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Volkswagen Polo 1995 - 2010 Workshop Manual - Electrical System PDF
Volkswagen Polo 1995 - 2010 Workshop Manual - Electrical System PDF
Workshop Manual
Bora 1999 ➤ , Bora Variant 1999 ➤ ,
CC 2010 ➤ , Eos 2006 ➤ , Golf 1998 ➤ ,
Golf 2004 ➤ , Golf 2009 ➤ ,
Golf Plus 2005 ➤ , Golf Plus 2009 ➤ ,
Golf Variant 1998 ➤ , Lupo 1999 ➤ ,
Lupo 3L 1999 ➤ , Passat 1997 ➤ ,
Passat 2006 ➤ , Passat CC 2009 ➤ ,
Passat Variant 1997 ➤ , Phaeton 2003 ➤ ,
Polo 1995 ➤ , Polo 2002 ➤ ,
Polo 2010 ➤ , Polo KH IN 2010 ➤ ,
Polo Lim IN 2011 ➤ ,
Polo Lim RUS 2011 ➤ , Scirocco 2009 ➤ ,
Sharan 1996 ➤ , Sharan 2011 ➤ ,
Tiguan 2008 ➤ , wTouaregagen
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Electrical System, General Information
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Service Department. Technical Information
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Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
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27 - Starter, current supply, CCS rised ara
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90 - Gauges, instruments ss a ra
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96 - Lights, bulbs, switches - interior
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97 - Wiring
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
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27 - Starter, current supply, CCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
erm
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1 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.1 Fundamentals for batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
h re
hole
1.2 Types of batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
spec
es, in part or in w
1.3 Warning notices and safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
t to the co
1.4 Battery terminal connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Checking battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
rrectness of i
2.1 Checking the various types of batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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2.5 Battery tester with printer VAS 6161 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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2.6 Midtronics MCR340V battery tester only for USA/Canada vehicles . . . . . . . . . . . . . . . . . . 18
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3 Charging battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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90 - Gauges, instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
92 - Windscreen wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1 Washer fluid line hose couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.1 Windscreen and rear window washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.2 Headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2 Hose repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.2 Repairing smooth pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.3 Repairing corrugated pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3 Distinguishing features of jointless wiper blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
97 - Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Contents i
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...
Electrical System, General Information - Edition 07.2010
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ii Contents
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...
Electrical System, General Information - Edition 07.2010
27 – Starter, current
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Danger of injury! Observe warning notices and safety regula‐
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Caution
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1.1 Fundamentals for batteries
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serviced and maintained according to the specifications in this
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Caution
Caution
WARNING
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
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1.3.1 Dangers when handling vehicle batter‐
ies
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Recognition and avoidance of dangers
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Batteries can be dangerous. These dangers can be avoided when
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are observed.
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♦ It is prohibited to cause sparks through grinding, welding, an
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batteries. Smoking is also prohibited. Sparks generated
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5. - Never dispose of old batteries in household waste system!
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6. - There is a danger of an explosion when working with batteries.
A highly explosive gas is produced when batteries are charged.
7. - Always follow instructions on battery, in ELSA "Electrical Sys‐
tem, General Information" and in owner's manual.
8. - Battery acid is very caustic; therefore wear eye protection and
gloves when working with batteries. Do not tilt battery. Acid can
leak out of the gas vents of some batteries.
1. Battery 3
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...
Electrical System, General Information - Edition 07.2010
Caution
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♦ Battery terminals should not be coated with grease.
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♦ The battery clamps should be fitted so that the battery ter‐
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♦ Once the battery clamps have been tightened to the speci‐
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2 Checking battery
WARNING
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⇒ page 14 .
4. Depending on the result of the battery test, „perform current
draw test“ ⇒ page 22 .
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⇒ page 14
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Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...
Electrical System, General Information - Edition 07.2010
WARNING
Caution
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not correctly seated and tightened, the wiring may burn. Which
hole
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magic eye
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WARNING
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Note
♦ Air bubbles can form below the magic eye particularly when
the battery is being charged, including during normal vehicle
operation. These distort the colour displayed by the magic eye.
♦ Because the magic eye is located in only one cell, the display
applies only to this cell. An exact determination of the battery
condition is only possible through a battery load test
⇒ page 9 or a battery test ⇒ page 14 .
♦ The magic eye can be located at various positions on the bat‐
tery. AG. Volkswagen AG d
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Three different colour d b displays are possible:
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♦ »Green«, abattery
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♦ »Black«, battery partly discharged, charge state < 65 % or
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WARNING
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2. Checking battery 7
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...
Electrical System, General Information - Edition 07.2010
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 .
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♦ »Colourless or light yellow«, electrolyte level too low. The bat‐
erm
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tery must be renewed.
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WARNING
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not be checked or charged. Do not slave/jump start the vehicle!
Danger of explosion when checking and charging or slave/ rrectness of i
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It is not necessary to remove or disconnect battery when using
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Observe the ⇒ instruction manual of Battery tester with printer -
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with printer -VAS 5097 A- on the unit or table: Cold cranking cur‐
h re
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rent ⇒ page 11 .
spec
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2.4.1 Description of battery tester with printer
-VAS 5097 A-
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Battery tester with printer -VAS 5097 A-
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3 - Red LED, „battery cannot be tested“, recharge battery.
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4 - Start button
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7 - Selection switch (battery tester to pick-off point on battery/
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9 - Printer
WARNING
2. Checking battery 9
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...
Electrical System, General Information - Edition 07.2010
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tester with printer -VAS 5097 A- .
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Performing battery load test:
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WARNING
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Batteries where the magic eye is colourless or light yellow must
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The battery must have a temperature of at least 10 °C.
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– Connect red terminal „+“ of tester to positive terminal.
– Connect black terminal „-“ of tester to negative terminal.
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Note
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♦ Ensure test clamps have a good contact!
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♦ Observe technical product information TPI 2012182 for battery
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switch ⇒ page 9 .
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2- Connected to external test points in engine compartment
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– Check that the figures given on the battery are correct for the
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settings on the battery tester.
– Press start test button ⇒ page 9 .
The green LED lights up ⇒ page 9 . The test program runs through
automatically. The test result is printed out by the printer
⇒ page 12 . If the unit does not start (LED does not light up, no
print out), recharge battery ⇒ page 25 and test again.
– Switch off unit ⇒ page 9 .
– Remove test terminals.
Note
2. Checking battery 11
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...
Electrical System, General Information - Edition 07.2010
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.
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2.4.4 Evaluating test result of battery load test
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Because of the high load on the battery during this test (a high
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current flows) the battery voltage drops.
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♦ If the battery is OK, the voltage value drops only to the mini‐
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mum voltage.
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♦ After the test is completed, this low voltage value remains over t to the co
a longer period, and the voltage increases very slowly again.
♦ Perform test once only. Repeating the test falsifies the result.
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♦ The test printout is urequired
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Printout from battery tester Measure to be performed
Starting capability very good Battery OK.
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Starting capability good Battery OK.
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Starting capability poor Evaluation by carrying out a
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current draw test when charg‐
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2. Checking battery 13
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...
Electrical System, General Information - Edition 07.2010
WARNING
Note
pt
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3 - Paper slot
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14
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Rep. gr.27 - Starter, current supply, CCS
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...
Electrical System, General Information - Edition 07.2010
WARNING
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jump starting
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– Switch on unit.
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♦ Maintenance test (only in new cars before registration, in sta‐
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♦ Service test ⇒ page 16
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2. Checking battery 15
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...
Electrical System, General Information - Edition 07.2010
Note
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Batteries where the magic eye is colourless or light yellow must
un
pt
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ab
Danger of explosion when checking and charging or slave/
ility
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spec
urposes, in part or in wh
t to the co
– Select „Maintenance test“ in the menu.
– Connect scanner.
rrectnes
Note
s o
cial p
f inform
If no scanner is available, write vehicle identification number on
mer
atio
om
n
c
i
or
n
– Scan in vehicle identification number.
thi
te
sd
iva
o
– Select „On battery terminal“ or „On jump-start point“.
pr
cum
r
fo
en
ng
– Start test.
– Print out test log if necessary.
WARNING
WARNING
pt
y li
erm
ab
3- Measured voltage
ility
ot p
wit
h re
ole,
f inform
Note
mer
atio
om
i
or
n thi
te
sd
iva
o
pr
en
ng
t.
yi Co
Evaluating battery test results for guarantee and service tests ht. Cop py
rig
rig ht
Battery test results Measures
py by
co Vo
by lksw
cted agen
Battery OK No measures on battery
Prote AG.
2. Checking battery 17
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...
Electrical System, General Information - Edition 07.2010
ce
le
un
pt
Battery cell defective - renew. Renew battery.
an
d
itte
y li
Check connection. Connect cable directly to bat‐
rm
ab
tery and not to jump start termi‐
pe
ility
ot
nal.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Battery OK No measure
Charge battery immediately. Charge battery fully
rrectness of i
⇒ page 25 .
l purpos
nform
ercia
a
com
ti
a weak cable contact.
on in
r
te o
nal.
rp
cum
fo
en
g
t.
yi Co
op
pears on display.
C py
t. rig
gh ht
yri by
2.6 Midtronics -MCR340V- battery tester
op Vo
by c lksw
cted agen
Prote
only for USA/Canada vehicles
AG.
WARNING
Danger of injury.
Before working on the battery, read through the warning and
safety regulations carefully, and comply with them ⇒ page 2 .
Dispose of electrolyte (mixture of sulphuric acid and water)
safely! Waste electrolyte is only allowed to be disposed of at
appropriately indicated collecting points. Comply with the lo‐
cally applicable disposal guidelines.
Do not test batteries that are liberating gas. Otherwise, there
is a danger of explosion.
WARNING
Note
pt
an
d
second/convenience battery).
itte
y li
erm
ab
manual MCR340V .
spec
urposes, in part or in wh
t to the co
Note
rrectne
Prerequisites:
c
i
or
n thi
te
sd
iva
o
r
WARNING
p
cum
r
fo
en
ng
t.
yi
Before working on the battery, read through the warning and
Co
Cop py
safety regulations carefully, and comply with them ⇒ page 2 .
t. rig
gh ht
pyri by
Vo
o
Batteries where the magic eye is colourless or light yellow must
c by lksw
cted agen
not be checked or charged. Do not slave/jump start the vehicle!
Prote AG.
2. Checking battery 19
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...
Electrical System, General Information - Edition 07.2010
Note
ce
e
nl
pt
du
an
itte
y li
WARNING
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Danger of explosion when checking and charging or slave/
es, in part or in w
jump starting
t to the co
These batteries must be renewed.
rrectness of i
– Switch off ignition and all electrical consumers.
l purpos
nf
ercia
o
– Switch on tester.
rm
m
atio
m
n in
or c
sd
iva
o
r
rp
cu
o
m
f
en
ng
Note
t.
yi Co
Cop py
t. rig
Ensure test clamps have a good contact!
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
– Select „In vehicle“ or „Outside vehicle“.
AG.
Note
Use the print function of the Midtronics -MCR340- tester if the test
results are required for handling warranty applications.
Note
Always use DIN value from battery sticker! Otherwise, test result
will be falsified.
Note
ce
le
y li
erm
ab
– Check battery terminals are ility
ot p
corrosion.
spec
urposes, in part or in wh
t to the co
– Charge battery
⇒ page 55 .
System noise – Switch off all electrical con‐
rrectne
sumers.
f in
ed off.
atio
om
i
or
n thi
te
sd
a
o
r
cum
r
fo
t.
yi
ply as standard.
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
21
Prote AG.
2. Checking battery
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...
Electrical System, General Information - Edition 07.2010
Note
WARNING
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
Note
ility
ot
wit
, is n
h re
♦ Ensure that the correct charging mode is set on the charger
hole
spec
es, in part or in w
t to the co
♦ VAS 5095 A ⇒ page 26
♦ VAS 5900 ⇒ page 30
rrectness of i
♦ VAS 5903 ⇒ page 41
l purpos
a
com
tion in
Note
r
te o
thi
s
iva
do
For battery tester with printer -VAS 6161- , the current draw test
r
rp
cum
fo
t.
draw test“ appears on the display.
yi Co
Cop py
t. rig
gh ht
yri by
The current draw test must be carried out when the test result with cop Vo
by lksw
battery tester with printer -VAS 5097A- is as follows: cted agen
Prote AG.
ce
le
un
pt
♦ When charging a battery, battery temperature must be at least
an
d
itte
≥ +10 °C.
y li
erm
ab
ility
♦ The charger must be capable of outputting a charge current of
ot p
wit
at least 30 A, as for example with VAS 5095A, VAS 5900, VAS
is n
h re
5903
ole,
spec
urposes, in part or in wh
t to the co
pick-up clamp, e.g. VAS 5051B/7, when charging with battery
charger -VAS 5095A- . Battery charger -VAS 5900- and bat‐
tery charger -VAS 5903- display the current draw on the unit.
rrectne
– Connect battery to battery charger and start charging se‐
quence.
ss o
– Measure charging current of battery after 5 minutes.
cial p
f inform
Test result:
mer
atio
m
n
c
(e.g. > 6.1 A for a 61 Ah battery), fully charge battery and test
i
or
n thi
e
again.
t
sd
iva
o
pr
cum
r
fo
en
ng
Note
t.
yi Co
Cop py
ht. rig
ht
For Eos with two 6V absorbent glass mat batteries, the charge
rig by
opy Vo
current must only be 5 % higher than the nominal capacity of the
by c lksw
cted agen
battery. Example for Eos: the 50 Ah battery must have a charge
Prote AG.
– 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.
WARNING
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“ .
2. Checking battery 23
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...
Electrical System, General Information - Edition 07.2010
Test conditions
The battery must not have been charged or discharged within the
last 2 days.
– Check battery no-load voltage with hand multimeter -V.A.G
1526 B- .
No-load voltage Charge Condition of battery
11.60 V 0% Discharged, no capacity Heavily discharged ⇒ page 59 .
AG. Volkswagen AG d
agen oes
olksw not
Measured value edMeasure
by
V
to be performed gu
ara
ris nte
No-load voltage ≥ 12.5 V autho
No-load voltage OK eo
ra
s c
No-load voltage < 12.5 V s Charging battery ⇒ page 25
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
3 Charging battery
WARNING
AG. Volkswagen AG d
agen oes
ksw
Danger of injury! Observe warning notices and safety regula‐ byV
ol not
gu
tions ⇒ page 2 ! rised ara
nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
Caution
an
itte
y li
erm
ab
To prevent damage to the battery and vehicle, the following
ility
ot p
should be observed concerning types of battery ⇒ page 1 .
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
WARNING
rrectness of i
not be checked or charged. Do not slave/jump start the vehicle!
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
cu
o
m
-VAS 5095 A- . For additional information refer to ⇒ operating
f
en
ng
t.
yi
instructions for battery charger -VAS 5095 A- .
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
Note Prote
cted AG.
agen
3. Charging battery 25
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...
Electrical System, General Information - Edition 07.2010
ce
e
1 - ON / OFF switch (0 = charger OFF)
nl
pt
du
an
itte
y li
2 - Charging current indicator (I > 12 A)
erm
ab
ility
ot p
3 - Charging current indicator, battery partially charged > 90 %
wit
, is n
h re
4 - Maintaining charge; lights up green when battery is fully charg‐
hole
ed
spec
es, in part or in w
t to the co
5 - Malfunction indicator
6 - Support mode indicator
rrectness of i
7 - Support mode/normal mode changer-over switch
l purpos
nform
mercia
at
om
ion
c
VAS 5095 A-
in t
or
his
ate
do
priv
cum
WARNING
for
en
ng
t.
yi Co
op
Danger of injury! Observe warning notices and safety regula‐
C py
ht. rig
tions ⇒ page 2 !
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Caution
Always set battery type 2.4 V/C (volts/battery cell) when charg‐
ing! This applies for all batteries.
Note
WARNING
ce
le
minal on battery.
un
pt
an
d
itte
y li
erm
ab
Note
ility
ot p
wit
is n
h re
In vehicles with start/stop function and battery monitor control unit
ole,
spec
urposes, in part or in wh
t to the co
stop system to malfunction.
rrectne
terminal.
– Switch on battery charger ⇒ page 25 .
ss o
cial p
f
The charging current indicators ⇒ page 26 -2- and -3- light up
inform
yellow. When only the light emitting diode (LED) -3- lights up yel‐
mer
n
c
If the LED lights up green ⇒ page 26 -4- the charger has switched
i
or
n thi
e
sd
iva
o
pr
en
ng
t.
yi
– Remove charger unit terminals from battery terminals.
Co
Cop py
t. rig
3.1.3 Charging totally discharged battery with
gh ht
pyri by
Vo
o
by c lksw
battery charger -VAS 5095 A-
cted agen
Prote AG.
WARNING
Note
3. Charging battery 27
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...
Electrical System, General Information - Edition 07.2010
WARNING
ce
le
pt
an
d
itte
y li
battery charger -VAS 5095A-
rm
ab
pe
ility
ot
General notes:
wit
, is n
h re
The support mode provides the onboard supply with power when
hole
spec
the battery is removed or disconnected.
es, in part or in w
t to the co
For further information, refer to the ⇒ operating manual VAS
5095A .
rrectness of i
The support mode is suitable in the following situations:
♦ Support mode of onboard supplies without installed battery
l purpos
a
com
tion in
WARNING
r
te o
thi
s
iva
do
cum
tions ⇒ page 2 !
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c
WARNING
lksw
cted agen
Prote AG.
Caution
ce
cables are connected incorrectly. The charger unit may be nl
e
pt
du
damaged.
an
itte
y li
erm
ab
ility
ot p
– Remove battery.
wit
, is n
h re
hole
spec
Caution
es, in part or in w
t to the co
When battery is removed, ensure there is no contact between
terminal clamp connected to positive clamp and body earth.
rrectness of i
Also ensure there is no contact between battery clamps.
l purpos
nform
mercia
at
Note
om
ion
c
in t
or
his
ate
do
priv
c
earth. Connecting it to battery negative terminal will cause start/
um
for
en
g
t.
yi Co
Cop py
ht. rig
– Connect black terminal clamp „+“ to negative terminal of ve‐
rig ht
py by
o Vo
hicle. by c lksw
cted agen
Prote AG.
– Check setting for battery type on normal/support mode switch
⇒ page 25 . It must be switched on support mode.
– Check polarity of charger unit cables.
– Switch on battery charger.
The battery charger starts with support mode.
End battery support mode:
– Switch off battery charger.
– Disconnect black terminal clamp „-“ of charger unit from neg‐
ative terminal of vehicle.
– Disconnect red terminal clamp „+“ of charger unit from positive
terminal of vehicle.
– Pull charger plug out of battery charger.
3. Charging battery 29
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ e,nEos AG. V2006
olkswa➤
gen, AGolf
G do 199 ...
ag
Electrical System, General Information - Edition
V olksw 07.2010 es n
ot g
y ua
db ran
rise tee
3.1.5 Charging battery in maintenance mode s au
tho or
ac
with battery charger -VAS 5095 A- s
ce
e
nl
pt
du
an
itte
y li
WARNING
erm
ab
ility
ot p
wit
Danger of injury! Observe warning notices and safety regula‐
, is n
h re
tions ⇒ page 2 !
hole
spec
es, in part or in w
t to the co
WARNING
rrectness of i
Batteries where the magic eye is colourless or light yellow must
l purpos
nform
ercia
jump starting
m
at
These batteries must be renewed.
om
ion
c
in t
or
his
ate
do
priv
c
that the battery is charged correctly and is maintained in fully
um
for
en
charged condition.
ng
t.
yi Co
op py
– Proceed as for charging battery ⇒ page 26 . t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
Note
AG.
WARNING
WARNING
Note
ce
le
un
pt
an
d
y li
rm
ab
pe
1 - Display
ility
ot
wit
, is n
h re
hole
spec
3 - Adjustment button „Down“ ↓
es, in part or in w
t to the co
4 - START / STOP
5 - INFO
rrectness of i
l purpos
nform
mercia
a
com
tio
WARNING
n in
r
te o
thi
s
iva
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
WARNING cop Vo
by lksw
cted agen
Prote AG.
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 31
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...
Electrical System, General Information - Edition 07.2010
Note
Note
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
by
32
copy Vo
by lksw
Rep. gr.27 - Starter, current supply, CCS cted agen
Prote AG.
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...
Electrical System, General Information - Edition 07.2010
Note
AG. Volkswagen AG d
agen oes
ksw
♦ In the battery type „standard by
V charge“ the parallel use of con‐
ol not
gu
sumers while charging riseis
d possible. The charging period will bearante
longer. tho eo
s au ra
c
♦ The battery charger will switch to maintenance mode after
s
ce
e
nl
pt
du
an
100 % charge the battery should remain connected for this
itte
y li
erm
period.
ab
ility
ot p
wit
, is n
h re
hole
spec
1- Displayed battery voltage is not as per nominal voltage:
es, in part or in w
t to the co
– Press respective button „Up“ ↑ or „Down“ ↓ until charging
sequence starts.
2- Displayed battery voltage is not as per nominal voltage –
rrectness of i
charging sequence already started:
l purpos
nf
ercia
or
sequence starts again.
m
m
atio
om
n in
or c
thi
te
sd
iva
cu
o
m
f
en
ng
WARNING
Caution
3. Charging battery 33
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...
Electrical System, General Information - Edition 07.2010
WARNING
Caution
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Note
nform
ercia
a
com
tio
thi
do
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
AG. Volkswagen AG d
agen oes
lksw not
In vehicles with start/stop
d b yV
o
function and battery monitor gcontrol
ua unit
-J367- fitted, black
oris terminal clamp „-“ must be connectedanto
e r
teebody
earth. Connecting
au
th it to battery negative terminal will cause start/ or
ac
stop system ss to malfunction.
ce
le
un
pt
an
d
y li
rm
ab
The charger unit recognises the voltage required for the connec‐
pe
ility
ot
wit
, is n
h re
hole
spec
At a charge condition of approx. 80 - 85 % of the battery voltage,
es, in part or in w
the battery charger switches to the „final charge“ mode. The fourth
t to the co
bar appears in display -1-. The battery is ready for use.
rrectness of i
Note
l purpos
tion in
thi
s
iva
sequence starts.
um
fo
en
ng
t.
yi
2- Displayed battery voltage is not as per nominal voltage –
Co
op py
charging sequence already started:
. C rig
ht ht
rig by
opy Vo
– Press START / STOP twice. by c lksw
cted agen
Prote AG.
– 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
WARNING
WARNING
ce
e
nl
pt
du
an
itte
y li
erm
ab
Caution
ility
ot p
wit
, is n
h re
hole
spec
tive. Connect battery charger terminal clamps correctly to
es, in part or in w
t to the co
battery terminals.
♦ When charging always set the battery charger to the cor‐
rect type of battery ⇒ operating instructions for battery
rrectness of i
charger -VAS 5900- !
l purpos
nform
ercia
io
damaged. n
c
in t
or
his
ate
do
priv
t.
yi Co
op py
Special tools and workshop equipment required t. C rig
gh ht
pyri by
♦ Battery charger -VAS 5900-
co Vo
by lksw
cted agen
Prote AG.
Note
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Charging battery 37
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...
Electrical System, General Information - Edition 07.2010
Note
Note
an
itte
y li
ab
tery.
ility
ot p
wit
, is n
spec
t to the co
atio
m
n in
or c
thi
e
General notes:
t
sd
iva
o
r
rp
cu
The support mode provides the onboard supply with power when
o
m
f
t.
yi Co
op py
For further information, refer to the ⇒ operating manual VAS t. C rig
gh ht
5900 . yri
p by
co Vo
by lksw
cted
The support mode is suitable in the following situations:
agen
Prote AG.
WARNING
WARNING
ce
e
nl
pt
du
an
– Switch off ignition and all electrical consumers.
itte
y li
erm
ab
ility
ot p
Caution
wit
, is n
h re
hole
spec
ing totally discharged batteries/support mode“ is not ac‐
es, in part or in w
t to the co
tive. Connect battery charger terminal clamps correctly to
battery terminals.
♦ It can cause sparks through a short-circuit.
rrectness of i
♦ Danger of explosion
l purpos
damaged.
o
n in
or c
thi
te
sd
iva
o
r
– Remove battery.
rp
cu
o
m
f
en
ng
t.
– Connect charger plug to battery charger. The last selected op
yi Co
operating mode will appear on display ⇒ page 31 .
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
Caution
cted agen
Prote AG.
Note
3. Charging battery 39
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...
Electrical System, General Information - Edition 07.2010
Note
pt
Note
du
an
itte
y li
erm
ab
charge.
spec
es, in part or in w
riod.
♦ The battery is always ready for use.
rrectness of i
nform
WARNING
mercia
at
ion
tions ⇒ page 2 !
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
WARNING
When the battery is fully charged the battery charger -VAS 5900-
switches to maintenance mode.
n AG. Volkswagen AG do
– Proceed as for charging battery ⇒ page 31 . olkswage es n
ot g
byV ua
At a charge condition of 100 % all bars appearrisin
ed display. ran
tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
3.3 Battery charger -VAS 5903-
l purpos
WARNING
nf
ercia
orm
m
atio
m
tions ⇒ page 2 !
o
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
WARNING
f
en
ng
t.
yi Co
Cop py
Batteries where the magic eye is colourless or light yellow must
t. rig
gh ht
yri by
not be checked or charged. Do not slave/jump start the vehicle! cop Vo
by lksw
cted agen
Prote
Danger of explosion when checking and charging or slave/
AG.
jump starting
These batteries must be renewed.
Note
3. Charging battery 41
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...
Electrical System, General Information - Edition 07.2010
WARNING
AG. Volkswagen AG d
agen oes
lksw not
Danger of injury! Observe
d by Vo
warning notices and safety gregula‐
ua
ran
tions ⇒ page 2 !orise tee
h
aut or
ac
ss
ce
le
un
pt
an
d
WARNING
itte
y li
rm
ab
pe
ility
wit
h re
hole
jump starting
es, in part or in w
t to the co
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
Note
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3. Charging battery 43
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...
Electrical System, General Information - Edition 07.2010
Note
ce
e
nl
pt
du
an
– Disconnect black terminal clamp „-“ of charger from negative
itte
y li
terminal.
erm
ab
ility
ot p
wit
, is n
terminal on battery.
h re
hole
spec
– Pull charger plug out of battery charger.
es, in part or in w
t to the co
3.3.3 Charging battery in refresh charge
mode with battery charger -VAS 5903-
rrectness of i
l purpos
WARNING
nf
ercia
tions ⇒ page 2 !
m
atio
om
n in
or c
thi
te
sd
iva
WARNING
r
rp
cu
o
m
f
en
ng
t.
yi
Batteries where the magic eye is colourless or light yellow must
Co
op py
not be checked or charged. Do not slave/jump start the vehicle!
t. C rig
gh ht
pyri by
Vo
Danger of explosion when checking and charging or slave/
co lksw
by
cted agen
jump starting Prote AG.
ce
le
vehicles as the voltage peaks will damage the onboard elec‐
un
pt
an
d
tronics.
itte
y li
erm
ab
If there is a requirement to use „refresh charge“ mode the bat‐
ility
ot p
tery must be disconnected from the onboard supply.
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
Caution
rrectne
type of battery ⇒ operating instructions for battery charger -
VAS 5903- !
ss
The „refresh charge“ mode is suitable for:
o
cial p
f in
♦ Wet batteries, where distilled water can be replenished.
form
mer
atio
Do not use operating mode „refresh charge“ with maintenance-
om
n
c
i
or
n thi
te
sd
iva
o
pr
c
The „refresh charge (refr)“ operating mode is only used on sus‐
um
r
fo
en
ng
Note
3. Charging battery 45
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...
Electrical System, General Information - Edition 07.2010
ce
le
un
pt
-J367- fitted, black terminal clamp must be connected to body
an
d
itte
y li
earth. Connecting it to battery negative terminal will cause start/
erm
ab
stop system to malfunction.
ility
ot p
wit
is n
h re
– Connect black terminal clamp „-“ to negative terminal.
ole,
spec
urposes, in part or in wh
The charger unit recognises the voltage required for the connec‐
t to the co
ted battery (6 V, 12 V or 24 V) and initiates the charging sequence.
rrectne
the battery charger switches to the „final charge“ mode. The fourth
bar appears in display -1-. The battery is ready for use.
ss o
cial p
f in
Note
form
mer
atio
m
n
c
i
or
n thi
te
sd
iva
o
Possible faults and fault rectification:
pr
cum
r
fo
en
ng
WARNING
WARNING
ce
le
un
pt
an
d
itte
Caution
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
battery terminals.
urposes, in part or in wh
t to the co
♦ When charging always set the battery charger to the cor‐
rect type of battery ⇒ operating instructions for battery
charger -VAS 5903- !
rrectne
♦ Totally discharged battery is not recognised by battery
charger ⇒ page 59 .
ss o
cial p
f
♦ Do not press START / STOP button when charger unit
inform
cables are connected incorrectly. The charger unit may be
mer
damaged.
atio
om
n
c
i
or
n thi
te
o
r
cum
r
fo
en
ng
3. Charging battery 47
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...
Electrical System, General Information - Edition 07.2010
Note
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
ce
le
un
pt
If a button is not pressed within 5 seconds the charger will return
an
d
itte
y li
to the main menu (select operating mode).
rm
ab
pe
ility
ot
wit
, is n
h re
hole
Then follows the enquiry for "is charger cable terminal polarity
spec
correct".
es, in part or in w
t to the co
– Check polarity of charger unit cables.
– Confirm polarity of charger unit cables with START / STOP .
rrectness of i
Charger will start charging sequence for totally discharged bat‐
l purpos
tery.
Ending battery charging sequence:
nform
ercia
a
com
tio
terminal.
thi
s
iva
do
cum
fo
terminal on battery.
en
ng
t.
yi Co
op
– Pull charger plug out of battery charger. C py
t. rig
gh ht
pyri by
Vo
co
3.3.5 Charging battery in support mode with
by lksw
cted agen
Prote AG.
battery charger -VAS 5903-
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
WARNING
WARNING
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Caution
wit
, is n
h re
♦ The terminal polarity protection in operating mode „charg‐
hole
♦ Danger of explosion
l purpos
at
om
damaged.
ion
c
in t
or
his
ate
do
riv
– Remove battery.
p
cum
for
en
g
t.
yi Co
operating mode will appear on display ⇒ page 31 . Cop py
t. rig
gh ht
pyri by
Vo
co
Caution
by lksw
cted agen
Prote AG.
Note
ce
le
hicle.
un
pt
an
d
itte
y li
– Press START / STOP for approx. 5 seconds. The menu
erm
ab
„charging totally discharged batteries/support mode“ will be
ility
ot p
activated.
wit
is n
h re
– Press respective button „Up“ ↑ or „Down“ ↓ to set respective
ole,
spec
battery voltage (6 V, 12 V or 24 V).
urposes, in part or in wh
t to the co
Note
rrectne
If a button is not pressed within 5 seconds the charger will return
to the main menu (select operating mode).
ss o
cial p
f in
– Confirm the selected battery voltage with START / STOP .
form
mer
Then follows the enquiry for "is charger cable terminal polarity
atio
om
correct".
n
c
i
or
n thi
e
sd
iva
o
pr
c
– Confirm polarity of charger unit cables with START / STOP .
um
r
fo
en
ng
t.
yi
The battery charger starts with support mode.
Co
Cop py
t. rig
gh ht
End battery support mode: yri
p by
o Vo
by c lksw
cted
– Press START / STOP .
agen
Prote AG.
Note
WARNING
3. Charging battery 51
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...
Electrical System, General Information - Edition 07.2010
WARNING
When the battery is fully charged the battery charger -VAS 5903-
switches to maintenance mode.
– Proceed as for charging battery ⇒ page 42 .
At a charge condition of 100 % all bars appear in display.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
52
Prote AG.
Rep. gr.27 - Starter, current supply, CCS
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...
Electrical System, General Information - Edition 07.2010
WARNING
ce
e
pt
du
an
itte
y li
erm
ab
Danger of explosion when checking and charging or slave/
ility
ot p
jump starting
wit
, is n
h re
These batteries must be renewed.
hole
spec
es, in part or in w
t to the co
Battery charger -VAS 5906- has been specially developed for
charging in vehicle onboard supply during vehicle presentation.
rrectness of i
It has an automatic charging characteristic for starter batteries, 3
- 300 AH.
l purpos
orm
atio
m
n in
or c
Tester starts fully automatically and does not require any settings.
thi
te
sd
a
o
r
rp
cu
o
en
ng
t.
5906 .
yi Co
Cop py
t. rig
gh ht
yri by
3.4.2 Charging battery with battery charger -
cop Vo
by lksw
cted agen
VAS 5906-
Prote AG.
WARNING
WARNING
3. Charging battery 53
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...
Electrical System, General Information - Edition 07.2010
WARNING
Note
pt
an
itte
y li
erm
wit
, is n
t to the co
Caution
at
om
battery.
on
c
in t
or
battery.
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
erm
ab
Batteries in VW vehicles are only allowed to be charged with bat‐
ility
ot p
wit
, is n
h re
hole
spec
Midtronics -INC 940- battery charger combines battery charging
es, in part or in w
t to the co
The following charging and analysis procedures apply to all bat‐
teries, all battery installation locations (engine compartment or
rrectness of i
luggage compartment) and battery application purposes (starter
battery or second/convenience battery).
l purpos
nf
ercia
o
LEDs and the operating procedures described in the ⇒ operating
rm
m
atio
om
n in
c
thi
te
sd
a
o
r
rp
cu
information.
o
m
f
en
ng
t.
yi Co
op
WARNING
C py
ht. rig
rig ht
py by
co Vo
Danger of injury! Observe warning notices and safety regula‐
by lksw
cted agen
Prote
tions ⇒ page 2 !
AG.
WARNING
3. Charging battery 55
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...
Electrical System, General Information - Edition 07.2010
WARNING
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
spec
INC 940 .
t to the co
minal on battery.
m
at
om
ion
c
in t
r
Note
o
his
ate
do
riv
cum
or
en
ng
t.
yi
earth. Connecting it to battery negative terminal will cause start/
Co
op py
stop system to malfunction.
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted
– Connect black terminal clamp „-“ of battery charger to negative
agen
Prote AG.
terminal.
– Connect Midtronics -INC 940- battery charger to an earthed
socket.
– Set „ON/OFF“ switch of Midtronics -INC 940- battery charger
to „ON“.
– Select „Automatic“ or „Manual“ charging mode.
– Select test „In vehicle“ or „Outside vehicle“.
– Select battery type „Standard “ or „AGM“ (absorbent glass
mat).
Note
pt
y li
ab
⇒ page 58 .
pe
ility
ot
wit
, is n
h re
hole
spec
WARNING
es, in part or in w
t to the co
tion in
r
thi
and test).
s
iva
do
r
rp
cum
en
ng
t.
yi Co
♦ Display last test results. Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
Note
cted agen
Prote AG.
3. Charging battery 57
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...
Electrical System, General Information - Edition 07.2010
Note
pt
du
an
– Wait until all electrical loads
itte
y li
monitored by onboard sup‐
erm
ab
ply control unit have switch‐
ility
ot p
ed off.
wit
, is n
h re
hole
t to the co
ply as standard.
l purpos
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
Solar panel VAS 6102A
erm
ab
ility
ot p
General description:
wit
is n
h re
Solar panel -VAS 6102A- supports onboard supply and prevents
ole,
spontaneous battery discharging.
spec
urposes, in part or in wh
t to the co
Solar panel -VAS 6102A- achieves max. voltage of 14.3 V and a
charging current of max. 255 mA.
Solar panel -VAS 6102A- is allowed to be used for charging all
rrectne
rechargeable lead or lead gel batteries.
Solar panel -VAS 6102A- is connected to diagnostic connection
ss o
in vehicle.
cial p
f inform
A green LED is integrated in the frame to indicate its function. The
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
– Secure solar panel -VAS 6102A- on interior mirror -1-.
pr
cum
r
fo
en
ng
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.
WARNING
3. Charging battery 59
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...
Electrical System, General Information - Edition 07.2010
WARNING
Caution
Note
AG. Volkswagen AG d
agen oes
ksw
♦ Totally discharged by
Vbatteries in vehicles before registration
ol not
gu
must be exchanged
rised prior to delivery. Preliminary damageara
nte can‐
not be excluded.
tho eo
s au ra
c
♦ Batteries that have not been used for a long period of time
s
ce
le
pt
an
d
itte
y li
ab
ility
ot
wit
, is n
spec
es, in part or in w
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
le
un
pt
an
d
y li
rm
ab
pe
ility
– Connect vehicle diagnostic tester ⇒ page 78 .
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
following menu options in succession:
♦ Drive
rrectness of i
♦ Engine code
l purpos
nform
ercia
tem
m
a
com
ti
♦ Functions
on in
r
te o
thi
♦ Activating and deactivating cruise control system (CCS)
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
90 – Gauges, instruments
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
– To loosen the connection, rotate the lock ring -1- through 90°
an
d
itte
y li
-arrow- and pull off the hose connection.
rm
ab
pe
ility
– To secure the connection, push on the hose connection and
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
a
com
tion in
thi
do
r
cum
fo
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– 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.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
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.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
spec
es, in part or in w
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
♦ Hot air blower -V.A.G 1416/- or ht. rig
rig ht
py by
o Vo
♦ Hot air blower -VAS 1978/14- by c lksw
cted agen
Prote AG.
2. Hose repair 65
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...
Electrical System, General Information - Edition 07.2010
Note
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
le
un
pt
wiper blades
an
d
itte
y li
erm
ab
Distinguishing features from Bosch and Federal Mogul.
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
Bosch wiper blades -1 and 2-:
rrectness o
cial p
f inform
mer
atio
om
n
c
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or
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te
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t.
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op
Federal Mogul wiper blades -1-:
C py
t. rig
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pyri by
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by
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Prote AG.
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an
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– If repairs are to be made to the headlight with gas discharge rm
ab
bulbs, observe the following:
pe
ility
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, is n
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hole
spec
es, in part or in w
t to the co
♦ Assembly notes for gas discharge bulbs ⇒ page 70
♦ Disposal regulations for gas discharge bulbs ⇒ page 70
rrectness of i
Special tools and workshop equipment required
l purpos
♦ Protective goggles
♦ Gloves
nform
mercia
a
WARNING
com
tion in
r
te o
thi
It is absolutely necessary to disconnect the battery earth strap
s
iva
do
r
rp
c
marked with yellow high voltage symbols.
um
fo
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t.
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Then switch dipped beam on and off again. This will eliminate
Co
op py
any possible residual voltage.
t. C rig
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pyri by
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The gas discharge lamp control unit must never be operated
o
by c lksw
cted agen
without a gas discharge lamp. Prote AG.
Due to the high voltage (above 28000 V when igniting the gas
discharge bulb) and temperatures, the gas discharge bulb
must only be operated in the headlight housing.
WARNING
♦ Never change bulbs if you are not familiar with the appro‐
priate procedures, safety precautions and tools.
WARNING
ce
e
nl
pt
du
an
itte
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erm
WARNING
ab
ility
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wit
, is n
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move ignition key.
hole
spec
es, in part or in w
t to the co
no voltage in any components, including the dissipation of
residual voltage after the headlights are switched off.
• Residual voltage can be dissipated by turning the dipped
rrectness of i
beams on and then off again after withdrawing the ignition
l purpos
key.
• When working on the headlight system, ensure that the
nform
ercia
at
om
ion
c
in t
or
his
ate
do
priv
c
WARNING
um
for
en
ng
t.
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op
• The bulbs may be operated in the headlight housing only C py
ht. rig
(protection against contact due to very hot bulbs, absorp‐ rig ht
py by
tion of UV radiation, avoidance of dazzling light, protection
co Vo
by lksw
cted
against explosion).
agen
Prote AG.
WARNING
Caution
ce
le
un
pt
would vaporise the oil of the finger prints which would then
an
d
itte
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erm
ab
headlight.
ility
ot p
wit
♦ A light bulb must always be renewed with a bulb of the
is n
h re
same sort. The designation appears on the base of the
ole,
spec
urposes, in part or in wh
t to the co
♦ Properly engage connectors during installation and en‐
sure tight seating of the connection.
rrectne
Disposal regulations for gas discharge bulbs
ss o
cial p
f
WARNING
inform
mer
atio
m
n
c
i
or
n
tional waste.
thi
te
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o
pr
cum
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ng
t.
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• These components must be recycled in accordance with Cop py
national law.
t. rig
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pyri by
Vo
o
• Dispose of only in containers intended for this purpose at
by c lksw
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an authorised collection point.
Prote AG.
Caution
pt
du
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ab
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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m
f
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ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. 12 V socket 71
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...
Electrical System, General Information - Edition 07.2010
ce
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nl
pt
du
an
itte
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erm
ab
with the puller T 40148.
ility
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, is n
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sockets without illuminated retaining sleeve.
hole
spec
Usually sockets without illumination cannot be removed with‐
es, in part or in w
t to the co
rrectness of i
2.1 General description
l purpos
Caution
nf
ercia
or
If excessive force is exerted on sockets without illumination,
m
m
atio
the retaining sleeve may be damaged.
om
n in
or c
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rp
cu
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f
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ng
Caution
ce
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un
pt
an
d
itte
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Usually sockets without illumination cannot be removed with‐
erm
ab
out being damaged.
ility
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is n
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ole,
spec
urposes, in part or in wh
t to the co
wiring tail
2 - Cigarette lighter
rrectne
3 - Socket
s
4 - Cigarette lighter socket
s o
cial p
f in
5 - Retaining sleeve
form
mer
n
c
7 - Bulb carrier
i
or
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te
sd
iva
o
pr
cum
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fo
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ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Cigarette lighter U1 73
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...
Electrical System, General Information - Edition 07.2010
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
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
s c
Removing s
ce
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nl
pt
du
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socket if necessary.
erm
ab
ility
ot p
wit
, is n
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Note
hole
spec
es, in part or in w
Caution
rrectness of i
l purpos
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
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f
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ng
t.
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Cop py
t. rig
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yri by
74
cop Vo
by lksw
Rep. gr.96 - Lights, bulbs, switches - interior Prote
cted AG.
agen
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...
Electrical System, General Information - Edition 07.2010
– Push puller -arrow- into socket so that locking lugs -1- engage
in recesses -2-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
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wit
is n
h re
ole,
spec
– Pull grip -3- in direction of -arrow- to release locking lugs of
urposes, in part or in wh
retaining sleeve.
t to the co
– Pull socket out of retaining sleeve using puller.
rrectne
Caution
ss
The socket wiring can be damaged.
o
cial p
f in
Take care not to stretch the wiring when pulling out the socket.
form
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
r
cum
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fo
en
ng
t.
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Cop py
ht. rig
Caution rig ht
py by
co Vo
by lksw
cted agen
When using the thrust piece, ensure that no surrounding com‐
Prote AG.
Note
2. Cigarette lighter U1 75
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...
Electrical System, General Information - Edition 07.2010
Note
Caution
ce
together and check if the cigarette lighter remains in the re‐ e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
– Check if cigarette lighter remains in removal position after
es, in part or in w
t to the co
Installing
Install in reverse order of removal.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
e
sd
iva
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cu
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f
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ng
t.
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Cop py
t. rig
Note
gh ht
pyri by
Vo
co lksw
by
cted agen
♦ On some vehicles, the illumination is not provided by a light
Prote AG.
Removing:
– Remove socket ⇒ page 74 .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
– Remove light bulb in direction of -arrow-.
e
nl
pt
du
an
itte
Installing:
y li
erm
ab
ility
Installation is carried out in reverse order of removal.
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Cigarette lighter U1 77
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...
Electrical System, General Information - Edition 07.2010
97 – Wiring
1 Vehicle diagnostic, testing and infor‐
mation systems
WARNING
pt
du
y li
ab
ility
ot p
h re
hole
♦ Additional information
spec
es, in part or in w
t to the co
atio
n in
or c
thi
te
sd
iva
Note
o
r
rp
cu
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m
f
en
ng
t.
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Observe the latest operating instructions for vehicle diagnostic
Co
op py
tester , which are displayed after selecting the „Administration“ t. C rig
gh ht
and „Operating Manual“ keys. pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Special tools and workshop equipment required
only ones fitted with CAN wiring and therefore allowing CAN di‐
un
pt
an
d
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erm
ab
ility
ot p
h re
– Apply handbrake.
ole,
spec
urposes, in part or in wh
-arrow- in vehicle.
cial p
f inform
– Switch on ignition.
mer
atio
m
n
c
i
or
n thi
te
sd
va
Note
i
o
pr
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fo
en
ng
t.
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All other and the following vehicle diagnostic, testing and infor‐
Co
op py
mation systems or vehicle diagnostic and service information
t. C rig
gh ht
systems are connected accordingly in the sequence described
pyri by
Vo
co
above.
by lksw
cted agen
Prote AG.
Note
All other and the following vehicle diagnosis, testing and informa‐
tion systems or vehicle diagnostic and service information sys‐
tems are connected accordingly in the sequence described
above.
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byV ua
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u or
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ss
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an
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itte
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ab
ility
ot p
wit
is n
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ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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o
pr
cum
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fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
Note
wit
is n
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ole,
Additional information:
spec
urposes, in part or in wh
t to the co
⇒ Operating instructions Wiring harness repair set -VAS 1978-
rrectne
Upgrade kit -VAS 1978/50- is required to bring the „old“ wiring
ss
harness repair set -VAS 1978- up to the latest standard of wiring
o
cial p
f
harness repair set -VAS 1978A- . The upgrade kit comprises of 4
inform
assembly and 10 release tools, a new set of crimping pliers for
mer
atio
m
1978/1-1- , 4.0 - 6.0 mm2 -VAS 1978/2 A- and head adapter for
o
n
c
i
or
JPT contacts -VAS 1978/9-1- . Also included are new stickers, a n thi
e
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cum
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fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
Additional information:
ce
le
un
pt
an
d
itte
Release tool set -VAS 1978/35- serves as a means of releasing
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erm
ab
various primary and secondary locking devices in Group vehicles.
ility
ot p
The set comprises of 26 different tools with which, for example,
wit
is n
round connector systems, flat contacts with one or two fasteners
h re
ole,
and also single wire seals can be released or fitted.
spec
urposes, in part or in wh
Allocation of the correct release tool to the respective locking de‐
t to the co
vices can be gleaned from the table in the ⇒ operating instruc‐
tions of -VAS 1978/35- .
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
2.2.1 Special pliers with insert
iva
o
pr
cum
r
fo
The special pliers without insert -VAS 1978/1- with insert for spe‐
en
ng
t.
yi Co
cial pliers -VAS 1978/2- is part of the wiring harness repair set - Cop py
VAS 1978- and is used to crimp connectors during wiring harness
t. rig
gh ht
yri
repairs.
p by
o Vo
by c lksw
cted agen
Prote
Colour of crimp Colour of crimp re‐ Wiring cross section
AG.
connector cess
Yellow Yellow. 0.35 mm2
Red Red. 0.5 mm2 - 1.0 mm2
Blue Blue 1.5 mm2 - 2.5 mm2
Yellow. Yellow. 4.0 mm2 - 6.0 mm2
Note
WARNING
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
The assembly tools serve as a means of sliding the single wire
, is n
h re
seals fully into the contact housing without damage and thereby
hole
spec
assure complete sealing between single wire and contact hous‐
es, in part or in w
ing.
t to the co
Four assembly tools for single wire seals are included in each
wiring harness repair set -VAS 1978 B- and previous versions.
rrectness of i
Assembling single wire seals ⇒ page 99 .
l purpos
nform
mercia
a
com
tion in
r
te o
do
r
rp
en
t.
yi Co
op py
Wire strippers -VAS 1978/3- are included in wiring harness repair
. C rig
ht ht
rig
set -VAS 1978 B- and previous versions. py by
co Vo
by lksw
cted agen
The wire strippers have an adjustable limit stop within the pliers Prote AG.
jaws, with which the desired length of insulation to be removed
can be adjusted.
Stripping:
– Adjust the sliding limit stop in the pliers jaws to the desired
length of insulation to be removed.
– Insert the end of the wire from the front fully into the pliers jaws
and squeeze the pliers together completely.
– Open the pliers and removed the stripped wire end.
– Cut the wire if necessary with the cutting part on the upper side
of the wire strippers.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
2.2.5 Hot air blower, 220 V / 50 Hz -VAS
ot p
wit
is n
1978/14-
h re
ole,
spec
urposes, in part or in wh
t to the co
Caution
rrectne
plastic parts or insulating material with the hot air blower.
Observe the operating instructions of the hot air blower without
ss
fail!
o
cial p
f inform
mer
atio
m
junction with shrink element for hot air blower -VAS 1978/15- to
o
n
c
i
or
n
shrink fit the crimp connectors. After crimping, the crimp connec‐
thi
te
tor has to be shrink fitted using the hot air blower in order to
sd
iva
o
prevent any ingress of moisture.
pr
cum
r
fo
en
ng
t.
yi Co
Hot air blower, 220 V/50 Hz -VAS 1978/14- is included in wiring Cop py
harness repair set -VAS 1978 B- and previous versions.
t. rig
gh ht
pyri by
Vo
co
Shrink fitting crimp connectors using hot air blower, 220 V / 50 Hz
by lksw
cted agen
Prote
-VAS 1978/14- ⇒ page 94 , or ⇒ page 96 .
AG.
– Unclip both locking pins -arrows- from the body of the crimping
pliers.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
– Insert the required head adapter from above -arrow- in the
an
itte
y li
body of the crimping pliers.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
body of the crimping pliers.
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Caution
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.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
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tho
u or
a ac
ss
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
and wiring with cross sections up to 0.35 mm2 ⇒ page 91 .
le
un
pt
an
d
itte
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erm
ab
for the fault memory to be interrogated, erased and/or for the
ility
ot p
systems to be reset.
wit
is n
h re
♦ If possible, do not loosen any earth wires from the body (dan‐
ole,
spec
ger of corrosion).
urposes, in part or in wh
t to the co
♦ Wiring harness repair set -VAS 1978 B- and previous versions
do not cover all wiring cross sections that occur in the vehicle.
If the required wiring cross section is not available, the next
rrectne
largest one should be used.
♦ Screened wires must not be repaired. If damaged they must
s
be replaced complete.
s o
cial p
f in
i
or
n thi
te
sd
va
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
Note ht. rig
rig ht
py by
co Vo
by lksw
Observe the general notes on repairs to the vehicle electrical
cted agen
Prote AG.
system ⇒ page 85 .
ce
sioner wiring e
nl
pt
du
an
itte
y li
In addition to the general notes on repairs to wiring harnesses,
erm
ab
ility
the following instructions must be observed on how to repair wir‐
ot p
wit
, is n
h re
hole
spec
WARNING
es, in part or in w
t to the co
♦ Airbag and seat belt tensioner can fail.
♦ Faulty repairs to the airbag and seat belt tensioning sys‐
rrectness of i
tem can cause malfunctions in the passenger protection
l purpos
system.
♦ For repairs to airbag and belt tensioner wiring harnesses,
nform
ercia
at
(ETKA) .
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
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
♦ Repairs in the area
lksw
ofenthe
ag
A
airbag ornbelt
AG dotensioner should not
es n
be more than y V30 cm from the next contact housing.
o ot g
ua Together
db
with theoryellow
ise insulating tape, this gives a clearraindication
nte of
repairs
auth that have already been carried out. eo
r a
ss c
♦ The wires to the triggering units (airbags) are entwined as
ce
e
nl
an
y li
erm
wit
, is n
have the same length. When wires -1- and -2- are entwined,
spec
t to the co
fail.
♦ There must not be any section of wiring, for example in the
vicinity of crimp connectors -arrow-, longer than B = 100 mm
rrectness of i
orm
m
In the event of repairs, the entire fibre optic wiring harness must
o
n in
or c
observed:
t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi
Note
Co
Cop py
t. rig
gh ht
yri
♦ Avoid sharp bends in the fibre optic cable; the bend radius
p by
co Vo
by lksw
should be no tighter than 25 mm. Prote
cted AG.
agen
ce
le
the following table:
un
pt
an
d
itte
y li
Powertrain CAN, high wire Orange/black
erm
ab
ility
ot p
Convenience CAN, high wire Orange/green
wit
is n
h re
Infotainment CAN, high Orange/violet
ole,
spec
CAN low wire, (all) Orange/brown
urposes, in part or in wh
t to the co
♦ Repairs to CAN bus wiring can be carried out either with sec‐
tions of repair wiring with the correct cross section or with
entwined wires „green/yellow“ or „white/yellow“ from the elec‐
rrectne
tronic parts catalogue (ETKA) ⇒ Electronic parts catalogue
(ETKA) .
ss
♦ When repairs are performed, both bus wires must have the
o
cial p
f i
same length. When twisting the wires -1- and -2- together, the
nform
length of each complete twist must be A = 20 mm.
mer
atio
m
n
c
i
vicinity of crimp connectors -arrow-, longer than B = 50 mm
or
n thi
e
sd
iva
o
pr
c
♦ Mark the area of repair with yellow insulation tape to make it
um
r
fo
en
ng
easy to identify.
t.
yi Co
Cop py
t. rig
gh
2.4.4 Renewal of aerial wiring
ht
pyri by
Vo
o
by c lksw
cted agen
Prote
A new repair concept has been developed for repair work on aer‐
AG.
ce
le
un
pt
an
d
itte
Note
y li
rm
ab
pe
ility
Note that the total length of an aerial wire, depending on vehicle
ot
wit
, is n
h re
control unit, traffic information control unit or aerial amplifier. Only
hole
spec
the defective section of aerial wire must be replaced.
es, in part or in w
t to the co
– Pull defective aerial wire connections off units.
– Determine the routing of the defective aerial wire in vehicle
rrectness of i
and measure the total length of the aerial connecting wire to
l purpos
be replaced.
The total length of aerial connecting wire is the sum of the length
nform
ercia
of adapter cables required -1- and -3- and the connecting wire
m
-2-.
a
com
tion in
– To determine the length of connecting wire required, subtract
r
te o
thi
60 cm from the measured total length of aerial connecting wire
s
iva
do
-2-.
r
rp
cum
fo
en
g
– Procure the required adapter cables -1- and -3- and connect‐
n
t.
yi Co
ing wire -2- at length calculated as genuine part from the . Cop py
Electronic parts catalogue (ETKA).
t rig
gh ht
pyri by
Vo
co
– Cut off connectors of defective aerial wire.
by lksw
cted agen
Prote AG.
The remainder of the defective aerial wire remains in the vehicle.
– Connect adapter cables -1- and -3- to equipment in vehicle.
– Route and attach the connection line -2- in the immediate vi‐
cinity of the factory routing.
Note
pt
du
Note
an
itte
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erm
ab
ility
contacts. The repair contact must always be the same type as the
wit
, is n
h re
spec
es, in part or in w
Note
nform
mercia
at
When doing this, the small diameter of the single wire seal must
om
io
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or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Open the crimping pliers and insert the end of the repair wire
in the opening of the crimping pliers for wire stripping.
olkswagen AG
en AG. V
– Push the single wire seal towardsolkthe
swastripped wire end until
g does
itnot
is flush with the wiring insulation.
ed by V gu
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ss
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un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
pliers.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Insert the stripped wire end with the positioned single wire seal
in the crimp contact until it comes into contact with the „wire
stop“.
– Crimp the contact, wire and single wire seal by closing the
crimping pliers fully.
– Open the crimping pliers again and remove the successfully
crimped contact.
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
tion
Repair position with single crimp connector
rrectne
– Place the wire to be repaired to one side (about 20 cm either
side of the repair position). ss o
cial p
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
– Cut out the damaged piece of wiring using the wire strippers -
p by
o Vo
by c lksw
VAS 1978/3- . Prote
cted AG.
agen
Note
If, after the damaged wire has been cut out, both ends of the ve‐
hicle's own wiring are too short for a repair using single crimp
connectors, use a piece of repair wire of the appropriate length
with two crimp connectors ⇒ page 96 .
– Strip the wire ends of insulation by 6 - 7 mm using the wire wagen AG. Volkswagen AG doe
strippers. yV
olks s no
t gu
b ara
ed nte
oris e
th or
au ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
urposes, in part or in wh
t to the co
– Push the crimp connector on both stripped wire ends of the
vehicle's own single wire and crimp it on using the crimping
rrectne
pliers.
ss o
Note
cial p
f inform
mer
♦ Ensure without fail that the correct crimp recess is chosen for
atio
m
n
c
i
or
n
♦ The insulation on the wires must not be crimped.
thi
te
sd
iva
o
pr
cum
After crimping, the crimp connector has to be shrink fitted using
r
fo
en
ng
Caution
Note
ce
le
un
pt
an
d
2.4.7 Wiring open circuit with two repair posi‐
itte
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erm
ab
tions
ility
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spec
– Place the wire to be repaired to the side at two points (about
urposes, in part or in wh
t to the co
– If necessary, unbind the wiring harness using the folding knife.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
e
– Place the yellow repair wire next to the damage wiring harness
t
sd
va
and, using wire strippers -VAS 1978/3- , cut the repair wire to
i
o
pr
cum
the required length.
r
fo
en
ng
t.
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– Cut the damaged section of wire out of the vehicle's own single Cop py
wire.
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
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.
– 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
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un
pt
an
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Note
erm
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ility
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♦ Ensure that, where several wires have to be repaired, the
is n
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crimp connectors are not directly adjacent to each other. To
ole,
spec
prevent the circumference of the wiring harness from becom‐
urposes, in part or in wh
t to the co
slightly.
♦ If the repair position was already wrapped, this section has to
rrectne
be wrapped again with yellow insulation tape once the repair
has been carried out.
s
♦ Attach the repaired wiring harness with a cable tie, if neces‐
s o
cial p
f
sary, to prevent it from generating noise when the vehicle is in
inform
motion.
mer
atio
om
n
c
n thi
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nectors
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op py
2.5.1 Notes on repairs to contact housings
t. C rig
gh ht
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and connectors
op Vo
by c lksw
cted agen
Prote AG.
Note
– Push the new contact of the repair wire into the contact hous‐
ing until it engages.
– Slide the single wire seal onto the repair wire.
Note
The small diameter of the single wire seal must face the contact
housing.
– Slide the single wire seal into the contact housing using the
correct assembly tool ⇒ page 99 .
– Trim the repair wire and the single wire of the vehicle's own
wiring harness accordingly using wire strippers -VAS 1978/3- .
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
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aut ra
ss c
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un
pt
an
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ab
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and the vehicle's own single wire using the wire strippers.
ot
wit
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h re
– Crimp the stripped ends of the repair wire and single wire of
hole
spec
the vehicle's own wiring harness using the crimping pliers and
es, in part or in w
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
Note
pt
fore first be pushed onto the wire.
an
d
itte
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erm
ab
♦ It is essential that the single wire seals are of the correct size
ility
to fit the cross section of the repair wire. The outer diameter
ot p
wit
h re
contact housing. Only carry out the repair using the correct
ole,
spec
assembly tool.
urposes, in part or in wh
t to the co
priate release tool -A- and then pull the wire with the single
wire seal backwards -arrow- out of the contact housing.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Cut off the old contact with the single wire seal from the vehi‐
cle's own wiring harness.
– Slide the repair wire with the new contact in the respective
socket of the contact housing until it engages.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
– Place the single wire seal -A- on the free end of the repair wire.
t to the co
Note
rrectness of i
The small diameter of the single wire seal must face the contact
l purpos
housing.
nf
ercia
– Slide the single wire seal -A- on the repair wire until it reaches
rm
m
n in
or c
thi
te
sd
iva
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cu
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– Slide the single wire seal -A- using the respective assembly
m
f
en
ng
t.
tool -B- fully into the contact housing.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Trim the repair wire and the single wire of the vehicle's own
wiring harness accordingly using wire strippers -VAS 1978/3- .
– Crimp the stripped ends of the repair wire and single wire of
the vehicle's own wiring harness using the crimping pliers and
a crimp connector, as described in the chapter entitled „Wiring
open circuits with one repair position“ ⇒ page 94 .
Note
♦ For technical reasons, the contact housings for cut and clamp
AG. Volkswagen
technique can only be supplied with the cut
kswand clamp con‐
agen AG do
es n
tacts inserted. y Vol ot g
ua
db e ran
ris tee
♦ These contacts can be removed
ut just like any other contact
ho or
housing if they are not needed.
ss
a ac
ce
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pt
an
d
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
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e
nl
pt
du
an
itte
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Note
erm
ab
ility
ot p
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, is n
system ⇒ page 85 .
h re
hole
spec
♦ To release, always use the correct release tools. Under no
es, in part or in w
t to the co
housings with force.
♦ Damaged contact housings must always be replaced. New
rrectness of i
contact housings can be ordered from the OTC in Kassel.
l purpos
nform
ercia
at
om
ing.
ion
c
in t
or
his
ate
do
priv
c
Fitting locations.
um
for
en
ng
t.
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op
Allocation of the correct release tool to the respective locking de‐ C py
t. rig
vices can be gleaned from the table in the ⇒ operating instruc‐
gh ht
pyri by
tions of -VAS 1978/35- .
o Vo
by c lksw
cted agen
Prote AG.
2.6.2 Secondary locking element
The secondary locking mechanism is a housing catch (second
line locking mechanism) that secures all the wires in one contact
housing. If a secondary locking mechanism is fitted to a contact
housing, this must always be opened or removed using the ap‐
propriate tool before releasing and pulling out individual crimp
contacts.
The secondary locking mechanism is different in colour from the
rest of the contact housing. This makes it easier to identify the
secondary locking mechanism and clarifies its intended function.
The types of contact housing shown here are just a few examples
to show the different functions of secondary locking mechanism.
Example 1:
The housing catch is disengaged by removing a „toothed ele‐
ment“ -arrow-.
Example 2:
The housing catch is disengaged by opening a „flap“ -arrow-.
Example 3:
The housing catch can be disengaged by detaching a „slide“
-arrow-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
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un
pt
an
d
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rm
ab
ility
ot
wit
, is n
locking mechanism.
♦ Round connector systems ⇒ page 103
nform
ercia
a
com
tio
thi
do
cum
fo
of -VAS 1978/35- .
en
ng
t.
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op
2.6.4 Round connector systems
C py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote
Note
AG.
Note
– 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.
ce
e
pt
du
ab
ility
ot p
wit
, is n
spec
– Grab hold of the contact by the wire and push it lightly into the
contact housing -arrow-.
rrectness of i
l purpos
Note
nf
locking tab of the contact is lifted up by the housing edge and can
rm
m
atio
n in
or c
thi
te
sd
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m
f
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ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
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nl
pt
du
an
– At the same time, push the release tool in the direction of the
itte
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contact housing and pull out the released contact from the
erm
ab
ility
contact housing -arrow-.
ot p
wit
, is n
– The release tool can be pulled out of the contact housing again
h re
hole
once the contact has been removed.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Flat connector with two locking tabs:
m
at
om
i
– Insert the release tool appropriate for the contact housing in
on
c
in t
or
his
ate
– Grab hold of the contact by the wire and push it fully into the
do
priv
c
contact housing -arrow-.
um
for
en
ng
t.
yi Co
Cop py
. rig
Note
t
gh ht
pyri by
Vo
co lksw
by
cted
By pushing the contact in the direction of the contact housing, the
agen
Prote AG.
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 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
– 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.
n AG. Volkswagen AG do
Note lks wage es n
o ot g
byV ua
d ran
ir se
If necessary, any housing catches tho in place (secondary locking tee
or
mechanisms) must be released ss
auor removed prior to disengaging ac
the contacts using the prescribed tool ⇒ page 102 .
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le
un
pt
an
d
itte
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Faston contacts:
rm
ab
pe
ility
– Insert the release tool appropriate for the contact housing in
ot
wit
the release port of the contact housing.
, is n
h re
hole
– Grab hold of the contact by the wire and push it lightly into the
spec
contact housing.
es, in part or in w
t to the co
Note
By pushing the contact in the direction of the contact housing, the rrectness of i
l purpos
locking tabs of the contact are lifted up by the housing edge and
disengaged using the release tool.
nform
mercia
– At the same time, push the release tool in the direction of the
com
tion in
contact housing and pull out the released contact from the
r
te o
thi
do
r
– The release tool can be pulled out of the contact housing again
rp
cum
fo
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
GT 150/280 contacts:
– Insert the release tool appropriate for the contact housing un‐
der the locking tab into the contact housing.
– Push the tool onto the limit stop -arrow- in the contact housing.
AG. Volkswagen AG d
agen oes
olksw not
The contact is ejected from the contact housing.
d by V gu
ara
rise nte
o
– The release tool can be pulled outauof
t the contact housing again
h eo
ra
once the contact has been ejected.
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Contacts without locking tabs:
l purpos
– Insert the release tool under the locking tab of the contact
housing.
nform
ercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
The contact is ejected from the contact housing.
co lksw
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cted agen
Prote AG.
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Note
un
pt
an
d
itte
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erm
ab
ility
work.
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wit
is n
h re
ole,
t to the co
rrectnes
f inform
atio
♦ VAG 1331
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
WARNING
– 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
Caution
Take care not to abrade excessively the tin coating and ensure
that the copper does not appear. This could produce a galvanic
cell which destroys metal and causes faulty repair.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
Note ise
d b ara
nte
or eo
th
u ra
As the thickness
ss a
of the tin coating may differ according to the de‐ c
sign, the cleaning process must be performed step by step and a
ce
e
nl
pt
du
y li
erm
ab
ility
ot p
– Insert adapter into ring terminal and grind off corrosion and dirt
wit
, is n
spec
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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m
f
en
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t.
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Cop py
t. rig
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Vo
co lksw
by
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Prote AG.
Note
ce
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nl
pt
tions ⇒ page 2 !
du
an
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erm
ab
ility
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nals.
hole
spec
es, in part or in w
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3.1.2 Repairing threaded connections
Special tools and workshop equipment required
rrectness of i
♦ VAG 1331
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
WARNING
– Disconnect battery.
– 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.
Note
pt
du
WARNING
an
itte
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erm
ab
tions ⇒ page 2 !
wit
, is n
h re
hole
spec
t to the co
minal
Special tools and workshop equipment required
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
111
cted agen
Prote AG.
3. Contact surface cleaning set VAS 6410
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
lkswagen AG
does
hibited since the missing adhesion in the threads may causebyaVolk not
gu
torque excess and, therefore, the break of the threaded connec‐
ris
ed
ara
nte
tion. ut
ho eo
ra
a c
ss
ce
e
nl
pt
du
WARNING
an
itte
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erm
ab
ility
Danger of injury! Observe warning notices and safety regula‐
ot p
tions ⇒ page 2 !
wit
, is n
h re
hole
spec
es, in part or in w
– Disconnect battery.
t to the co
– Check battery clamp and battery terminal for corrosion or dirt.
– Clean battery clamp using wire brush of battery terminal clean‐
rrectness of i
er with circular movements.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
WARNING
ce
le
un
pt
an
d
itte
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Note
rm
ab
pe
ility
ot
wit
Optimum contact is ensured when the components to be secured
, is n
h re
are tightened to the specified torque after cleaning.
hole
spec
es, in part or in w
t to the co
3.1.4 Anti-corrosion treatment
rrectness of i
Caution
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a
com
tion in
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te o
Note
thi
s
iva
do
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cum
en
g
que.
n
t.
yi Co
Cop py
♦ Always use hose supplied with anticorrosive agent tin.
ht. rig
rig ht
py by
o Vo
♦ Use protection wax for cold area.
by c lksw
cted agen
Prote AG.
♦ Use cavity sealing agent for warm area.
♦ The sealing agent independently reaches the respective
points through capillary action.
– Hold injector below ring terminal and spray pin all around.
– Hold injector above ring terminal and spray pin and wiring eye
all around.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
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a ac
ss
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un
pt
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rm
ab
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ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
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thi
s
iva
do
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cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
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 .
Note
n AG. Volkswagen AG do
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tho
u or
a ac
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
Note
AG. Volkswagen AG d
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♦ If necessary, replace attachment parts,
yV
olkcable
sw ties or marking not
gu
rings to match the uniform probeiseto
d b the defective probe as ara
nte
specified. thor eo
u ra
sa c
♦ The wires should not be crimped
s or cut as otherwise the func‐
ce
e
pt
du
an
itte
y li
erm
ab
– Place both Lambda probes next to each other so that the sen‐
wit
, is n
h re
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
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e
nl
pt
du
an
itte
y li
erm
ab
4.3 Types of protective tube on uniform
ility
ot p
wit
Lambda probes
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
tube can also be used as a means of identification.
l purpos
nf
ercia
orm
m
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Only used on 4-pin LSF Lambda probes and 6-pin LSU Lambda
probes.
Type D4, 12 openings at 1.4 mm each
Only used on 4-pin LSF Lambda probes and 6-pin LSU Lambda
probes.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
118
cop Vo
by lksw
Rep. gr.97 - Wiring Prote
cted AG.
agen