Connect battery charger terminal clamps correctly to battery terminals. ♦ It can cause sparks through a short-circuit. ♦ Danger of explosion ♦ Ensure charger terminal clamps are seated securely. ♦ Do not press START / STOP button when charger unit cables are connected incorrectly. The charger unit may be damaged. – Remove battery.

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Caution

When battery is removed, ensure there is no contact between terminal clamp connected to positive clamp and body earth. Also ensure there is no contact between battery clamps. – Connect red terminal clamp „+“ to positive terminal of vehicle. Note

In vehicles with start/stop function and battery monitor control unit -J367- fitted, black terminal clamp must be connected to body earth. Connecting it to battery negative terminal will cause start/ stop system to malfunction.

50

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

ht rig py Co t.

– Connect charger plug to battery charger. The last selected operating mode will appear on display ⇒ page 31 .

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es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

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a ss

– Press START / STOP for approx. 5 seconds. The menu „charging totally discharged batteries/support mode“ will be activated. – Press respective button „Up“ ↑ or „Down“ ↓ to set respective battery voltage (6 V, 12 V or 24 V). Note

If a button is not pressed within 5 seconds the charger will return to the main menu (select operating mode). – Confirm the selected battery voltage with START / STOP . Then follows the enquiry for "is charger cable terminal polarity correct". – Check polarity of charger unit cables. Prote cted by c o p yri gh t. C op yi

The battery charger starts with support mode.

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– Press START / STOP .

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End battery support mode:

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– Confirm polarity of charger unit cables with START / STOP .

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

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– Disconnect black terminal clamp „-“ of charger unit from neg‐ ative terminal of vehicle. – Disconnect red terminal clamp „+“ of charger unit from positive terminal of vehicle. – Pull charger plug out of battery charger.

3.3.6

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

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

an electrical consumer draws current from the battery, the battery charger -VAS 5903- automatically compensates the charge.

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

riod.

♦ The battery is always ready for use. ♦ Observe battery manufacture's maintenance instructions! WARNING

Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 !

3. Charging battery

51

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 WARNING

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle! Danger of explosion when checking and charging or slave/ jump starting These batteries must be renewed. When the battery is fully charged the battery charger -VAS 5903switches to maintenance mode. – Proceed as for charging battery ⇒ page 42 . At a charge condition of 100 % all bars appear in display.

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Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010

3.4

Battery charger -VAS 5906-

3.4.1

General description

Battery charger - VAS 5906WARNING

Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 ! olksw

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

These batteries must be renewed.

Battery charger -VAS 5906- has been specially developed for charging in vehicle onboard supply during vehicle presentation. It has an automatic charging characteristic for starter batteries, 3 - 300 AH. The maximum charging voltage 14.4 V is not exceeded. All elec‐ trical loads are supported by up to 30 A by the trickle charging. For sustained operation, battery charger -VAS 5906- changes to trickle charging once battery is fully charged. Tester starts fully automatically and does not require any settings. All that is required is to connect crocodile clips and mains cable. For further information, refer to the ⇒ operating manual VAS 5906 .

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Charging battery with battery charger VAS 5906AG.

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

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WARNING

Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 !

WARNING

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle! Danger of explosion when checking and charging or slave/ jump starting These batteries must be renewed.

3. Charging battery

53

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 Overview of operating panel: 1-

Charge condition display 25 %.

2-

Charge condition display 50 %.

3-

Charge condition display 75 %.

4-

Charge condition display 100 %.

5-

Display ready

6-

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

7-

Malfunction display.

– Place charger in engine compartment or under vehicle. – Connect mains cable to charger and plug it into mains. Charger is in no-load operation - ready light is on. WARNING

Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 ! – Switch off ignition. – Connect red charging cable to positive terminal „+“ on battery. Note

In vehicles with start/stop function and battery monitor control unit -J367- fitted, black terminal clamp must be connected to body AG. Volkswagen AG d earth. Connecting it to battery negative terminal willswcause agen start/ oes k not l stop system to malfunction. Vo gu by

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– Connect black charging cable to tery.

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Charging starts after about 2 seconds.

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Number of LEDs lit indicates charge condition of battery. Battery has been charged up once all lights are lit. When battery is fully charged, battery charger -VAS 5906- auto‐ matically switches over to trickle charging. Caution

Danger of sparking if charging terminals are removed too soon. Terminate charging by pressing start/stop button. – Press start/stop button to terminate charging. – Disconnect black charging cable from negative terminal „-“ on battery.

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

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010

3.5

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

Warning and safety regulations ⇒ page 2 General description ⇒ page 55 AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d e with Midtronics -INC 940battery tester nte is r o eo h ut ra a c s s

Charge battery ⇒ page 56 . Dealing with problems ⇒ page 58

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Batteries in VW vehicles are only allowed to be charged with bat‐ tery chargers approved by VW. In the USA/Canada, it is permitted for the Midtronics -INC 940- battery charger to be used. Midtronics -INC 940- battery charger combines battery charging with a charge condition checks and a battery test. The following charging and analysis procedures apply to all bat‐ teries, all battery installation locations (engine compartment or luggage compartment) and battery application purposes (starter battery or second/convenience battery). Always comply with the safety regulations, the regulations for setting up the battery charger, the display menu/display buttons, LEDs and the operating procedures described in the ⇒ operating manual INC 940 . Read through ⇒ operating manual INC 940 carefully. Refer to ⇒ Self-study programme No. ; Vehicle batteries for more information.

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General description of Midtronics -INC 940- battery tester

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3.5.1

Danger of injury! Observe warning notices and safety regula‐ 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

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle! Danger of explosion when checking and charging or slave/ jump starting These batteries must be renewed.

3. Charging battery

55

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010

3.5.2

Charging battery

Prerequisites: WARNING

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle! Danger of explosion when checking and charging or slave/ jump starting These batteries must be renewed. INC 940 initial setup performed (dealership number, date/time) ⇒ operating manual INC 940 . – Check general information ⇒ page 55 . – Open bonnet or cover for other installation location of battery.

n AG. Volkswagen AG do es n ot g V ua by d an e Determine whetherrisbattery type is „Standard“ (wet battery) ror tee tho glass mat battery). or „AGM“ (absorbent u ac a ss

wage⇒ page 6 . – Perform visual check of battery olks

–

Note

♦ For additional information, refer to the ⇒ operating manual

INC 940 .

Perform charging procedure: – Switch off all electrical consumers. – Switch off ignition and remove ignition key. – Connect red terminal clamp „+“ of charger unit to positive ter‐ minal on battery. Note

In vehicles with start/stop function and battery monitor control unit -J367- fitted, black terminal clamp must be connected to body earth. Connecting it to battery negative terminal will cause start/ stop system to malfunction.

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

– 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).

56

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

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♦ Battery temperature must be at least 10 °C.

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– Close all vehicle doors.

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 – Select test type „Warranty“ or „Miscellaneous“. Note additional details (depending on type of test). Note ♦ For additional information, refer to the ⇒ operating manual

INC 940 .

♦ If necessary, make a note of menu items required for „War‐

ranty“ test type ⇒ Warranty service circular .

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

Measures:

Battery OK

Battery can be returned to op‐ eration. ♦ Test found low charge level.

Charging required

♦ Charging starts and approx‐ imate charging duration is displayed. ♦ Achieved cold-start per‐ formance and remaining charging time are displayed, and are updated regularly. Battery defective. Charging Re‐

gen AG AG. Volkswa procedure does is interrupted. agen ksw not l new battery. o V gu y ara db e nte is r o eo h ut ra a c s s Note

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Renew battery.

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WARNING

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

When charging and testing procedure has finished, Midtronics INC 940- battery charger displays „Battery good“ or „Renew battery“ and total charging time.

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

♦ Print last test result (for warranty). Prote cted by c o p yri gh t. C op yi

♦ Display last test results. agen lksw Vo by

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♦ Generate test code (only possible after automatic charging and test). ht rig py Co t.

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In case Midtronics -INC 940- shows fault messages or text dis‐ plays other than those listed above, please refer to ⇒ page 58 .

For additional information, refer to the ⇒ operating manual INC 940 .

3. Charging battery

57

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010

3.5.3

Dealing with problems with Midtronics INC 940- battery tester

Under certain circumstances, the display may show errors or messages according to status. The most frequent display messages are listed below, together with suggested solutions. Note

For messages not listed here, please refer to ⇒ operating manual INC 940 . Display message

Measures

Check connection.

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

Terminals connected?

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System noise

– Check battery terminals are tightened according to reg‐ ulations and do not have corrosion. Safety function of tester. n AG. Volkswagen AG do – Connect terminals es n wage to battery s k l ot g o before starting charging pro‐ yV ua b d ran cedure. ir se tee o h t or – s Switch off all electrical con‐ ac au s sumers.

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– Wait until all electrical loads monitored by onboard sup‐ ply control unit have switch‐ ed off. – Remove ignition key. – Disconnect any suspect electrical equipment not connected to onboard sup‐ ply as standard.

Wait a few minutes and repeat charging procedure ⇒ page 56 .

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Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 . Volkswage

Solar panel -VAS 6102A-

3.6.1

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

Solar panel VAS 6102A

Solar panel -VAS 6102A- supports onboard supply and prevents spontaneous battery discharging. 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 rechargeable lead or lead gel batteries. Solar panel -VAS 6102A- is connected to diagnostic connection in vehicle. A green LED is integrated in the frame to indicate its function. The brighter the LED, the higher the charging current. Integrated electronics prevent battery overcharging.

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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.

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– Place underside on dash panel -2-.

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

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– Pull attachment string tight so that solar panel -VAS 6102A- is positioned close to windscreen. – Connect solar panel -VAS 6102A- to diagnostic connection of vehicle. Connection procedure is as for vehicle diagnostic tester ⇒ page 78 – Check function of solar panel -VAS 6102A- . Green LED indi‐ cates function of solar panel -VAS 6102A- .

3.7

Totally discharged batteries WARNING

Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 ! A battery is designated „totally discharged“ when the no-load volt‐ age is less than 11.6 V.

3. Charging battery

59

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 WARNING

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle! Danger of explosion when checking and charging or slave/ jump starting These batteries must be renewed.

Caution

♦ Totally discharged batteries freeze prematurely. ♦ Frozen batteries should no longer be used.

Note

♦

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♦ Batteries that have not been used for a long period of time pe rm itte d

discharge themselves, e.g. those fitted in stored vehicles.

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♦ In totally discharged batteries, the electrolyte is comprised al‐ es, in part or in w l purpos hole ercia , is n m ot com

♦ Totally discharged batteries sulphate, that means, the entire

plate surfaces of the battery harden.

♦ If a battery is recharged shortly after it has totally lost its

charge, the sulphation will mostly dissipate.

♦ If these batteries are not recharged, the plates continue to

harden and the ability to recharge is reduced. The result of which is a reduction in the battery output.

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– Check battery no-load voltage ⇒ page 25 .

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

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010

4

Cruise control system (CCS)

General description: The functions of the cruise control system are controlled by the engine control unit. – The cruise control system can be activated/deactivated ⇒ page 61 . Fault detection and fault display

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

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– Connect vehicle diagnostic tester ⇒ page 78 . – Select „Guided fault finding“ mode in vehicle diagnostic tester . – Using „GoTo“ button, select „Functions/component“ and the following menu options in succession: ♦ Drive ♦ Engine code

♦ 01 - On Board Diagnostic capable systems

♦ Functions

♦ Activating and deactivating cruise control system (CCS)

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

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4. Cruise control system (CCS)

61

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Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010

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Gauges, instruments

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Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010

92 –

Windscreen wash/wipe system

1

Washer fluid line hose couplings

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

1.1

Windscreen and rear window washer system

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

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

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– To loosen the connection, rotate the lock ring -1- through 90° -arrow- and pull off the hose connection.

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

– To loosen the connection, pull up the lock ring -1- by approx. 1 mm -arrow- and pull off the hose connection. r te o iva r rp fo g n

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

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

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1. Washer fluid line hose couplings

63

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Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 – To loosen the connection, pull up the lock ring -1- -arrow- and pull off the hose connection. – To secure connection, attach hose connection and press in clip -1- until it engages.

1.2

Headlight washer system

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

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Rep. gr.92 - Windscreen wash/wipe system

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w olks and hold the lock ring s not g – To secure the connection, push yV ua bhose d ran -arrow- and push on ithe connection. Check that the se‐ se tee r o curing clip has correctly engaged by depressing and trying to h or ut ac a pull off without the clip. ss

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010

2

Hose repair

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

2.1

General description

♦ The replacement parts can be found in the electronic parts catalogue (ETKA). ♦ Replacement parts are available for repair of both smooth and corrugated pipes.

2.2

Repairing smooth pipe

Smooth pipe with a diameter or 5x1 mm or 6x1 mm can be re‐ paired with EPDM hose. – Cut damaged section at right angles out of smooth pipe which is to be repaired. – Select the appropriate EPDM hose -2- and cable ties accord‐ ing to the electronic parts catalogue (ETKA). – Cut EPDM hose -2- so that ends -1- and -3- of smooth pipe can each be pushed about 10 mm into the EPDM hose -2-. – Secure the repair joints with cable ties -1-.

Repairing corrugated pipe

Special tools and workshop equipment required ♦ Hot air blower -VAS 5179- or

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♦ Hot air blower -VAS 1978/14-

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2.3

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2. Hose repair

65

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 Note ♦ Repair points must not be subjected to pulling or bending

forces.

♦ If the damaged section is longer than 20 mm, a new piece of

corrugated pipe must be used and the procedure described below must be performed twice.

– Cut damaged section at right angles out of corrugated pipe which is to be repaired. – Select suitable end pieces -2- and -3- and correct sized shrinkfit piping from the electronic parts catalogue (ETKA). – Heat end of corrugated pipe -1-. – Push connector -2- into corrugated pipe -2- -arrow A-. – Heat end of corrugated pipe -4-. – Push connector -3- into corrugated pipe -4- -arrow B-.

– Cut heat-shrink hose so that ends of corrugated pipe are each covered by about 20 mm -dimension x- of heat-shrink hose. – Push heat-shrink hose over corrugated pipe, join connectors and secure repair joints with heat-shrink hose.

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Rep. gr.92 - Windscreen wash/wipe system

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Distinguishing features from Bosch and Federal Mogul.

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Distinguishing features of jointless wiper blades

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When renewing wiper rubbers, note the make. When renewing wiper blades, the same make must be used.

Wiper blades can be identified according to wiper arm fastening.

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Federal Mogul wiper blades -1-:

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Bosch wiper blades -1 and 2-:

3. Distinguishing features of jointless wiper blades

67

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Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010

94 –

G do age es n ksw Lights, bulbs, switches exterior ot g Vol y ua b

1

Operation and safety notes for gas ss discharge bulbs

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– If repairs are to be made to the headlight with gas discharge bulbs, observe the following: ♦ Notes on dangerous high voltage/currents ⇒ page 68 ♦ Notes on pressure, temperature, radiation/arcs ⇒ page 69 ♦ Assembly notes for gas discharge bulbs ⇒ page 70 ♦ Disposal regulations for gas discharge bulbs ⇒ page 70 Special tools and workshop equipment required ♦ Gloves

It is absolutely necessary to disconnect the battery earth strap before working on parts of the gas discharge headlights marked with yellow high voltage symbols.

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.

The gas discharge lamp control unit must never be operated without a gas discharge lamp.

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Then switch dipped beam on and off again. This will eliminate any possible residual voltage.

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WARNING

Switch off ignition and all electrical consumers and re‐ move ignition key.

•

When working on headlight system, ensure that there is 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 beams on and then off again after withdrawing the ignition key.

•

When working on the headlight system, ensure that the lights cannot be switched on.

Notes on pressure, temperature, radiation/arcs WARNING ht rig py Co t.

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•

The bulbs may be operated in the headlight housing only (protection against contact due to very hot bulbs, absorp‐ tion of UV radiation, avoidance of dazzling light, protection against explosion).

•

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.

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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

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 Repair notes for gas discharge bulbs Caution

♦ Before exchanging a bulb, always switch off the affected . Volkswagen AG consumers. gen AG d a lksw

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♦ A light bulb must always be renewed with a bulb of the same sort. The designation appears on the base of the bulb or on the bulb glass. ♦ Properly engage connectors during installation and en‐ sure tight seating of the connection. Disposal regulations for gas discharge bulbs WARNING

•

Gas discharge bulbs contain metallic mercury (Hg) and traces of thallium; never destroy these bulbs.

•

These components must be recycled in accordance with national law.

•

Dispose of only in containers intended for this purpose at an authorised collection point. AG.

Rep. gr.94 - Lights, bulbs, switches - exterior

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sa ♦ Do not touch the bulb sglass with bare fingers; use clean cloth gloves. When the light bulb is switched on, the heat would vaporise the oil of the finger prints which would then settle on the reflector, impairing the brightness of the headlight.

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Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010

96 –

Lights, bulbs, switches - interior

1

12 V socket

1.1

Removing and installing 12 V socket Caution

If excessive force is exerted on sockets without illumination, the retaining sleeve may be damaged. Only illuminated sockets (cigarette lighter) can be removed with the puller T 40148. The puller does not manage to release the locking lugs of sockets without illuminated retaining sleeve. Usually sockets without illumination cannot be removed with‐ out being damaged. Volkswa-U1gen AG AG.lighter Refer to removing and installing cigarette does agen ksw not l o ⇒ page 72 . gu yV

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The removal of the socket illumination bulb -L42- is performed in the same way as the removal of the cigarette lighter illumination bulb -L28- ⇒ page 76 .

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1.2

1. 12 V socket

71

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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 Caution

Only illuminated sockets (cigarette lighter) can be removed with the puller T 40148.

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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.

2.1

General description 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.

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Usually sockets without illumination cannot be removed with‐ out being damaged. AG.

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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

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The puller does not manage to release the locking lugs of sockets without illuminated retaining sleeve.

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If excessive force is the retaining sleeve may be damaged.

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Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010

2.2

Assembly overview Caution

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1 - Cigarette lighter socket with wiring tail 2 - Cigarette lighter 3 - Socket 4 - Cigarette lighter socket 5 - Retaining sleeve 6 - Light bulb W 5 12 V 1.2 watt

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Usually sockets without illumination cannot be removed with‐ out being damaged.

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The puller does not manage to release the locking lugs of sockets without illuminated retaining sleeve.

2. Cigarette lighter U1

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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

If excessive force is exerted on sockets without illumination, the retaining sleeve may be damaged. Only illuminated sockets (cigarette lighter) can be removed with the puller T 40148. The puller does not manage to release the locking lugs of sockets without illuminated retaining sleeve. Usually sockets without illumination cannot be removed with‐ out being damaged. Special tools and workshop equipment required ♦ Puller -T 40148-

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– Remove cigarette lighter, dummy cigarette lighter etc. from socket if necessary.

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Note

For reasons of clarity, the socket is removed in the illustration. Caution

The socket or the retaining sleeve can be damaged. Ensure that the puller is seated correctly, otherwise the retain‐ ing lugs of the retaining sleeve will not be released.

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

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Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010

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– Pull grip -3- in direction of -arrow- to release locking lugs of retaining sleeve. – Pull socket out of retaining sleeve using puller. Caution

The socket wiring can be damaged. Take care not to stretch the wiring when pulling out the socket.

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When using the thrust piece, ensure that no surrounding com‐ ponents are damaged.

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Caution

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Depending on the fitting location, it is recommended to use the thrust piece 40148/1 -2- with the knurled nut -1-.

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– Push puller -arrow- into socket so that locking lugs -1- engage in recesses -2-.

– Pull off socket connector. Note

Depending on the space requirement, the vehicles are equipped with various electric sockets and cigarette lighter sockets. They differ in length and have different electrical connections. In the case of electric sockets or cigarette lighter sockets with a wiring tail, it may be necessary to perform additional work in order to gain access to the connector.

2. Cigarette lighter U1

75

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 – Release puller locking lugs by pressing spindle -1- in direction of -arrow B-. Then release puller -2- by turning it briefly to left -arrow A-. Remove puller from socket. Note

Ensure that the puller locking lugs are not spread. Caution

The cigarette lighter might be ejected out of the socket after the heating phase. When the puller is mounted, the socket retaining pressed apart and the retaining force is reduced.

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After removing the socket, carefully press the retaining springs together and check if the cigarette lighter remains in the re‐ moval position after the heating phase. – Carefully press socket retaining springs together -arrows-.

– Check if cigarette lighter remains in removal position after heating phase and ensure it is not ejected in vehicle interior. Install in reverse order of removal.

Removing and installing cigarette lighter illumination bulb -L28-

♦ 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

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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.

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♦ On some vehicles, the illumination is not provided by a light

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Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 – Press retaining lugs -arrows- and remove retaining sleeve to‐ gether with bulb carrier. – Unclip bulb carrier from retaining sleeve.

– Separate bulb carrier in areas -A- and -B-. – Open part -B- of bulb carrier.

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Installation is carried out in reverse order of removal.

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– Remove light bulb in direction of -arrow-.

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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

♦ All the operations described, e.g. adaptation, coding, etc. can

be performed using the vehicle diagnostic tester . „guided functions“ modes.

♦ Additional information ⇒ Self-study programme No. 202 ; Vehicle diagnostic, testing and information system VAS 5051 ⇒ Self-study programme No. 256 ; VAS 5052 ⇒ Self-study programme No. 294 ; Online connection of VAS 5051 – Connecting vehicle diagnostic tester ⇒ page 78

1.1

Connecting vehicle diagnostic tester

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Observe the latest operating instructions for vehicle diagnostic tester , which are displayed after selecting the „Administration“ and „Operating Manual“ keys. agen lksw Vo by

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Special tools and workshop equipment required

78

Rep. gr.97 - Wiring

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

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Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 ♦ Vehicle diagnostic tester

♦ Diagnostic cable -VAS 5051/6A- (5 m)

♦ Diagnostic cable -VASAG 5051/5A. Volkswage(3 n Am) agen ksw Vol y b ed ris Note o h t au ss

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Connecting vehicle diagnostic tester : – Apply handbrake.

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Only these cables are to be used for diagnosis, as they are the only ones fitted with CAN wiring and therefore allowing CAN di‐ agnosis and/or CAN communication.

– Vehicles with automatic gearbox, move selector lever to posi‐ tion „P“ or „N“. – Vehicles with manual gearbox, move gearstick to neutral po‐ sition.

– With ignition switched off, connect vehicle diagnostic tester using diagnostic cable -VAS 5051/6A- to diagnostic interface -arrow- in vehicle. – Switch on ignition.

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– Switch off all electrical consumers.

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All other and the following vehicle diagnostic, testing and infor‐ mation systems or vehicle diagnostic and service information systems are connected accordingly in the sequence described above.

1. Vehicle diagnostic, testing and information systems

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Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010

1.2

Connecting vehicle diagnostic tester Golf Model Year 1998 - 2003

– Apply handbrake. – Vehicles with automatic gearbox, move selector lever to posi‐ tion „P“ or „N“. – Vehicles with manual gearbox, move gear lever to neutral po‐ sition. – Pull out trim -1- in direction of arrow. – With ignition switched off, connect vehicle diagnostic tester using diagnostic cable to diagnostic interface -arrow- in vehi‐ cle. – Switch on ignition. – Switch off all electrical consumers. Note

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Rep. gr.97 - Wiring

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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.

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010

2

Repairing wiring harnesses and con‐ nectors

2.1

Wiring harness repair set

2.1.1

Wiring harness repair set -VAS 1978-

Additional information:

⇒ Operating instructions Wiring harness repair set -VAS 1978-

2.1.2

Upgrade kit -VAS 1978/50-

AG.

Wiring harness repair set -VAS 1978A-

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2.1.3

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Upgrade kit -VAS 1978/50- is required to bring the „old“ wiring harness repair set -VAS 1978- up to the latest standard of wiring harness repair set -VAS 1978A- . The upgrade kit comprises of 4 assembly and 10 release tools, a new set of crimping pliers for crimp connectors with head adapter 0.35 - 2.5 mm2 -VAS 1978/1-1- , 4.0 - 6.0 mm2 -VAS 1978/2 A- and head adapter for JPT contacts -VAS 1978/9-1- . Also included are new stickers, a new set of operating instructions, crimp connectors for 0.35 mm2 cable cross-section and a roll of black felt adhesive tape.

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Wiring harness repair set -VAS 1978- allows optimal repair quality . Volkswage to be achieved in the area of vehicle electrics.waUsing gen AGthe tools, n AG doe s no s k l o repairs to connectors and wiring open circuits can be carried out. t gu yV ara d b with contacts already To do this, complete repair wire sections e nte is r o eo crimped on are used and joined to h the vehicle's own wiring har‐ ut ra a ness with the aid of crimp connectors. A special set of pliers with c s s three different crimp recesses and a hot air blower for shrinking the crimp connectors make a perfect electrical connection.

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 agen oes ksw not l o gu y V, Eos 2006 ➤ , Golf 199 ... Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010d b➤ ara e nte s i r Electrical System, General Information - Edition 07.2010 o eo h ut ra a c s s

Release tool set -VAS 1978/35-

Release tool set -VAS 1978/35- serves as a means of releasing various primary and secondary locking devices in Group vehicles. The set comprises of 26 different tools with which, for example, round connector systems, flat contacts with one or two fasteners and also single wire seals can be released or fitted. Allocation of the correct release tool to the respective locking de‐ vices can be gleaned from the table in the ⇒ operating instruc‐ tions of -VAS 1978/35- .

2.2.1

Special pliers with insert

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Tool descriptions

Colour of crimp re‐ Wiring cross section cess

Yellow

Yellow.

Red

Red.

0.5 mm2 - 1.0 mm2

Blue

Blue

1.5 mm2 - 2.5 mm2

Yellow.

Yellow.

4.0 mm2 - 6.0 mm2

0.35 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.

82

Rep. gr.97 - Wiring

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Colour of crimp connector

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The special pliers without insert -VAS 1978/1- with insert for spe‐ cial pliers -VAS 1978/2- is part of the wiring harness repair set VAS 1978- and is used to crimp connectors during wiring harness repairs.

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2.1.4

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010

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 AG. Volkswagen AGmust Some tools are equipped with a tool safety does agen device. This ksw no l o be pushed over the tip of the tool y V after use in order to protect t gua b d ran e the tip and prevent personal injury. te ris

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Assembly tools for single wire seals

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2.2.3

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Releasing and dismantling contact housings ⇒ page 102 .

The assembly tools serve as a means of sliding the single wire seals fully into the contact housing without damage and thereby assure complete sealing between single wire and contact hous‐ ing. Four assembly tools for single wire seals are included in each wiring harness repair set -VAS 1978 B- and previous versions.

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Wire strippers -VAS 1978/3- are included in wiring harness repair set -VAS 1978 B- and previous versions.

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Wire strippers -VAS 1978/3- serve as a means of stripping insu‐ lation off wires and cutting wires in the correct manner.

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Assembling single wire seals ⇒ page 99 .

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The wire strippers have an adjustable limit stop within the pliers jaws, with which the desired length of insulation to be removed can be adjusted. AG.

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.

2. Repairing wiring harnesses and connectors

83

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010

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Hot air blower, 220 V / 50 Hz -VAS 1978/14Caution

When shrink-fitting, take care not to damage any other wiring, plastic parts or insulating material with the hot air blower. Observe the operating instructions of the hot air blower without fail!

Shrink fitting crimp connectors using hot air blower, 220 V / 50 Hz -VAS 1978/14- ⇒ page 94 , or ⇒ page 96 .

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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 1978/9-1In 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.

84

Rep. gr.97 - Wiring

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Hot air blower, 220 V/50 Hz -VAS 1978/14- is included in wiring harness repair set -VAS 1978 B- and previous versions.

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The hot air blower, 220 V / 50 Hz -VAS 1978/14- is used in con‐ junction with shrink element for hot air blower -VAS 1978/15- to shrink fit the crimp connectors. After crimping, the crimp connec‐ tor has to be shrink fitted using the hot air blower in order to prevent any ingress of moisture.

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2.2.5

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– Cut the wire if necessary with the cutting part on the upper side of the wire strippers.

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 – Unclip both locking pins -arrows- from the body of the crimping pliers.

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– Insert the required head adapter from above -arrow- in the body of the crimping pliers.

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– Lock the head adapter by engaging the pins -arrows- in the body of the crimping pliers.

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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.

2. Repairing wiring harnesses and connectors

85

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Rep. gr.97 - Wiring

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Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 ♦ Observe the latest notes in the respective workshop manual when carrying out repairs. ♦ Observe country-specific regulations. ♦ Always disconnect the battery earth strap before working on the electrical system. Disconnecting the battery earth strap (open circuit) provides a safe working environment for repairs to the electrical system. The battery positive wire need only be disconnected for removal of the battery. ♦ Before starting a repair, it is important to identify and rectify the cause of damage (e.g. sharp edges on body panels, de‐ fective electrical components, corrosion, etc.). ♦ For additional information, e.g. removal and installation of in‐ dividual components, please refer to the relevant workshop manual. ♦ Soldering is not permitted for repairs to vehicle wiring. ♦ Wiring harness and connector repairs to vehicle electrical sys‐ tem should be carried out using wiring harness repair set -VAS 1978 B- and previous versions only. Only use yellow wires from wiring harness repair set -VAS 1978 B- . ♦ Wiring harness repairs may not be integrated in the vehicle's own wiring harness and must be marked with the use of yellow adhesive tape. This indicates a previous repair. ♦ Crimp connectors may never be repaired. If necessary, lay wiring parallel to the defective wiring. After crimping, crimp connectors must to be shrink fitted using the hot air blower in gen AG. Volkswagen AG does a order to prevent any ingress of moisture. ksw not Vol y db

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♦ Carry out a function test after every repair. It may be necessary for the fault memory to be interrogated, erased and/or for the systems to be reset. ♦ If possible, do not loosen any earth wires from the body (dan‐ ger of corrosion). ♦ Wiring harness repair set -VAS 1978 B- and previous versions do not cover all wiring cross sections that occur in the vehicle. If the required wiring cross section is not available, the next largest one should be used. ♦ Screened wires must not be repaired. If damaged they must be replaced complete. ♦ Heat resistant wiring can be found in various places in the ve‐ hicle, mainly in the engine compartment. Heat resistant wiring can be identified by its slightly matt and softer insulation. To repair these wires, only heat resistant wiring may be used. r fo ng

Repairs to wiring harnesses

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Observe the general notes on repairs to the vehicle electrical system ⇒ page 85 .

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2.4

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e ♦ It is essential that the supplementary information is isobserved or h t regarding repairs to wiring harnesses in airbag aand belt ten‐ u ss aerial cables sioner systems, fibre optic cables, CAN bus lines, and wiring with cross sections up to 0.35 mm2 ⇒ page 91 .

Notes on repairs to airbag and belt tensioner wiring ⇒ page 88 Notes on repairs to fibre optic cables ⇒ page 89

2. Repairing wiring harnesses and connectors

87

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 Notes on repairs to CAN bus wiring ⇒ page 90 Notes on replacement of aerial cables ⇒ page 90 Notes on repairs to wiring with cross sections up to 0.35 mm2 ⇒ page 91 Notes on repair of wiring open circuit with one repair position ⇒ page 94 olkswagen AG en AG. V ag lksw

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WARNING

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In addition to the general notes on repairs to wiring harnesses, the following instructions must be observed on how to repair wir‐ ing in airbag and belt tensioner systems:

♦ Airbag and seat belt tensioner can fail. ♦ Faulty repairs to the airbag and seat belt tensioning sys‐ tem can cause malfunctions in the passenger protection system. ♦ For repairs to airbag and belt tensioner wiring harnesses, only contacts, connectors and wiring designed specifically for this purpose may be used ⇒ Electronic parts catalogue (ETKA) .

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Rep. gr.97 - Wiring

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88

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 Note ♦ Wires from airbag and belt tensioner wiring harness are only

allowed to be repaired using wiring harness repair set -VAS 1978 B- and previous versions.

♦ Observe the general notes on repairs to the vehicle electrical

system ⇒ page 85 .

♦ Observe vehicle stickers indicating high voltage components.

Before carrying out repairs, discharge residual voltage ⇒ General body repairs, interior; Rep. gr. 69 ; Occupant safety .

♦ For repairs to wiring in the airbag and belt tensioner system,

a maximum of two positions may be repaired. The more the repairs there are in the wiring, the greater the resistance and this can trigger faults in the self-diagnosis of the system.

♦ To avoid corrosion, the crimp connectors are always to be

shrink-fitted when performing airbag or belt tensioner wiring harness repairs.

♦ Do not incorporate the repaired wiring back in the vehicle's

own wiring harness and mark the area of repair clearly with yellow insulating tape. G. Volkswage

A AG dotensioner should not ag ♦ Repairs in the area ofenthe airbag ornbelt es n lksw

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standard with a twine spacing of 20 mm ± 5. This spacing is assured for series production via industrial standard numbers for wiring pairs and it is essential that it is adhered to on the repair lengths of entwined wiring.

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

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

♦ There must not be any section of wiring, for example in the

vicinity of crimp connectors -arrow-, longer than B = 100 mm with the wires not twisted.

2.4.2

Fibre optic cables (FOC)

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There is no provision for fibre optic cable repairs at Volkswagen. In the event of repairs, the entire fibre optic wiring harness must be replaced. To do this, the following safety precautions must be observed:

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♦ The wires to the triggering units (airbags) are entwined as

♦ Avoid sharp bends in the fibre optic cable; the bend radius agen lksw Vo by

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should be no tighter than 25 mm.

♦ 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. Repairing wiring harnesses and connectors

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Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010

2.4.3 ♦

Repairs to CAN bus wiring

AG. Volkswagen AG d agen oes ksw not l o gu yV b ara d An unshielded two-wire line -1- and -2- with a cross section of e nte is r o 2 2 eo h 0.35 mm or 0.5 mm is used for CAN bus wiring. ut ra a c s s

Orange/black Orange/green Orange/violet Orange/brown

♦ Repairs to CAN bus wiring can be carried out either with sec‐ tions of repair wiring with the correct cross section or with entwined wires „green/yellow“ or „white/yellow“ from the elec‐ tronic parts catalogue (ETKA) ⇒ Electronic parts catalogue (ETKA) . ♦ When repairs are performed, both bus wires must have the same length. When twisting the wires -1- and -2- together, the length of each complete twist must be A = 20 mm. ♦ There must not be any section of wiring, for example in the vicinity of crimp connectors -arrow-, longer than B = 50 mm with the wires not twisted. r fo ng

General description: ♦ Aerial wires must not be repaired, but if repair is required, they must be replaced only by connecting wires and adapter cables offered as genuine parts. ♦ Replacement parts can be found in the ⇒ Parts catalogue (ETKA): Special catalogue; Electrical connections; Genuine accessories; Subgroup 35 from illustration No. 035-20 . ♦ These genuine parts are suitable for all aerial wires and wire diameters which may need to be replaced. ♦ The connector housings for aerial wires are only available as genuine parts in one colour. However, they can be used for all colours of aerial connector. ♦ No provision has been made for replacement of individual aerial connectors in the event of repair. ♦ The wires can be used retroactively for all VW models, with all installed aerial wire diameters. ♦ All adapter and connection wires are suitable for all transmitter and receiver signals. ♦ This repair method can also be used for testing or retrofitting.

90

Rep. gr.97 - Wiring

AG.

A new repair concept has been developed for repair work on aer‐ ial wires. Now connecting wires in different lengths and various adapter cables are available as replacement parts instead of a complete aerial wire.

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Renewal of aerial wiring

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2.4.4

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♦ Mark the area of repair with yellow insulation tape to make it easy to identify.

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Powertrain CAN, high wire Convenience CAN, high wire Infotainment CAN, high CAN low wire, (all)

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♦ The colour codes of the CAN bus wiring can be gleaned from the following table:

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 Assembly overview of aerial cable: Example: aerial wire between radio and aerial is defective. The following wires are required for the repair: 1-

Adapter cable, to radio connection. Length approx. 30 cm.

2-

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Adapter cable, to aerial

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Installing a new aerial cable:

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Note that the total length of an aerial wire, depending on vehicle equipment level, can be divided into sections by aerial diversity control unit, traffic information control unit or aerial amplifier. Only the defective section of aerial wire must be replaced. – Pull defective aerial wire connections off units. – Determine the routing of the defective aerial wire in vehicle and measure the total length of the aerial connecting wire to be replaced. The total length of aerial connecting wire is the sum of the length of adapter cables required -1- and -3- and the connecting wire -2-. r te o iva r rp fo g n

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The remainder of the defective aerial wire remains in the vehicle.

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– Cut off connectors of defective aerial wire.

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– Procure the required adapter cables -1- and -3- and connect‐ ing wire -2- at length calculated as genuine part from the Electronic parts catalogue (ETKA).

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– To determine the length of connecting wire required, subtract 60 cm from the measured total length of aerial connecting wire -2-.

– 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

Special tools and workshop equipment required ♦ Crimping pliers, complete -VAS 1978/1 A-

2. Repairing wiring harnesses and connectors

91

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 ♦ Head adapter 0.35 mm² - 2.5 mm² -VAS 1978/1-1-

For repairs to wiring with cross sections up to 0.35 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 1978/9AAG. Volkswagen AG d agen oeshead or crimping pliers (base tool) -VAS 1978/1-2with attached w s k not l Vo gu y 1978/9-1adapter for JPT contacts -VAS , the correct connection b ara d e between crimp contact, wire ris and single wire seal is assured. The ntee o h t or tool is only to be usedafor u the application described. a

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Crimped to the repair wiring are normal contacts and gold-plated contacts. The repair contact must always be the same type as the contact installed in the factory. Crimping on new contact with single wire seal – Insert head adapter for JPT contacts -VAS 1978/9-1- in crimp‐ ing pliers (base tool) -VAS 1978/1-2- ⇒ page 84 . – Attach the single wire seal to the repair wire. Note

When doing this, the small diameter of the single wire seal must face the contact to be crimped on.

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Rep. gr.97 - Wiring

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92

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Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 – Open the crimping pliers and insert the end of the repair wire in the opening of the crimping pliers for wire stripping.

– Close the crimping pliers fully. – Open the crimping pliers again and removed the stripped wire end.

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– Insert the new crimp contact in the mounting of the crimping pliers.

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g does swastripped wire end until – Push the single wire seal towardsolkthe itnot V gu y b is flush with the wiring insulation. ara d e

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2. Repairing wiring harnesses and connectors

93

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Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 – Insert the stripped wire end with the positioned single wire seal in the crimp contact until it comes into contact with the „wire stop“. – Crimp the contact, wire and single wire seal by closing the crimping pliers fully. – Open the crimping pliers again and remove the successfully crimped contact.

2.4.6

Wiring open circuit with one repair posi‐ tion

Repair position with single crimp connector – Place the wire to be repaired to one side (about 20 cm either side of the repair position).

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– Cut out the damaged piece of wiring using the wire strippers VAS 1978/3- .

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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 .

94

Rep. gr.97 - Wiring

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– If necessary, unbind the wiring harness using the folding knife.

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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 gen AG en AG. V does wagprocess. in the correct manner to carry out the crimping no olks

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– Push the crimp connector on both stripped wire ends of the vehicle's own single wire and crimp it on using the crimping pliers. Note

♦ Ensure without fail that the correct crimp recess is chosen for

the crimp connectors being used ⇒ page 82 .

♦ The insulation on the wires must not be crimped. r fo ng

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– Heat up the crimp connector using the hot air blower along a straight line, working from the middle outwards, until it is sealed completely and the adhesive escapes from the ends.

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– Place shrink element for hot air blower -VAS 1978/15- on hot air blower, 220 V / 50 Hz -VAS 1978/14- .

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After crimping, the crimp connector has to be shrink fitted using the hot air blower in order to prevent any ingress of moisture.

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– Strip the wire ends of insulation by 6 - 7 mm using the wire wagen AG. Volkswagen AG doe s no olks strippers. t gu yV

Caution

When shrink-fitting, take care not to damage any other wiring, plastic parts or insulating material with the hot air blower. Observe the operating instructions of the hot air blower without fail!

Note ♦ Ensure that, where several wires have to be repaired, the

crimp connectors are not directly adjacent to each other. To prevent the circumference of the wiring harness from becom‐ ing to great, position the crimp connectors so they are offset slightly.

♦ If the repair position was already wrapped, this section has to

be wrapped again with yellow insulation tape once the repair has been carried out.

♦ Attach the repaired wiring harness with a cable tie, if neces‐

sary, to prevent it from generating noise when the vehicle is in motion.

2. Repairing wiring harnesses and connectors

95

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Wiring open circuit with two repair posi‐ tions

Repair position with interlinked wire. – Place the wire to be repaired to the side at two points (about 20 cm to both sides of the relevant repair position). – If necessary, unbind the wiring harness using the folding knife.

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– Place the yellow repair wire next to the damage wiring harness and, using wire strippers -VAS 1978/3- , cut the repair wire to the required length. c o p yri gh t . C op yi

– Cut the damaged section of wire out of the vehicle's own single wire. agen lksw Vo by

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– Strip the wire ends of insulation by 6 - 7 mm using the wire strippers. – Push the crimp connector onto one side of the vehicle's own single wire and on the other side onto the repair wire.

– Crimp the connector using the crimping pliers to both wire ends. – Repeat this procedure on the other end of the repair wire. Note ♦ Ensure without fail that the correct crimp recess is chosen for

the crimp connectors being used ⇒ page 82 .

♦ The insulation on the wires must not be crimped. After crimping, the crimp connector has to be shrink fitted using the hot air blower in order to prevent any ingress of moisture. – Place shrink element for hot air blower -VAS 1978/15- on hot air blower, 220 V / 50 Hz -VAS 1978/14- .

96

Rep. gr.97 - Wiring

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2.4.7

➤ , Golf 199 ...

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Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 – Heat up the crimp connector using the hot air blower along a straight line, working from the middle outwards, until it is sealed completely and the adhesive escapes from the ends. Caution

When shrink-fitting, take care not to damage any other wiring, plastic parts or insulating material with the hot air blower. AG. Volkswagen n wage

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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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Repairs to contact housings and con‐ nectors Prote cted by c o p yri gh t. C op yi

Notes on repairs to contact housings and connectors

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2.5

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sn ks Observe the operating instructions Vol of the hot air blower withoutot gu by ara d fail! e nt ris

Note ♦ Observe the general notes on repairs to the vehicle electrical

system ⇒ page 85 .

♦ Allocation of the appropriate crimp contacts to the contact

housings is by way of the part number stamped on the contact housing. Listed in illustration 198 (electrical connecting ele‐ ments) in ⇒ Electronic parts catalogue (ETKA) are the part numbers for the contact housings in conjunction with the as‐ sociated crimp contacts.

♦ Damaged contact housings must always be replaced. ♦ New contact housings can be ordered from the OTC in Kassel.

2.5.2

Repairs to contacts in contact housings

– If necessary, first open or disengage the secondary locking mechanism of the contact housing ⇒ page 102 .

2. Repairing wiring harnesses and connectors

97

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 – Disengage the contact (primary locking mechanism) using the appropriate release tool ⇒ page 102 . – Pull the contact by the single wire out of the contact housing. – Select the yellow repair wire with the correct contact from the wiring harness repair set . – Place the wire to be repaired from the vehicle's own wiring harness to one side (about 20 cm either side of the repair po‐ sition). – If necessary, unbind the wiring harness using the folding knife.

– Push the new contact of the repair wire into the contact hous‐ ing until it engages. – Slide the single wire seal onto the repair wire. Note

The small diameter of the single wire seal must face the contact housing. – Slide the single wire seal into the contact housing using the correct assembly tool ⇒ page 99 .

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– Strip the 6 - 7 mm of insulation from the end of the repair wire and the vehicle's own single wire using the wire strippers.

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– Trim the repair wire and the single wire of the vehicle's own wiring harness accordingly using wire strippers -VAS 1978/3- .

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Rep. gr.97 - Wiring

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98

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– 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 .

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 Note ♦ Ensure that, where several wires have to be repaired, the

crimp connectors are not directly adjacent to each other. To prevent the circumference of the wiring harness from becom‐ ing to great, position the crimp connectors so they are offset slightly.

♦ If the repair position was already wrapped, this section has to

be wrapped again with yellow insulation tape once the repair has been carried out.

♦ Attach the repaired wiring harness with a cable tie, if neces‐

sary, to prevent it from generating noise when the vehicle is in motion.

2.5.3

Fitting single wire seals

Note ♦ Single wire seals prevent the ingress of moisture and dirt in

the contact housing. They are installed, wagen AG in the olksexample, n AG. Vfor oes wage engine compartment and must be reinstalled dfollowing ksalways not l o gu yV b repairs. ara ed is or

th ♦ As standard, the single wire seal is crimped together with the au un le

to fit the cross section of the repair wire. The outer diameter of the single wire seal is based on the socket diameter of the contact housing. Only carry out the repair using the correct assembly tool.

Assembling single wire seal:

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– Disengage the contact locking mechanism using the appro‐ priate release tool -A- and then pull the wire with the single wire seal backwards -arrow- out of the contact housing.

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♦ It is essential that the single wire seals are of the correct size

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contact on the wire; ss this is not the case with the repair wires. Before crimping the repair line, the single wire seal must there‐ fore first be pushed onto the wire.

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2. Repairing wiring harnesses and connectors

99

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Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 – 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.

Note

The small diameter of the single wire seal must face the contact housing. – Slide the single wire seal -A- on the repair wire until it reaches the contact housing.

– Slide the single wire seal -A- using the respective assembly tool -B- fully into the contact housing. agen lksw Vo by

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Rep. gr.97 - Wiring

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100

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– Place the single wire seal -A- on the free end of the repair wire.

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Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 – Trim the repair wire and the single wire of the vehicle's own wiring harness accordingly using wire strippers -VAS 1978/3- . – Crimp the stripped ends of the repair wire and single wire of the vehicle's own wiring harness using the crimping pliers and a crimp connector, as described in the chapter entitled „Wiring open circuits with one repair position“ ⇒ page 94 .

2.5.4

Repairs to contact housings using cut and clamp technique

Note agen technique can only be supplied with the cut kswand clamp con‐ Vol tacts inserted. y db e ris

ho ♦ These contacts can be removed ut just like any other contact

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a housing if they are not needed. ss

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contacts crimped on ⇒ Electronics parts catalogue (ETKA) .

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♦ Repair wires can be supplied that already have the appropriate

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♦ For technical reasons, the contact housings for cut and clamp AG. Volkswagen

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2. Repairing wiring harnesses and connectors

101

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Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010

2.6

Releasing and dismantling contact housings

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Note

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Notes on releasing and dismantling con‐ tact housings es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

2.6.1

system ⇒ page 85 .

rrectness of i t to the co nform spec at i h re o n wit in t his

♦ Observe the general notes on repairs to the vehicle electrical ♦ To release, always use the correct release tools. Under no

circumstances should the contacts be pulled out of the contact housings with force.

♦ Damaged contact housings must always be replaced. New

contact housings can be ordered from the OTC in Kassel.

♦ As an aid to disengage the secondary locking mechanisms, a

small screwdriver can be used.

♦ The socket/pin assignment can be found stamped on the sec‐

ondary locking mechanism or on the rear of the contact hous‐ ing. tors, see ⇒ Current flow diagrams, Electrical fault finding and Fitting locations.

The secondary locking mechanism is a housing catch (second line locking mechanism) that secures all the wires in one contact housing. If a secondary locking mechanism is fitted to a contact housing, this must always be opened or removed using the ap‐ propriate tool before releasing and pulling out individual crimp contacts. The secondary locking mechanism is different in colour from the rest of the contact housing. This makes it easier to identify the secondary locking mechanism and clarifies its intended function. The types of contact housing shown here are just a few examples to show the different functions of secondary locking mechanism. Example 1: The housing catch is disengaged by removing a „toothed ele‐ ment“ -arrow-.

102

Rep. gr.97 - Wiring

AG.

Secondary locking element

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2.6.2

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Allocation of the correct release tool to the respective locking de‐ vices can be gleaned from the table in the ⇒ operating instruc‐ tions of -VAS 1978/35- .

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♦ For more detailed information about the locations of connec‐

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 Example 2: The housing catch is disengaged by opening a „flap“ -arrow-.

Example 3:

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Primary locking element

The primary locking mechanism is what fixes an individual crimp contact in the contact housing. If necessary, any housing catches in place (secondary locking mechanisms) must be released or removed prior to disengaging the contacts using the prescribed tool ⇒ page 102 . The types of primary locking mechanisms shown as follows are just a few examples to show the different functions of primary locking mechanism. ♦ Round connector systems ⇒ page 103 ♦ Flat connector systems ⇒ page 104

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♦ Special connector systems ⇒ page 106

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Note

Round connector systems

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2.6.4

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Allocation of the correct release tool to the respective locking de‐ vice can be gleaned from the table in the ⇒ operating instructions of -VAS 1978/35- .

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2.6.3

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The housing catch can be disengaged by detaching a „slide“ -arrow-.

If necessary, any housing catches in place (secondary locking mechanisms) must be released or removed prior to disengaging the contacts using the prescribed tool ⇒ page 102 .

2. Repairing wiring harnesses and connectors

103

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 – Insert the release tool appropriate for the contact housing in the release port of the contact housing. – Grab hold of the contact by the wire and push it lightly into the contact housing -arrow-. Note

By pushing the contact in the direction of the contact housing, the locking tabs of the contact are lifted up by the housing edge and disengaged using the release tool. – At the same time, push the release tool in the direction of the contact housing -arrow- and pull out the released contact from the contact housing. – The release tool can be pulled out of the contact housing again once the contact has been removed.

2.6.5

Flat connector systems

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Note

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If necessary, any housing catches in place (secondary locking mechanisms) must be released or removed prior to disengaging the contacts using the prescribed tool ⇒ page 102 .

rrectness of i t to the co nf o r m spec atio h re n in wit

Flat connector with one locking tab:

– 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 tab of the contact is lifted up by the housing edge and can be disengaged using the release tool.

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104

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... Electrical System, General Information - Edition 07.2010

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

Bora 1999 ➤ , Bora

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– At the same time, push the release tool in the direction of the contact housing and pull out the released contact from the contact housing -arrow-. – The release tool can be pulled out of the contact housing again once the contact has been removed.

Flat connector with two locking tabs:

– Insert the release tool appropriate for the contact housing in the release port of the contact housing.

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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.

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Note

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– Grab hold of the contact by the wire and push it fully into the contact housing -arrow-.

– At the same time, push the release tool in the direction of the contact housing and pull out the released contact from the contact housing -arrow-. – The release tool can be pulled out of the contact housing again once the contact has been removed.

Asymmetrical: – Insert the release tool appropriate for the contact housing in the release port of the contact housing. – Grab hold of the contact by the wire and push it lightly into the contact housing -arrow-. Note

By pushing the contact in the direction of the contact housing, the locking tabs of the contact are lifted up by the housing edge and disengaged using the release tool.

2. Repairing wiring harnesses and connectors

105

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 – At the same time, push the release tool in the direction of the contact housing and pull out the released contact from the contact housing -arrow-. – The release tool can be pulled out of the contact housing again once the contact has been removed.

2.6.6

Special connector systems

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Note

Faston contacts:

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the contacts using the prescribed tool ⇒ page 102 .

es, in part or in w l purpos hole ercia , is n m ot com

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– 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. 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.

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Rep. gr.97 - Wiring

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106

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– The release tool can be pulled out of the contact housing again once the contact has been removed.

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– At the same time, push the release tool in the direction of the contact housing and pull out the released contact from the contact housing -arrow-.

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 GT 150/280 contacts: – Insert the release tool appropriate for the contact housing un‐ der the locking tab into the contact housing. – Push the tool onto the limit stop -arrow- in the contact housing.

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AG. Volkswagen AG d agen oes ksw not l o V gu y b The contact is ejected from the contact housing. ara d nte ise r o eo h t the contact housing again – The release tool can be pulled outauof ra c s once the contact has been ejected. s

Contacts without locking tabs: – Insert the release tool under the locking tab of the contact housing.

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The contact is ejected from the contact housing.

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– Push through the release tool with a light upward movement -arrow- onto the limit stop.

AG.

2. Repairing wiring harnesses and connectors

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3

Contact surface cleaning set -VAS 6410-

3.1

Using contact surface cleaning set -VAS 6410-

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or ac

The illustrations shown here are just a few examples of repair work. Contact surface cleaning set VAS 6410

3.1.1

Repairing ring terminals

Special tools and workshop equipment required

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♦ VAG 1331

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Note

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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 cleaning set lkswagensurface ocontact AG do e G. V eof wagstructural -VAS 6410- is adapted to the conditions vehicles and s s k n l o o yV ensures the process of repair work as well ast gauacomfort‐ bsecurity d r a nte able procedure.orise e

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Note ♦ The use of penetrating fluid, contact spray or grease etc. is

prohibited since the missing adhesion in the threads may cause a torque excess and, therefore, the break of the threa‐ ded connection.

♦ The grey sanding pads are suitable for light dirt and "soft sur‐

faces". The red sanding pads are suitable for heavy dirt and "hard surfaces".

108

Rep. gr.97 - Wiring

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 WARNING

Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 ! – Disconnect battery. – Loosen cap nut and remove ring terminal from threaded con‐ nection. – Check ring terminal for corrosion, dirt etc. – Select suitable adapter and suitable sanding pad. Note

As an alternative, the sanding block may also be used. Caution

Take care not to abrade excessively the tin coating and ensure that the copper does not appear. This could produce a galvanic cell which destroys metal and causes faulty repair.

– Check ring terminal and regrind if necessary.

rrectness of i t to the co nf o r m spec atio h re n in wit

– Insert adapter into ring terminal and grind off corrosion and dirt with circular movements.

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es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

As sign, the cleaning process must be performed step by step and a visual check of the ring terminal is necessary between the steps.

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3. Contact surface cleaning set VAS 6410

109

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Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 – If necessary, remove punching burr on ring terminal using the deburrer. – Tighten ring terminal to specified torque ⇒ Current flow dia‐ grams, Electrical fault finding and Fitting locations. Note

Optimum contact is ensured when the components to be secured are tightened to the specified torque after cleaning. – Apply suitable anti-corrosion treatment to connection ⇒ page 113 . – Reconnect battery. WARNING

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es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

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Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 !

3.1.2

rrectness of i t to the co nf o r m spec atio h re n in wit

– Teach in electric windows again, enter radio code, set clock and, if necessary, recode control units which emit code sig‐ nals.

Repairing threaded connections

Special tools and workshop equipment required

♦ The grey sanding pads are suitable for light dirt and "soft sur‐

faces". The red sanding pads are suitable for heavy dirt and "hard surfaces". WARNING

Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 ! – Disconnect battery.

110

Rep. gr.97 - Wiring

AG.

prohibited since the missing adhesion in the threads may cause a torque excess and, therefore, the break of the threa‐ ded connection.

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♦ The use of penetrating fluid, contact spray or grease etc. is

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Note

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♦ VAG 1331

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 – Loosen cap nut and remove ring terminal from threaded con‐ nection. – Check threaded connection for corrosion, dirt etc. – Select suitable adapter and suitable sanding pad for threaded connection. Caution

Take care not to abrade excessively the tin coating and ensure that the copper does not appear. This could produce a galvanic cell which destroys metal and causes faulty repair.

Note

As the thickness of the tin coating may differ according to the de‐ sign, the cleaning process must be performed step by step and a visual check of the ring terminal is necessary between the steps. – Set adapter on threaded connection and grind off corrosion and dirt with circular movements. – Check threaded connection and regrind if necessary. – Tighten connection and, if necessary, locating element again to specified torque ⇒ Current flow diagrams, Electrical fault finding and Fitting locations. Note

Optimum contact is ensured when the components to be secured are tightened to the specified torque after cleaning. AG. Volkswagen AG d agen oes

w – Apply suitable anti-corrosion treatment to threaded connection olks yV b d ⇒ page 113 . se

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WARNING

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– Reconnect battery.

not gu ara nte eo ra c

rrectness of i t to the co nform spec at i h re o n wit in t his

Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 ! – Teach in electric windows again, enter radio code, set clock and, if necessary, recode control units which emit code sig‐ nals.

3.1.3

Cleaning battery clamp and battery ter‐ minal

Special tools and workshop equipment required

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3. Contact surface cleaning set VAS 6410

111

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 ♦ VAG 1331

Note

The use of penetrating fluid, contact spray or grease etc. is pro‐ swagen AG. Vo hibited since the missing adhesion in the threads may causebyaVolk ed torque excess and, therefore, the break of the threaded connec‐ ris o h tion. ut

lkswagen AG does not gu ara nte eo ra c

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WARNING

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a ss

– Disconnect battery.

rrectness of i t to the co nform spec at i h re o n wit in t his

Danger of injury! Observe warning notices and safety regula‐ tions ⇒ page 2 !

– Check battery clamp and battery terminal for corrosion or dirt. – Clean battery clamp using wire brush of battery terminal clean‐ er with circular movements.

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Rep. gr.97 - Wiring

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112

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 – Clean battery terminal using underside of battery terminal cleaner with circular movements. WARNING

Danger of injury! Observe warning notices and safety regula‐ . Volkswagen AG does tions ⇒ page 2 ! kswagen AG n and tighten battery

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Note

Optimum contact is ensured when the components to be secured are tightened to the specified torque after cleaning.

3.1.4

Anti-corrosion treatment Caution

Note

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Missing anti-corrosion treatment results in damage to the on‐ board supply.

rrectness of i t to the co nform spec a t i h re o n in wit thi s

es, in part or in w l purpos hole ercia , is n m ot com

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–

ol yV db e ris ho Reconnect battery ut a ss torque.

♦ All threaded connections must be tightened to specified tor‐ ht rig py Co t.

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♦ Always use hose supplied with anticorrosive agent tin. agen lksw Vo by

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♦ Use protection wax for cold area.

♦ 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

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010

n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

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Rep. gr.97 - Wiring

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114

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– Hold injector above ring terminal and spray pin and wiring eye all around.

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010

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.

rrectness of i t to the co nform spec at i h re o n wit in t his

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

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n AG. Volkswagen AG do es n wage s k l ot g o yV ua b d ran ir se tee o h t or u ac a ss

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4. Renewing Lambda probe

115

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Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 – Tie back any excess in the uniform probe length (approx. 50 250 mm) to the size of the defective probe and secure with cable ties -1-. – Check that the connector housing of the Lambda probe is compatible with the onboard supply side. – If necessary, replace the onboard supply system connector with the Lambda probe connector housing supplied ⇒ page 97 Note ♦ The connector housing should only be replaced on older ve‐

hicles. On new vehicles, the connector housing coding match‐ es.

♦ Observe pin assignment. For reasons of clarity, respective

pins in new connector housing have a colour marking.

♦ Further notes can be found in the leaflet of the new lambda

probe.

– Install the new Lambda probe in the vehicle.

4.2

Renewing LSU Lambda probe (6-pin) Note AG. Volkswagen AG d agen oes

sw ♦ If necessary, replace attachment parts, ties or marking olkcable yV

d b the defective probe as rings to match the uniform probeiseto r o specified. h t

u sa

– Remove the old Lambda probe.

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116

rrectness of i t to the co nform spec at i h re o n wit in t his

– Place both Lambda probes next to each other so that the sen‐ sor housings are at the same height.

do c um en

es, in part or in w l purpos hole ercia , is n m ot p om c r erm o e t a itte riv du p or nl f e g n

tion of the Lambda probe will be impaired.

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s ♦ The wires should not be crimped or cut as otherwise the func‐

not gu ara nte eo ra c

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010 – Tie back any excess in the uniform probe length (approx. 50 250 mm) to the size of the defective probe and secure with cable ties -1-. – Install the new Lambda probe in the vehicle.

Note

In addition to identifying by way of the part number, the protective tube can also be used as a means of identification. Type D1, 6 openings at 3.5 mm each Only used on 4-pin LSF Lambda probes. Type D2, 6 openings at 2 mm each

thi sd o cu m en

es, in part or in w l purpos hole ercia , is n m m ot p o c erm or e t a itte iv r du rp o nl f e ng

Types of protective tube on uniform Lambda probes

rrectness of i t to the co nf o r m spec atio h re n in wit

4.3

ility ab y li an pt ce

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Only used on 4-pin LSF Lambda probes and 6-pin LSU Lambda probes. Type D4, 12 openings at 1.4 mm each

4. Renewing Lambda probe

117

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ... Electrical System, General Information - Edition 07.2010

AG. Volkswagen AG d agen oes ksw not l o V gu y b ara d nte ise r o eo h t u ra a c s s

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AG.

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Rep. gr.97 - Wiring

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118

do c um en

r te o iva r rp fo g n

rrectness of i t to the co nform spec a t i h re o n in wit thi s

es, in part or in w l purpos hole ercia , is n m ot com

pe rm itte d

ility ab y li an pt ce

un le

Only used on 4-pin LSF Lambda probes and 6-pin LSU Lambda probes.