K0059101320-Electrical System General Information

Service
Workshop Manual
Ameo 2017 ➤ , Arteon 2018 ➤ ,
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CC 2012 ➤ , Eos 2006 ➤ , Golf 1998 ➤ ,
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Service Department. Technical Information

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Electrical System, General Information
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
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92 - Windscreen wash/wipe system
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94 - Lights, bulbs, switches - exterior
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96 - Lights, bulbs, switches - interior
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Technical information should always be available to the foremen and mechanics,

because their careful and constant adherence to the instructions is essential to
ensure vehicle road-worthiness and safety. In addition, the normal basic safety
precautions for working on motor vehicles must, as a matter of course, be
observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2018 Volkswagen AG, Wolfsburg K0059101320

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All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2018 Volkswagen AG, Wolfsburg K0059101320

Ameo 2017 ➤ , Arteon 2018 ➤ , Atlas 2017 ➤ , Bora 1999 ➤ , Bora Varian ...
Electrical System, General Information - Edition 01.2018
Contents
27 - Starter, current supply, CCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Fundamentals for batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Types of batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Warning notices and safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Battery terminal connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Checking battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Checking the various types of batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Information about battery replacement and battery gas venting . . . . . . . . . . . . . . . . . . . . 8
2.4 Checking colour indicator in battery cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5 Battery tester with printer VAS 6161 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.6 Midtronics MCR340V battery tester only for USA/Canada vehicles . . . . . . . . . . . . . . . . . . 16
2.7 Current draw test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3 Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.1 Battery charger VAS 5095 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.2 Battery charger VAS 5900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.5 Battery charger VAS 5908 . . . . . . . . . . . . . . . . . . . . .w.ag. e.n.A.G.. V . o. lk. s.w.a.g.en. A. G. d. o.e. . . . . . . . . . . 55
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3.6 Midtronics INC 940 battery charger only for USA/Canada by
Vol
. . . . . . . . . . . . . . . . .no.t .gu. a. . . . . . 64
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3.7 Solar charger module VAS 6102B . . . . . .o.ris.e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . a. n.te.e . . 68
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3.8 Totally discharged batteries . . . . . . . . .s a.u. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .r a.c 69
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4 Cruise control system (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
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4.1 Activating and deactivating cruise control system (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . . 71
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90 - Gauges, instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
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92 - Windscreen wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
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1 Washer fluid line hose couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
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1.1 Windscreen and rear window washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.2 Headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2 Hose repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
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2.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
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2.2 Repairing smooth pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

2.3 Repairing corrugated pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 nf
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3 Distinguishing features of jointless wiper blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
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94 - Lights, bulbs, switches - exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

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1 Operation and safety notes for gas discharge lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

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96 - Lights, bulbs, switches - interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

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1 12 V socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
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1.1 Removing and installing 12 V socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pyri
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1.2 Removing and installing socket illumination bulb L42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
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2 Cigarette lighter U1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2.2 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2.3 Removing and installing cigarette lighter socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.4 Removing and installing cigarette lighter illumination bulb L28 . . . . . . . . . . . . . . . . . . . . . . 86
97 - Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Contents i
1 Vehicle diagnosis, testing and information systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

1.1 Connecting vehicle diagnostic tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.2 Connecting vehicle diagnostic tester Golf Model Year 1998 - 2003 . . . . . . . . . . . . . . . . . . 90
2 Repairs to wiring harnesses G. Volkswagen A.G.d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.2 Wiring harness hrepair
oris set . . . . . . . . . . . . . . . . . . . . . . . . .nt.ee. . . . . . . . . . . . . . . . . . . . . . . . 94
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2.3 Tool descriptions
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2.4 Repairs to wiring harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
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2.5 Repairs to fibre optic cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
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2.6 Repair of aerial wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
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2.7 Repairs to contact housings and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
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2.8 Releasing and dismantling contact housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
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3 Contact surface cleaning set VAS 6410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
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3.1 Using contact surface cleaning set VAS 6410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
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4 Renewing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
4.1 Renewing LSF Lambda probe (4-pin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
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4.2 Renewing LSU Lambda probe (6-pin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
4.3 Types of protective tube on uniform Lambda probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
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ii Contents
27 – Starter, current supply, CCS

1 Battery
(VRL011357; Edition 01.2018)
WARNING
Danger of injury! Observe warning notices and safety regula‐

tions ⇒ page 3 !
Caution
To prevent damage to the battery or vehicle, read the informa‐

tion about the types of battery ⇒ page 1 .
1.1 Fundamentals for batteries

To ensure long use of the battery, the battery must be checked,
serviced and maintained according to the specifications in this
manual.
Apart from supplying energy for starting the engine, the battery
has other tasks: it acts as a buffer and supplies electrical energy
to the complete electrical on-board supply of the vehicle.
1.2 Types of lkbatteries

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The description for the following batteries is for maintenance-

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free batteries. No stickers may be removed and do not replen‐

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ish with distilled water. Only perform a visual check. Refer to

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1.2.1 Battery with »standard« colour indicator

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

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WARNING
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It is not permissible to test or charge batteries whose colour

indicator is light yellow. Do not slave/jump start the vehicle!
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Danger of explosion when checking and charging or slave/

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These batteries must be renewed.

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This battery is equipped with a colour indicator. The colour indi‐
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1. Battery 1
1.2.2 Battery with »enhanced« colour indica‐

tor
This is a maintenance-free battery with liquid electrolyte (wet bat‐
tery).
Caution
No stickers may be removed and do not replenish with distilled

water. Only perform a visual check. Refer to chapter, Checking
battery ⇒ page 6 .
WARNING
It is not permissible to test or charge abatteries

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The battery is used for particular requirements in certain vehicles
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equipped with a start/stop system. The battery can be identified
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An “EFB” battery may only be replaced with another “EFB” bat‐

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The “EFB” battery has a colour indicator to enable the electrolyte rrectness of i
level to be checked.
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Checking the colour indicator ⇒ page 9

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1.2.3 Absorbent glass mat battery

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Maintenance-free battery with a contained electrolyte and no col‐
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Lead-acid battery where the electrolyte is contained within a mi‐
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croscopic glass mat (AGM). The battery is sealed and fitted with
valves.
AGM is the abbreviation for Absorbent Glass Mat.
Due to containment of the electrolyte, this type of battery cannot
have a colour indicator. Absorbent glass mat batteries are iden‐
tified by the abbreviation AGM on the battery.
Note
Always replace an absorbent glass mat battery with another ab‐

sorbent glass mat battery.
2 Rep. gr.27 - Starter, current supply, CCS

1.3 Warning notices and safety regulations

⇒ “1.3.1 Dangers when handling vehicle batteries”, page 3
⇒ “1.3.2 Safety markings on battery”, page 4
⇒ “1.3.3 Working on airbag system”, page 4
1.3.1 Dangers when handling vehicle batter‐

ies
Recognition and avoidance of dangers
Batteries can be dangerous. These dangers can be avoided when
the warnings on the battery, in the operating manual and in ELSA
are observed.
WARNING
♦ Untrained personnel e.g. apprentices and trainees, may

only work on batteries when supervised by a trained spe‐
cialist such as a vehicle mechanic/foreman or vehicle
electrician/foreman.
♦ Acid is highly corrosive. There is a considerable danger of
acid burns if personnel do not handle batteries correctly.
Therefore suitable measures must be taken to ensure that
equipment/solutions etc. are available to neutralize acid
burns. A suitable solution is: e.g. a soap solution.
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♦ If electrolyte leaks from a battery it may cause skinyV
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♦ The gas which forms when charging ands the gas which
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♦ Batteries whose magic eye shows light yellow must be re‐
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♦ It is prohibited to cause sparks through grinding, welding,
cutting operations and use naked lights in the vicinity of
batteries. Smoking is also prohibited. Sparks generated rrectness of i
by electrostatic charging must also be avoided. Always
touch the vehicle body before touching the battery.
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♦ Only work on batteries in well ventilated and suitable

rooms.
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1. Battery 3
1.3.2 Safety markings on battery

Safety markings on battery
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2. - Wear eye protection before commencing
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3. - Keep children away from acid and batteries.
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4. - Disposal: old batteries are classed as hazardous waste. They
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may only be disposed of through a suitable collection centre and
ot
wit
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only in accordance with respective legislation.
h re
hole
spec
5. - Never dispose of old batteries in household waste system!
es, in part or in w
t to the co
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‐
rrectness of i
tem, General Information" and in owner's manual.
l purpos
8. - Battery acid is very caustic; therefore wear eye protection and

gloves when working with batteries. Do not tilt battery. Acid can
nform
ercia
leak out of the gas vents of some batteries.

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1.3.3 Working on airbag system
ion in
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WARNING
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When work is performed on the airbag system (pyrotechnical
Co
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components, airbag control unit - J234- , wiring) the battery t. C rig
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earth strap must be disconnected with the ignition switched on. pyri by
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Exception: in vehicles with a battery in the vehicle interior, the
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ignition must be switched off.
♦ Then, cover the negative terminal.
♦ A waiting time of 10 seconds is necessary after discon‐
necting the battery.
♦ Battery must be connected with ignition switched on.
♦ No persons may be in the interior when the battery is re‐
connected.
Ensure, in this case, that you are not within the effective range
of the airbag and the belt tensioner.
If when reconnecting the battery and the ignition was not in the
on position - warning lights in dash panel will not light up - the
ignition may only be switched on (key/button) from the driver's
seat with the seat set in the rearmost position.
1.4 Battery terminal connection
WARNING

tions ⇒ page 3 !

Caution
To prevent damage to the battery terminal clamps and battery

terminals, the following should be observed:
♦ The battery terminal clamps should only be fitted by hand
and without using force.
♦ Battery terminals should not be coated with grease.
♦ The battery clamps should be fitted so that the battery ter‐
minal is either flush with the clamp or protruding from it.
♦ Once the battery terminal clamps have been tightened to
the specified torque, the threaded connections should not
be tightened any further.
AG. Volkswagen AG d
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t to the co
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f inform
mer
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Cop py
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1. Battery 5
2 Checking battery
WARNING

tions ⇒ page 3 !
Caution

Note
Observe the chapter "Battery" for the respective vehicle ⇒ Main‐

tenance ; Booklet .
2.1 Checking the various types of batteries
2.1.1 Checking a battery with colour indicator
WARNING

tions ⇒ page 3 !
AG. Volkswagen AG d
Carry out procedure in sequence as follows: lksw
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1. Visual check ⇒ page 7 ise
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nte
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2. Check the colour indicator, “3-colour”, ⇒ page 9 or “2-s au ra
c
colour”, ⇒ page 10 s
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du
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WARNING y li
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wit
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es, in part or in w
jump starting.
t to the co

rrectness of i
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3. Battery test with battery tester with printer - VAS 6161-

⇒ page 11 .
nform
ercia
4. Depending on the result of the battery test, “perform current

draw test” ⇒ page 20 .
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2.1.2 Absorbent glass mat battery

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Carry out procedure in sequence as follows:

a
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or
1. Visual check ⇒ page 7

f
en
ng
t.
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2. Battery check using battery tester with printer - VAS 6161- Cop py
t. rig
⇒ page 11 opyri
gh by
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ht
c by lksw
cted agen
Prote
6
AG.
Rep. gr.27 - Starter, current supply, CCS
3. Depending on the result of the battery test, “perform current

draw test” ⇒ page 20 .
2.2 Visual check
WARNING

tions ⇒ page 3 !
It is essential first to visually check the external condition, the ter‐

minals of the battery, the plugs of the gas vent openings and that
the battery is seated securely before performing more extensive
tests. G. Volkswagen nA AG do
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Note oris tee
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ut or
ac
sa
Observe the chapter "Battery" for the respective
s vehicle ⇒ Main‐
ce
e
tenance ; Booklet .
nl
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du
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Caution
wit
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♦ The battery will be damaged if the battery is not secured
spec
correctly.
es, in part or in w
t to the co
♦ Vibrations shorten the life of the battery, there is a danger
of an explosion, the cell plates may be damaged and the
clamping bracket may damage the battery housing.
rrectness of i
♦ Check battery is securely seated, if necessary tighten se‐
l purpos
curing bolt to specified torque.

nf
ercia
or
Performing this test establishes:

m
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atio
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♦ If battery housing is damaged Electrolyte can leak out if the

o
n in
or c
housing is damaged. If battery acid leaks out, serious damage

thi
te
to the vehicle could be caused. Treat components affected by

sd
iva
leaked battery acid immediately with acid neutraliser or a soap

r
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solution.
f
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t.
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op
♦ Check whether the battery terminals (battery wire connec‐ C py
t. rig
tions) are damaged. The necessary contact on the battery
gh ht
pyri by
terminal clamps cannot be guaranteed if the battery terminals
co Vo
by lksw
cted
are damaged. When connecting the battery clamps, tighten
agen
Prote AG.
the battery clamps to torque specified in this workshop manual
“Electrical system” for the respective vehicle. If the battery ter‐
minal clamps are not correctly seated and tightened, the wiring
may burn. Which will cause malfunctions in the electrical sys‐
tem. Therefore it can no longer be guaranteed that the vehicle
will function correctly.
♦ Whether the gas vent hose and the plug are fitted correctly.
On vehicles with batteries in the passenger compartment or
luggage compartment, it is essential to ensure that the gas
vent hose is fitted correctly. Make sure that there are no ex‐
posed gas vent openings in the area of the positive battery
terminal. If a gas vent opening is exposed in this area, it must
be sealed with a plug. The gas vent hose must be connected
in the area of the negative battery terminal to the exposed gas
vent opening. Observe chapter
⇒ “2.3 Information about battery replacement and battery gas
venting”, page 8
2. Checking battery 7
2.3 Information about battery replacement

and battery gas venting
♦ For safety reasons, it is important to determine which side of
the battery gas is vented from.
. Volkswagen AG
gen AG does
♦ For areas of application in which a gas vent hose is used,
Vol
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a
not
sure that the gas vent hose is seated securely andedthat
by the gas gu
ara
vent opening on the opposite side is sealed. horis nte
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a
♦ When renewing the vehicle battery, make sabsolutely sure that
s c
the gas vent opening in the area of the positive battery terminal
ce
le
un
pt
is not exposed. Should a vent opening be exposed in this area,
an
d
itte
y li
it must be sealed with a plug and the vent in the area of the
rm
ab
negative battery terminal must be opened.
pe
ility
ot
wit
, is n
♦ If the vehicle is installed with an AGM battery outside the en‐
h re
gine compartment, ensure that the battery is replaced with a
hole
spec
different AGM battery.
es, in part or in w
t to the co
♦ For launch of the Passat 3C (2006), the gas vent opening is
always on the negative battery terminal side.
♦ If there is a protective cap with sprayed on plug on the battery
rrectness of i
positive terminal of the replacement part battery
l purpos
000.915.105.DX, with the exception of 000.915.105.DN and

all Economy batteries with single index, this must also be
changed on the negative battery terminal or positive battery
nform
ercia
terminal side according to the situation. A list of batteries can

be found here ⇒ page 8 .
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tion in
♦ All AGM, EFB+, EFB batteries and the 36AH battery with orig‐
r
te o
thi
inal part no.: 000.915.105.DN, installed e.g. in the up! and
s
iva
Polo, have a protective cap without sprayed on plug on the
do
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c
positive battery terminal. The gas vent on the positive battery
um
fo
en
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terminal side is already sealed here.

n
t.
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op py
If a genuine replacement part battery is discovered with the fol‐
t. C rig
gh ht
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lowing part numbers, a red sealing plug must be fitted either on p by
co Vo
the positive or negative battery terminal side. If this is not installed,
by lksw
cted agen
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it must be retrofitted - genuine part no.: 000.915.506
AG.
List of batteries with protective cap and sprayed on plug

OES wet:
♦ “36 Ah” 000.915.105.DA
♦ “44 Ah” 000.915.105.DB
♦ “51 Ah” 000.915.105.DC
♦ “60 Ah” 000.915.105.DD
♦ “61 Ah” 000.915.105.DE
♦ “72 Ah” 000.915.105.DG
♦ “80 Ah” 000.915.105.DH
♦ “85 Ah” 000.915.105.DJ
♦ “95 Ah” 000.915.105.DK
♦ “110 Ah” 000.915.105.DL
♦ “36 Ah” 000.915.105.DN
Economy batteries:
♦ “61 Ah” JZW.915.105.
♦ “72 Ah” JZW.915.105.A
♦ “85 Ah” JZW.915.105.B

♦ “44 Ah” JZW.915.105.C

♦ “36 Ah” JZW.915.105.D
♦ “95 Ah” JZW.915.105.E
♦ “80 Ah” JZW.915.105.F
2.4 Checking colour indicator in battery cov‐

er
2.4.1 Checking colour indicator, “3-colour”
WARNING

tions ⇒ page 3 !
General information about colour indicator:

Applies for all batteries with “1J0”, “7N0” and “3B0” indexes in
original equipment and for all replacement batteries 191 915 105
AB and from “000 915 105 AX” index. en AG. V
olkswagen AG
ag does
lksw not
The colour indicator provides you with information dabout
by
Vo the elec‐ gu
ara
trolyte level and charge state of the battery. orise nte
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ut ra
Before carrying out a visual check, tap thessinspection
a window c
lightly and carefully using the handle of a screwdriver. The air
ce
e
nl
pt
bubbles, which can influence the display, will dissipate when do‐
du
an
itte
ing this. This will make the colour indicator reading more accurate.
y li
erm
ab
ility
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Note
h re
hole
spec
♦ Air bubbles can form under the sight glass, particularly when
es, in part or in w
a battery has been recharged, i.e. also when the battery has
t to the co
been charged during normal vehicle operation. These falsify
the reading of the colour indicator.
rrectness of i
♦ Since the colour indicator is only located in one battery cell,
the indicator also only applies to this battery cell. Determining
l purpos
the exact condition of the battery is possible only by means of

a battery test ⇒ page 11 .
nform
ercia
♦ The colour indicator can be located at various positions on the

m
battery.
at
om
ion
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in t
or
Three different colour displays are possible:

his
ate
do
priv
♦ »Green«, battery is charged sufficiently.

cum
for
en
ng
t.
♦ »Black«, battery partly discharged, charge state < 65% or
yi Co
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completely discharged
C py
t. rig
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yri by
♦ »Colourless or light yellow«, battery must be renewed. cop Vo
by lksw
cted agen
Prote AG.
AG. Volkswagen
Ameo 2017 ➤ , Arteon ksw2018 ➤ , Atlas 2017 ➤es,nBora
agen AG do
1999 ➤ , Bora Varian ...
Vol ot g
Electrical System,
d b General Information - Edition 01.2018
y ua
ra
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ris
tho eo
s au ra
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WARNING
s
ce
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un
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an
d
itte
y li
erm
ab
ility
ot p
wit
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jump starting.
ole,
spec
t to the co
2.4.2 Checking colour indicator, “2-colour”
rrectne
WARNING
ss o
cial p
f in
form
mer
tions ⇒ page 3 !
atio
om
n
c
i
or
n thi
General information about colour indicator:
te
sd
iva
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pr
c
The general introduction of the “2-colour” display took place grad‐
um
r
fo
ually in 2009. The “2-colour” indicator does not include the colour
en
ng
t.
yi
»green« for indicating the charge level.
Co
Cop py
t. rig
gh ht
The colour indicator provides you with information on the elec‐ yri
p by
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trolyte level of the battery. by c lksw
cted agen
Prote AG.
The battery's charge state can no longer be read off via the colour
indicator. The battery test has to be used for this purpose,
⇒ page 11
Before carrying out a visual check, tap the magic eye lightly and
carefully using the handle of a screwdriver. The air bubbles, which
can influence the display, will dissipate when doing this. The col‐
our display of the magic eye will therefore be more accurate.
Note
♦ Air bubbles can form under the sight glass, particularly when
a battery has been recharged, i.e. also when the battery has
been charged during normal vehicle operation. These falsify
the reading of the colour indicator.
♦ Since the colour indicator is only located in one battery cell,
the indicator also only applies to this battery cell. Determining
the exact condition of the battery is only possible by means of
a battery test ⇒ page 11 .
♦ The colour indicator can be located at various positions on the
battery.
Three different colour displays are possible:

♦ »Black«, electrolyte level is OK.
♦ »Light yellow«, electrolyte level too low The battery must be
renewed.

AG. Volkswagen AG d
agen oes
olksw not
V
Ameo 2017 ➤ , Arteon 2018 d by ➤ , Atlas 2017 ➤ , Bora 1999 g➤
ua , Bora Varian ...
ran
ise
hoElectrical
r System, General Information - Edition
tee
or 01.2018
aut ac
ss
ce
le
un
pt
WARNING
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
jump starting.
es, in part or in w
t to the co
rrectness of i
2.5 Battery tester with printer - VAS 6161-
l purpos
General description:
nform
ercia
WARNING
m
a
com
tion in
r
te o
tions ⇒ page 3 !
thi
s
iva
do
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cum
fo
en
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It is not necessary to remove or disconnect battery when using

n
t.
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op
battery tester with printer - VAS 6161- . C py
t. rig
gh ht
yri
The battery tester with printer - VAS 6161- does not load the bat‐
p by
co Vo
by lksw
tery any more. It works on the principle of dynamic conductance Prote
cted AG.
agen
acquisition.
Every battery type is stored in the tester.
Data can be stored on an SD card.
The battery tester with printer - VAS 6161- can be updated via an
interface or an SD card, so that battery data from Volkswagen are
always up to date.
The integrated temperature sensor improves measurement qual‐
ity.
A 2D scanner is available as an option to read data directly from
the battery's 2D code.
Note
Observe the ⇒ operating manual of the battery tester with printer

- VAS 6161- .
2.5.1 Description of battery tester with printer

AG. Volkswagen AG d
agen
- VAS 6161-
by Vol
ksw oes
not
gu
ara
ed nte
1 - Integrated printerthoris e or
au ac
2 - Operating lever
ss for paper compartment
ce
e
nl
pt
3 - Paper slot
du
an
itte
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erm
4 - LCD screen with main menu
ab
ility
ot p
5 - Control panel with ON/OFF button
wit
, is n
h re
6 - Connection for battery test cable
hole
spec
es, in part or in w
7 - Memory card slot
t to the co
8 - Infrared temperature sensor
9 - Data transmitter for PC
rrectness of i
l purpos
2.5.2 Perform battery test with battery tester
nf
ercia
orm
with printer - VAS 6161- .
m
atio
om
n in
or c
thi
e
WARNING
t
sd
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o
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m
f
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t.
tions ⇒ page 3 !
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Cop py
t. rig
gh ht
pyri by
Vo
co
Special tools and workshop equipment required
by lksw
cted agen
Prote AG.
♦ Battery tester with printer - VAS 6161-
Performing battery test:
WARNING

jump starting.
– Switch off ignition and all electrical consumers.

– Check the colour indicator in batteries with an inspection win‐
dow ⇒ page 6 .
– Switch tester on.

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

– Connect black terminal “-” of tester to negative terminal.
Note
Ensure test clamps have a good contact!
– Select one of the following tests:
Note
♦ Genuine VW battery test: all Genuine VW batteries are to be

tested with this, both during and after warranty.
♦ “Non”-VW battery test: batteries from all other manufacturers
are to be tested with this.
♦ Stock maintenance: for batteries in showroom and storage
vehicles requiring maintenance.
♦ Genuine Volkswagen battery n AG. Volkswagen AG do

lkswage
⇒ “2.5.3 Genuine VVolkswagen battery test”, page
es n 13 .
o ot gu
y
db ar
♦ “Non”-VW battery
or
ise ⇒ “2.5.4 Non-VW battery test”, page
an 14 .
tee
h
ut or
♦ Stock maintenance
ss
a ac
⇒ “2.5.5 Carrying out stock maintenance”, page 14 .
ce
e
nl
pt
du
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ab
Note
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wit
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♦ The test is completed after about 10 seconds.

h re
hole
spec
♦ The result of the test is printed out by the printer.

es, in part or in w
t to the co
♦ The tester requires no cooling phase before it is ready for the

next measurement.
rrectness of i
2.5.3 Genuine Volkswagen battery test

l purpos
WARNING
nform
mercia

at
om
io

n
c
in t
or
his
e

at
do
riv
jump starting.
p
cum
for

en
ng
t.
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Cop py
t. rig
gh ht
yri by
– Select “Genuine Volkswagen battery test” in the menu.
cop Vo
by lksw
cted agen
Prote AG.
– Select “In vehicle” or “Outside vehicle”.
– Select “On battery terminal” or “On jump-start point”.
– Scan in 2D code of battery or manually select battery type and
amperage.
– Measure temperature. Hold temperature sensor about 5 cm
above one battery terminal until temperature stabilises.
– Start test.
– Print out test log if necessary.
2.5.4 “Non”-VW battery test Volkswage es n
ot g
y ua
db ran
rise tee
tho or
Note ss au ac
ce
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un
pt
♦ The print-out may vary depending on the software version.
an
d
itte
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erm
♦ Observe the ⇒ operating manual of the battery tester with
ab
ility
printer - VAS 6161- .
ot p
wit
is n
h re
ole,
spec
WARNING
t to the co
rrectne
jump starting.
ss o
cial p
f inform
mer
atio
– Select “Non-Volkswagen battery test” in the menu.
om
n
c
i
or
n
thi
te
sd
va
– Select battery type “Normal”, “AGM”, “2*6V” or “Gel”.

i
o
pr
cum
r
fo
en
ng
– Select “CCA”, “JIS”, “DIN”, “SAE”, “IEC” or “EN” norm.

t.
yi Co
Cop py
– Select battery value.
t. rig
gh ht
pyri by
Vo
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c by lksw
cted agen
above one battery terminal until temperature stabilises. Prote AG.
– Start test.
2.5.5 Carrying out stock maintenance
WARNING

jump starting.
– Select “Stock maintenance” in the menu.

– Connect scanner.
Note
If no scanner is available, write vehicle identification number on

test printout by hand.
– Scan in vehicle identification number.

– Scan in 2D code of battery or select type and make manually
in menu.


above terminal connection until temperature stabilises.
– Start test.
2.5.6 Comments concerning test print out
Note
♦ The print-out may vary depending on software version.

♦ The test printout is required for warranty claims.
1- Check type.
2- Battery test result
3- Measured voltage
4- Measured cold start value of battery.
5- Nominal cold start value of battery selected on tester.
6- Measured temperature of battery.
7- Fitting location of battery
8- Position of battery terminal clamp selected on tester.
9- Selected battery technology.
AG. Volkswagen AG d
agen oes
ksw
2.5.7 Assessing test results ol not
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Evaluating battery test results for guarantee and service
auth tests ra
ss c
Battery test results Measure
ce
le
un
pt
an
d
itte
Battery OK No measures on battery
y li
erm
ab
Battery OK - recharge. Charge battery ⇒ page 22 . In
ility
ot p
case of discharging, look for
wit
is n
fault
h re
ole,
spec
Perform current draw test Perform current draw test
⇒ page 20 . Fully charge bat‐
t to the co
tery ⇒ page 22 and repeat
test.
Renew battery Disconnect battery and repeat rrectne
test. The result “Renew battery”
may be caused by a weak cable
ss
contact.
o
cial p
f i
Battery cell defective - renew. Renew battery

nform
mer
Check connection. Connect cable directly to bat‐

atio
m
tery and not to jump start termi‐

o
n
c
nal.
i
or
n thi
te
Battery dead Renew battery

sd
iva
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pr
cum
r
fo
Evaluating battery test results for maintenance test

en
ng
t.
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op
C py
t. rig
gh ht
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Battery OK No measure cop Vo
by lksw
cted agen
Charge battery immediately. Charge battery fully
Prote AG.
⇒ page 22 .
Mark as defective. Mark as defective.

Check tester connection. Disconnect battery and repeat
test. The result “Check tester
connection” may be caused by
a weak cable contact.
Check connection. Connect cable directly to bat‐
tery and not to jump start termi‐
nal.
Noises Wait until measured value ap‐
pears on display.
Battery dead Renew battery
2.6 Midtronics - MCR340V- battery tester

only for USA/Canada vehicles
General description ⇒ page 16
Performing battery test with Midtronics - MCR340V- battery tester
⇒ page 17
Dealing with problems with Midtronics - MCR340V- battery tester
⇒ page 19
2.6.1 General description
WARNING
Danger of injury.
Before working on the battery, read through the warning and
n AG. Volkswagen AG
safety regulations carefully, and comply
olks
wage with them ⇒ pagedo3es. n
o V t gu
by ara
Dispose of electrolyte (mixture
ris
ed of sulphuric acid and water) nte
safely! Waste electrolyte
au
t is only allowed to be disposed of at
ho eo
ra
appropriately indicated
ss collecting points. Comply with the lo‐ c
cally applicable disposal guidelines.
ce
le
un
pt
an
d
Do not test batteries that are liberating gas. Otherwise, there

itte
y li
rm
is a danger of explosion.
ab
pe
ility
ot
wit
, is n
h re
hole
spec
WARNING
es, in part or in w
t to the co
It is not permissible to test or charge batteries whose magic

eye shows light yellow. Do not slave/jump start the vehicle!
rrectness of i

jump starting.
l purpos

nform
mercia
a
com
tion in
Note
r
te o
thi
s
iva
do
To prevent damage to the battery and vehicle, note the types of

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rp
cum
fo
battery and the remarks given ⇒ page 1 .

en
ng
t.
yi Co
Cop py
t.
Batteries in VW vehicles are only allowed to be tested with battery
rig
gh ht
yri by
testers approved by VW. In the USA/Canada, it is permitted for op Vo
by c lksw
the Midtronics - MCR340V- battery tester to be used. cted agen
Prote AG.
Read all the information about safety, set-up and operation in the
operating instructions for the Midtronics - MCR340V- battery test‐
er and follow the instructions to the letter.

AG. Volkswagen AG d
Electrical
lkswagenSystem, General Information
oes
n - Edition 01.2018
o ot g
yV ua
edb ran
Refer to ⇒ Self-study programme No. ;hoVehicle
ris batteries for more tee
information. aut or
ac
ss
The following charging and analysis procedures apply to all bat‐
ce
le
un
pt
teries, all battery installation locations (engine compartment or
an
d
itte
y li
luggage compartment) and battery application purposes (starter
rm
ab
battery or second/convenience battery).
pe
ility
ot
wit
Always comply with the safety regulations, the regulations for
, is n
h re
setting up the battery tester, the display menu/display buttons,
hole
spec
LEDs and the operating procedures described in the ⇒ operating
es, in part or in w
manual MCR340V .
t to the co
Note
rrectness of i
l purpos
Observe and comply with all subsections, remarks and referen‐

ces to the vehicle and battery type, etc. to be tested.
nform
ercia
2.6.2 Performing battery test with Midtronics -

m
a
com
t
MCR340V- battery tester
ion in
r
te o
thi
Prerequisites:
s
iva
do
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en
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WARNING
n
t.
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Cop py
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Before working on the battery, read through the warning and
gh ht
yri by
safety regulations carefully, and comply with them ⇒ page 3 .
op Vo
by c lksw
cted agen
Prote AG.
jump starting.
– Read general description ⇒ page 16 .

– Perform visual check ⇒ page 7 .
– Open bonnet or cover for other installation location of battery.
– Determine whether battery type is “Standard” or “AGM”.
– Remove covers from battery positive and negative terminals.
– Use wing covers or other kinds of cover before you use equip‐
ment in engine compartment or interior.
– Close all doors.
Note
♦ Battery temperature must be at least 10°C.

♦ For additional information, refer to the ⇒ operating manual
INC 940 .
AG. Volkswagen AG d
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Ameo 2017 d➤ by , Arteon 2018 ➤ , Atlas 2017 ➤ g, uBora
V
ara 1999 ➤ , Bora Varian ...
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Electrical orSystem,
is General Information - Edition 01.2018
nte
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th or
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ss
Perform test:
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WARNING
erm
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ility
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, is n
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hole
spec
es, in part or in w
t to the co
jump starting.
rrectness of i
l purpos

– Check magic eye on batteries with magic eye ⇒ page 6 .
nf
ercia
o
– Switch tester on.
rm
m
atio
m
– Connect red terminal “+” of tester to positive terminal.

o
n in
or c
thi
– Connect black terminal “-” of tester to negative terminal.
te
sd
iva
o
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rp
cu
o
m
f
en
ng
Note
t.
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Cop py
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Ensure test clamps have a good contact!
rig ht
py by
co Vo
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cted agen
Prote AG.
– Select “In vehicle” or “Outside vehicle”.
– Select “Warranty test”.
Note
Use the print function of the Midtronics - MCR340- tester if the

test results are required for handling warranty applications.
– Select battery type “Standard” or “AGM”.

– Make a note of DIN value of battery (from battery sticker).
Make a note of SAE value if sticker does not have any DIN
value.
– Enter DIN value in tester and perform battery test ⇒ operating
manual MCR340V .
– If you are using SAE value, access “Miscellaneous” menu and
change from “DIN” to “SAE” ⇒ operating manual MCR340V .
Note
Always use DIN value from battery sticker! Otherwise, test result
will be falsified.
2.6.3 Assessing test results

Results of battery test:
Battery OK None
Good - charge Charge battery ⇒ page 64 .
Use Incharge Charge battery ⇒ page 64 .
Renew battery Renew battery ⇒ Electrical sys‐
tem; Rep. gr. 27 ; Removing
and installing battery


Battery cell defective Renew battery ⇒ Electrical sys‐
tem; Rep. gr. 27 ; Removing
and installing battery
2.6.4 Dealing with problems with Midtronics -

MCR340V- battery tester
agen
AG. Volkswagen AG d
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Under certain circumstances, the display
ed
by
V
may show errors or ua
ran
messages according to status. horis tee
t or
au ac
The most frequent display messages
ss are listed below, together
with suggested solutions.
ce
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itte
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erm
ab
Note
ility
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wit
, is n
For messages not listed here, please refer to ⇒ operating manual
h re
hole
MCR340V .
spec
es, in part or in w
t to the co
Display message Measure
No display – Check whether terminals of
rrectness of i
battery tester are firmly con‐
nected to battery terminals.
l purpos
– Check battery terminals are
nform
ercia
tightened according to reg‐

ulations and do not have
m
at
corrosion.
om
ion
c
in t
or
– Charge battery
his
ate
⇒ page 64 .
do
priv
cum
or
System noise – Switch off all electrical con‐

f
en
g
sumers.
n
t.
yi Co
Cop py
ht. rig
– Wait until all electrical loads
rig ht
py by
monitored by on-board sup‐
co Vo
by lksw
cted
ply control unit have switch‐
agen
Prote AG.
ed off.
– Pull out ignition key.
– Disconnect any suspect

electrical equipment not
connected to on-board sup‐
ply as standard.
Wait a few minutes and test again ⇒ page 17 .
Note
If you have performed test at jump-start point and message does

not disappear, perform test directly on battery.
2.7 Current draw test
WARNING

eye shows light yellow. Do not slave/jump start the vehicle! AG. Volkswagen AG d
agen oes
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Danger of explosion when checking and charging or slave/ by Vol not
gu
ara
jump starting. rise
d
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These batteries must be renewed. ss au ra
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erm
ab
Note
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♦ Ensure that the correct charging mode is set on the charger
hole
so that the current draw test is not falsified.
spec
es, in part or in w
t to the co
♦ VAS 5095A ⇒ page 23
♦ VAS 5900 ⇒ page 28
rrectness of i
♦ VAS 5903 ⇒ page 40
l purpos
♦ VAS 5908 ⇒ page 55
nform
ercia
To quickly ascertain the state of discharged batteries, the battery

current draw test whilst charging helps to determine whether the
m
at
battery must be replaced or fully recharged.
om
ion
c
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or
his
ate
Note
do
priv
cum
for
en
g
For battery tester with printer - VAS 6161- , the current draw test
n
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op
must always be performed when the test result “Perform current C py
t. rig
draw test” appears on the display.
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The current draw test should always be carried out if
AG.
♦ The result of the test with battery tester with printer - VAS
6161- gave the following result:
1 - Perform current draw test
Performing a current draw test whilst charging the battery will
quickly establish whether a partly or fully discharged battery
⇒ page 69 can be recharged to return it to a serviceable condi‐
tion.
Test requirements:
♦ When charging the battery, its temperature must be at least ≥
+10°C.
♦ The charger must be capable of outputting a charge current of
at least 30 A, as for example with VAS 5095A, VAS 5900, VAS
5903
♦ The battery's current draw must be measured with a current
pick-up clamp, e.g. VAS 5051B/7, when charging with battery
charger - VAS 5095A- . Battery charger - VAS 5900- and bat‐
tery charger - VAS 5903- display the current draw on the unit.
Battery charger - VAS 5900- performs the current draw test
automatically with menu guidance.
– Connect battery to battery charger and start charging se‐
quence.
– Measure charge current of battery after 5 minutes.

Test result:
If the current draw A is higher than 10% of the nominal capacity
(e.g. > 6.1 A for a 61 Ah battery), fully charge battery and test
again.
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For Eos with twos6 V absorbent glass mat batteries, the charge
s c
current must only be 5% higher than the nominal capacity of the
ce
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battery. Example for Eos: the 50 Ah battery must have a charge
an
itte
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current higher than 2.5 A after 5 minutes of starting the charging
erm
ab
sequence.
ility
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wit
, is n
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– Fully charge the battery when the charge current is higher than
hole
10% of the nominal capacity (observe exception for Eos in
spec
es, in part or in w
above note).
t to the co
– Perform battery test after allowing battery to rest for two hours
⇒ page 12 .
rrectness of i
If the charge current, in amperes, lies below 10% of the nominal
capacity after 5 minutes of starting the charging sequence (5%
l purpos
for the 2 x 6 volt batteries in Eos) (example for 50 Ah battery <

5 A), renew battery. For warranty and goodwill cases, please
nform
ercia
complete the battery test sheet.

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
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rig ht
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co Vo
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Prote AG.
3 Charging the battery
Note
♦ A charger with a charge current of at least 70A is required if

the software is updated or flashed in a vehicle to prevent prob‐
lems during updating and flashing.
♦ “VAS 5903” ⇒ “3.3 Battery charger VAS 5903 ”, page 40
WARNING
wage
Danger of injury! Observe warning notices yV
o and safety regula‐
lks es n
ot g
tions ⇒ page 3 ! ir se
d b ua
ran
o tee
th or
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ss
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nl
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Caution
du
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itte
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erm
ab
ility
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es, in part or in w
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WARNING
rrectness of i
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jump starting.
nf
ercia

orm
m
atio
om
n in
c
3.1 Battery charger - VAS 5095 A-

or
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Note
ng
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agen
Prote AG.

This chapter describes the basic functions of the battery charger

- VAS 5095 A- . For additional information refer to ⇒ operating
instructions for battery charger - VAS 5095 A- .
Note
♦ The effective charge current can not be read on these units.

The charge current must be read externally using a pick-up
clamp.
♦ Observe ⇒ operating instructions for battery charger - VAS
5095 A- .

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3.1.1 Description of battery charger - VAS
itte
y li
erm
ab
5095 A-
ility
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wit
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hole
Note
spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
o
Charge current of charger: 12 A.
rm
m
atio
m
The battery charger - VAS 5095- is suitable for charging all 12V
o
n in
c
batteries supplied by Volkswagen.
or
thi
te
sd
iva
The battery charger charges without peaks in amperage or volt‐
o
r
rp
cu
age. This will not adversely effect the on-board electronics. The
o
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f
en
ng
battery can remain in the vehicle while it is being charged and

t.
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need not be disconnected. Cop py
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Battery charger - VAS 5095 A- p by
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1 - ON / OFF switch (0 = charger OFF) Prote AG.
2 - Charge current indicator (I > 12 A)

3 - Charge current indicator, battery partially charged > 90%
4 - Maintaining charge; lights up green when battery is fully charg‐
ed
5 - Malfunction indicator
6 - Support mode indicator
7 - Support mode/normal mode changer-over switch
8 - Charger cable, red terminal “+”, black terminal “-”
9 - Battery type change-over switch (on base of charger unit)
3.1.2 Charging battery with battery charger -

VAS 5095 A-
Note

WARNING

tions ⇒ page 3 !
3. Charging the battery 23

♦ Battery charger - VAS 5095 A-
Caution
Always set battery type 2.4 V/C (volts/battery cell) when charg‐
ing! This applies for all batteries.
Note
The battery must have a temperature of at least 10°C.
WARNING

jump starting.
These batteries must bewrenewed.
agen
AG. Volkswagen AG d
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ris
– Switch offuignition
tho and all electrical consumers. eo
ra
a c
ss
– Check setting for battery type on type of battery switch
ce
le
un
⇒ page 23 . Must be set to 2.4 V/C (volts/battery cell).

pt
an
d
itte
y li
– Connect red terminal clamp “+” of charger unit to positive ter‐

erm
ab
minal on battery.
ility
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is n
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ole,
Note
spec
t to the co
In vehicles with start/stop function and battery monitor control unit

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

ss
– Connect black terminal clamp “–” of battery charger to nega‐

o
cial p
tive terminal.
inform
mer
– Switch on battery charger ⇒ page 23 .

atio
om
The charge current indicators ⇒ page 23 -2- and -3- light up yel‐
n
c
i
or
low. If only the yellow light emitting diode (LED) -3- lights up,
thi
te
battery is partially discharged (approx. 90%).

sd
iva
o
pr
cum
r
If the green LED also lights up ⇒ page 23 -4-, the charger has
fo
en
ng
switched to "maintaining charge". The battery is fully charged.

t.
yi Co
Cop py
t. rig
– Switch off charging unit ⇒ page 23 . opyri
gh by
Vo
ht
c by lksw
cted agen
Prote AG.

– Remove charger unit terminals from battery terminals.
3.1.3 Charging totally discharged battery with

battery charger - VAS 5095 A-
Note

the software is updated orolkflashed
AG. V swagen Ain a vehicle to prevent prob‐
agen and flashing.
lems duringoupdating
G do
es n
lkswV ot
by gu
a
♦ “VASri5903”
se
d
⇒ “3.3 Battery charger VAS 5903ran”,te page 40
ho eo
ut
♦ “VAS
ss
a 5908” ⇒ “3.5 Battery charger VAS 5908 ”, page
ra
c 55
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un
pt
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itte
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WARNING
erm
ab
ility
ot p
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is n
tions ⇒ page 3 !
h re
ole,
spec
t to the co
The charger unit automatically recognises totally discharged bat‐
teries and initiates a gentle charging procedure with a low charg‐
ing current. The charge current is automatically adapted to suit
the charge condition of the battery. rrectness o
Note
cial p
f inform
mer
♦ Observe notes in chapter ⇒ page 69 .

atio
om
♦ Totally discharged batteries in unregistered vehicles must be

n
c
i
or
exchanged prior to delivery. Preliminary damage cannot be

thi
te
sd
a
excluded.
iv
o
pr
cum
r
fo
♦ The battery voltage must be at least 0.6 V.

en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
WARNING
p by
co Vo
by lksw
cted agen
Prote AG.
jump starting.
– Charge battery ⇒ page 23 .
3.1.4 Charging battery in support mode with

battery charger - VAS 5095A-
Note


General notes:
The support mode provides the on-board supply with power when
the battery is removed or disconnected. en AG. V
olkswagen AG
ag does
ol ksw not
For further information, refer to the ⇒ operatingy Vmanual VAS gu
db ara
5095A . ris
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ut
The support mode is suitable in the following
ss
a situations: ra
c
ce
e
♦ Support mode of on-board supplies without installed battery
nl
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itte
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♦ Power conservation when renewing the battery
erm
ab
ility
ot p
♦ Ancillaries test without battery
wit
, is n
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hole
WARNING
spec
es, in part or in w
t to the co
tions ⇒ page 3 !
rrectness of i
l purpos
WARNING
nf
ercia
orm
m
atio
om
n in
or c
thi
jump starting.
te
sd
iva
o
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rp
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f
en
ng
t.
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Cop py
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rig ht
py by
co Vo
by lksw
cted agen
Prote
Caution
AG.
♦ The terminal polarity protection in operating mode “charg‐

ing totally discharged batteries/support mode” is not ac‐
tive. Connect battery charger terminal clamps correctly to
battery terminals.
♦ It can cause sparks through a short-circuit.
♦ Danger of explosion
♦ Ensure charger terminal clamps are seated securely.
♦ Do not press START / STOP button when charger unit
cables are connected incorrectly. The charger unit may be
damaged.
– Remove battery.
Caution
When battery is removed, ensure there is no contact between

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

Note
In vehicles with start/stop function wand

agen battery monitor
AG. Volkswagen AGcontrol
doe unit
- J367- fitted, black terminalbyclamp
Volks
“–” must be connected stonobody
t gu
earth. Connecting it to battery
ris
ed negative terminal will cause start/ ara
nte
utho eo
r a ac
ss
ce
e
– Connect black terminal clamp “-” to negative terminal of vehi‐

nl
pt
du
cle.
an
itte
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erm
ab
– Check setting for battery type on normal/support mode switch
ility
ot p
⇒ page 23 . It must be switched on support mode.
wit
, is n
h re
– Check polarity of charger unit cables.
hole
spec
– Switch on battery charger.
es, in part or in w
t to the co
The battery charger starts with support mode.
End battery support mode:
rrectness of i
– Switch off battery charger.
l purpos
– Disconnect black terminal clamp “–” of charger unit from neg‐

ative terminal of vehicle.
nf
ercia
or
– Disconnect red terminal clamp “+” of charger unit from positive
m
m
atio
terminal of vehicle.
om
n in
or c
– Pull charger plug out of battery charger.
thi
te
sd
iva
3.1.5 Charging battery in maintenance mode o

r
rp
cu
o
m
f
with battery charger - VAS 5095 A-

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

WARNING

tions ⇒ page 3 !
WARNING

jump starting.
In maintenance mode the battery charger - VAS 5095 A- ensures

that the battery is charged correctly and is maintained in fully
charged condition.
– Proceed as for charging battery ⇒ page 23 .

Note agen
AG. Volkswagen AG d
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When a battery is being charged in maintenance mode ise and a
d
♦ or nte
electrical consumer draws current from the battery,autthe battery
h eo
ra
charger - VAS 5095 A- automatically compensates s the charge.
s c
ce
le
un
pt
♦ The maintenance mode can be continued for an unlimited pe‐
an
d
itte
riod.
y li
erm
ab
ility
♦ The battery is always ready for use.
ot p
wit
is n
h re
3.2 Battery charger - VAS 5900- ole,
spec
t to the co
Note
rrectne
s
s o
cial p
f i
nform
mer
atio
om
n
c
i
or
n thi
te
sd
WARNING
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
tions ⇒ page 3 ! t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
WARNING

jump starting.
This chapter describes the basic functions of the battery charger

- VAS 5900- . For additional information refer to ⇒ operating in‐
structions for battery charger - VAS 5900- .
Note
♦ The effective charge current can be read directly on this bat‐

tery charger.
♦ Observe ⇒ operating instructions for battery charger - VAS
5900- .


5900-
Note
. Volkswagen AG
gen AG does
swa
♦ A charger with a charge current yV
olk of at least 70A is required noift
gu
the software is updatedrisor
ed flashed in a vehicle to prevent prob‐ ran
b a
tee
lems during updating ut and flashing.
ho
or
a ac
ss
ce
e
nl
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itte
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erm
ab
ility
ot p
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The battery charger - VAS 5900- is suitable for charging all 12V
h re
hole
spec
es, in part or in w
Battery charger - VAS 5900-
t to the co
1 - Display
rrectness of i
2 - Adjustment button “Up” ↑
l purpos
3 - Adjustment button “Down” ↓

4 - START / STOP
nf
ercia
or
5 - INFO
m
m
atio
om
n in
or c
thi
e

t
sd
iva
o
r
rp
cu
VAS 5900-
o
m
f
en
ng
t.
yi Co
Cop py
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Note
rig ht
py by
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by lksw
cted agen
Prote
AG.

WARNING

tions ⇒ page 3 !
WARNING

jump starting.

♦ Battery charger - VAS 5900-
AG. Volkswagen AG d
agen oes
olksw not
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or eo
Note aut
h
ra
ss c
ce
e

nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
– Connect charger plug to battery charger. The last selected
, is n
h re
type of battery will appear on display.
hole
spec
– Set battery to respective operating mode with INFO .
es, in part or in w
t to the co
In the display the symbol -1- for “standard charge for wet batter‐
ies” or symbol -2- for “standard charge for gel/absorbent glass
mat batteries” will appear.
rrectness of i
– Set battery capacity (Ah) of battery to be charged using re‐

l purpos
spective button (“Up” ↑ or “Down” ↓ ).

– Connect red terminal clamp “+” to positive terminal on battery.
nform
mercia
at
om
ion
Note
c
in t
or
his
ate

do
priv

um
for
en
g

n
t.
yi Co
stop system to malfunction. Cop py
t. rig
gh ht
pyri by
Vo
o
– Connect black terminal clamp “–” to negative terminal. by c lksw
cted agen
Prote AG.
The charger unit recognises the voltage required for the connec‐
ted battery (6 V, 12 V or 24 V) and initiates the charging sequence
automatically.
At a charge condition of approx. 80 - 85% the battery charger

switches to the “final charge” mode. The fourth bar appears in
display -1-. The battery is ready for use.

At a charge level of 100%, all bars appear on the display.
Note
♦ In the case of battery type “standard charge”, the parallel op‐

eration of electrical consumers while charging is possible. The
charging period will be longer.
♦ The battery charger will switch to maintenance mode after
about 1-7 hours, depending on type of battery. To achieve a
100% charge the battery should remain connected for this pe‐
riod.
Possible faults and fault rectification:

1- Displayed battery voltage is not as per nominal voltage:
– Press and hold respective button (“Up” ↑ or “Down” ↓ ) until
charging process starts.
2- Displayed battery voltage is not as per nominal voltage –
charging process has already started:
– Press START / STOP twice.
AG. Volkswag
– Press and hold respective button (“Up”sw↑agor
en “Down” ↓ ) until
en AG
does
lk not
charging process starts again. by V o gu
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ise tee
3- Battery charger does not udetect
tho
r
a battery when battery volt‐ or
age is less than 2 V: ss a ac
ce
e
Display remains unchanged.

nl
pt
du
an
itte
y li
The battery type and ampere hours (Ah) as set is displayed.
erm
ab
ility
ot p
Ending battery charging sequence:
wit
, is n
h re
– Press START / STOP .
hole
– Disconnect black terminal clamp “–” of charger from negative spec

es, in part or in w
t to the co
terminal.
– Disconnect red terminal clamp “+” of charger from positive
terminal on battery.
rrectness of i

l purpos
3.2.3 Charging battery in service mode with

nf
ercia
or
battery charger - VAS 5900-

m
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WARNING

tions ⇒ page 3 !

Caution
The operating mode “service charge” is not permitted on VW

vehicles as the voltage peaks will damage the on-board elec‐
tronics.
If you nevertheless use “service charge” the battery must be
disconnected from the on-board supply.
WARNING

jump starting.
AG. Volkswagen AG d
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Caution horis nte
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When charging always set the battery charger to the correct s
ce
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nl
type of battery ⇒ operating instructions for battery charger -
pt
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VAS 5900- !
itte
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ab
The “service mode” is suitable for:
ility
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♦ Wet batteries where the magic eye allows charging (magic
h re
eye black or green)
hole
spec
es, in part or in w
t to the co
The operating mode “service charge (SERV)” is only used on
sulphated batteries. The battery is charged at a voltage of
> 14.4 V. This can result in a partial reduction of the sulphated
rrectness of i
layer. After charging, always check the colour of the magic eye
l purpos
before using the battery ⇒ page 9 .

nform
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Note

operating mode will appear on display ⇒ page 29 .

– Set battery to respective battery type with INFO .

In the display, the symbol -1- for “Service charge for wet batteries”
or symbol -2- for “Service charge for gel/absorbent glass mat bat‐
teries” will appear.
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In vehicles with start/stop function andthbattery
or is
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s au must be connected to body ra
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s terminal will cause start/
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– Connect black terminal clamp “–” to negative terminal.
ility
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automatically.
spec
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At a charge condition of approx. 80 - 85% of the battery voltage,
the battery charger switches to the “final charge” mode. The fourth
bar appears in display -1-. The battery is ready for use.
rrectness of i
l purpos
Note
nf
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The success of the “service charge” depends on the severity of
rm
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charging process starts. C py
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charging process has already started: cted agen
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3- Battery charger does not detect a battery when battery volt‐
age is less than 2 V:
The operating mode and ampere hours (Ah) as set are displayed.
– Disconnect black terminal clamp “–” of charger from negative
terminal.

3.2.4 Charging totally discharged batteries

with battery charger - VAS 5900-
Note

WARNING

tions ⇒ page 3 !
AG. Volkswagen AG d
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WARNING rised
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It is not permissible to test or charge batteries whose magic ss c
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un
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ab
jump starting.
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Caution
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s
battery terminals.
s o
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♦ When charging always set the battery charger to the cor‐
form
mer
rect type of battery ⇒ operating instructions for battery

atio
charger - VAS 5900- !
om
n
c
i
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♦ Totally discharged battery is not recognised by battery

thi
te
charger ⇒ page 69 .
sd
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damaged.
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Batteries with a voltage of less than 2 volts will not be recognised
AG.
automatically by battery charger - VAS 5900- .



AG. Volkswagen AG d
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nl
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Note
rrectness of i
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excluded.
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♦ The battery must have a temperature of at least 10°C.
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– Set battery to respective battery type with INFO .

Note


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– Press START / STOP for approx. 5 seconds. The olksmenu
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– Press respective button (“Up” ↑ or “Down”
s ↓ ) to set required
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battery voltage (6 V, 12 V or 24 V).

nl
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ab
ility
Note
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If a button is not pressed within 5 seconds the charger will return
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to the main menu (select operating mode).
es, in part or in w
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– Confirm the selected battery voltage with START / STOP .
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– Confirm polarity of charger unit cables with START / STOP .
nf
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Charger will start charging sequence for totally discharged bat‐

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Note

General notes:
The support mode provides the on-board supply with power when
the battery is removed or disconnected.
For further information, refer to the ⇒ operating manual VAS
5900 .
The support mode is suitable in the following situations:
WARNING
AG. Volkswagen AG d
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Danger of injury! Observe warning notices and safety regula‐ by
Vo gu
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tions ⇒ page 3 ! orised
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WARNING
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itte
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jump starting.
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Caution
nf
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♦ Do not press START / STOP button when charger unit cted agen
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damaged.
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operating mode will appear onVdisplay
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nform
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– Press START / STOP for approx. 5 seconds. The menu
r
te o
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“charging totally discharged batteries/support mode” will be
s
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activated.
r
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– Press respective button (“Up” ↑ or “Down” ↓ ) to set required

n
t.
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battery voltage (6 V, 12 V or 24 V). C py
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Note Prote AG.


correct".

3.2.6 Charging battery in maintenance mode

Note
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♦ A charger with a charge current of at least 70A is required if lkswagen oes
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♦ “VAS 5903” ⇒ “3.3 Battery charger VAS 5903 ”,sspage 40
a c
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nl
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itte
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Note
wit
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♦ When a battery is being charged in the maintenance mode and
es, in part or in w
an electrical consumer draws current from the battery, the
t to the co
battery charger - VAS 5900- automatically compensates the
charge.
rrectness of i
♦ The maintenance mode can be continued for an unlimited pe‐
riod.
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nf
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♦ Observe battery manufactures maintenance instructions!
orm
m
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WARNING
or
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tions ⇒ page 3 !
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WARNING
lksw
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jump starting.
When the battery is fully charged the battery charger - VAS 5900-
switches to maintenance mode.

3.3 Battery charger - VAS 5903-
Note

WARNING

tions ⇒ page 3 !
WARNING

jump starting.
AG. Volkswagen AG d
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This chapter describes the basic functions oris of the battery charger
e nte
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- VAS 5903- . For additional information
aut refer to ⇒ operating in‐
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ra
structions for battery charger - VASs 5903- .
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Observe ⇒ operating instructions for battery charger - VAS

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5903- .
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5903-
rrectness of i
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Note
♦ A charger with a charge current of at least 70 A is required if

nform
ercia

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The battery charger - VAS 5903- is suitable for charging all 12 V

1 - Display
2 - Adjustment button “Up” ↑
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3 - Adjustment button “Down” ↓
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4 - START / STOP tho tee
or
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5 - INFO ss
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ab
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VAS 5903-
wit
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Note
t to the co
rrectness of i
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nform
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at
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WARNING
in t
or
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p
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tions ⇒ page 3 !
f
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t.
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co
WARNING
by lksw
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jump starting.


Note

In the display the symbol -1- for “standard charge for wet batter‐
ies” or symbol -2- for “standard charge for gel/absorbent glass
mat batteries” will appear. agen
AG. Volkswagen AG d
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olks ot g
– Set battery capacity (Ah) of battery to be charged using
ed
by re‐
V ua
ran
spective button (“Up” ↑ or “Down” ↓ ). ho
ris tee
t or
au ac
– Connect red terminal clamp “+” to positive terminal
ss on battery.
ce
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itte
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Note
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ab
pe
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t to the co
rrectness of i
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automatically.
nform
ercia
At a charge condition of approx. 80 - 85% the battery charger

switches to the “final charge” mode. The fourth bar appears in
m
a
com
t
display -1-. The battery is ready for use.
ion in
r
te o
thi
s
iva
do
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cum
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t.
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t. rig
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co lksw
by
cted agen
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Note
♦ In the case of battery type “standard charge”, the parallel op‐

eration of electrical consumers while charging is possible. The
charging period will be longer.
♦ The battery charger will switch to maintenance mode after
about 1-7 hours, depending on type of battery. To achieve a
100% charge the battery should remain connected for this pe‐
riod.

charging process starts. n AG. Volkswagen A ge G do
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2- Displayed battery voltagebyis
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un
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charging process starts again.

itte
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The battery type and ampere hours (Ah) as set is displayed.
t to the co
– Press START / STOP . rrectne

s
terminal.
s o
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nform
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o
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3.3.3 Charging battery in refresh charge

iv
o
pr
cum
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mode with battery charger - VAS 5903-

fo
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WARNING
rig ht
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AG.
tions ⇒ page 3 !
WARNING

jump starting.

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r
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ssCaution
ce
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nl
pt
du
an
The operating mode “refresh charge” is not permitted on VW
itte
y li
erm
vehicles as the voltage peaks will damage the on-board elec‐
ab
ility
tronics.
ot p
wit
, is n
If you nevertheless use “refresh charge” mode the battery must
h re
hole
be disconnected from the on-board supply.
spec
es, in part or in w
t to the co
Caution
rrectness of i
When charging always set the battery charger to the correct
l purpos
type of battery ⇒ operating instructions for battery charger -

VAS 5903- !
nform
ercia
The “refresh charge” mode is suitable for:

m
at
om
i
♦ Wet batteries, where distilled water can be replenished.
on
c
in t
or
Do not use operating mode “refresh charge” with maintenance-
his
ate
free wet batteries.
do
priv
cum
for
en
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t.
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The “refresh charge (refr)” operating mode is only used on sus‐ C py
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pect defective batteries (e.g. sulphation). The battery will be rig ht
py by
charged to maximum specific gravity and the plates will be reac‐
co Vo
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agen
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Note


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ee ...
th or
Electrical
s au System, General Information - Edition 01.2018 ac
s
ce
e
nl
pt
du
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itte
y li
erm
In the display the symbol -1- for “refresh charge for wet batteries”
ab
ility
or symbol -2- for “refresh charge for gel/absorbent glass mat bat‐
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Note
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nform
ercia

m
at
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ion
c
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ate
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p
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or

f
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automatically.
Co
Cop py
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rig ht
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At a charge condition of approx. 80 - 85% of the battery voltage, co Vo
by lksw
the battery charger switches to the “final charge” mode. The fourth
cted agen
Prote AG.
bar appears in display -1-. The battery is ready for use.
Note
The success of the “refresh charge” depends on the severity of

the sulphation of the battery.

charging process has already started:
The operating mode and ampere hours (Ah) as set are displayed.
terminal.

3.3.4 Charging totally discharged battery with

Note

WARNING

tions ⇒ page 3 !
WARNING

AG. Volkswagen AG d
eye shows light yellow. Do not slave/jump
lkswagenstart the vehicle! oes
no
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Danger of explosion when rchecking
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jump starting. ut
ho eo
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These batteries must be
s
renewed.
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itte
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Caution
wit
is n
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spec


t to the co
battery terminals.
♦ When charging always set the battery charger to the cor‐
rrectne
rect type of battery ⇒ operating instructions for battery

charger - VAS 5903- !
ss
♦ Totally discharged battery is not recognised by battery

o
cial p
charger ⇒ page 69 .
inform
mer

atio
m

o
n
c
damaged.
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Batteries with a voltage of less than 2 volts will not be recognised

en
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t.
automatically by battery charger - VAS 5903- .
yi Co
Cop py
t. rig
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Note

excluded.

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3. Charging the battery

Note


AG. Volkswagen AG d
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– Press respective button (“Up”ris
ed ↑ or “Down” ↓ ) to set required
ara
nte
battery voltage (6 V, 12 V
ut or 24 V).
ho eo
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ss
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Note
an
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If a button is not pressed within 5 seconds the charger will return ab

ility
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is n
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ss o
Charger will start charging sequence for totally discharged bat‐

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mer

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Note

swage es n
General notes: byV
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The support mode provides the on-board
tho supply with power when tee
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ss
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For further information, refer to the ⇒ Operating Manual for VAS

un
pt
an
5903 .
d
itte
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ab
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is n
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WARNING
rrectne
s
tions ⇒ page 3 !
s o
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f inform
mer
atio
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WARNING
o
n
c
i
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te

sd
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p
cum
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t.
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op
jump starting. C py
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gh ht
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These batteries must be renewed. cop Vo
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cted agen
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Caution

battery terminals.
damaged.
– Remove battery.

– Connect charger plug to battery charger. The last selected lkswage es n
operating mode will appear on display ⇒ page 29 . d byV
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ua
ran
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Caution ss
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nl
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du
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Note
rrectness of i
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ercia

m
at
om
cle.
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ate
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um
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Co
Cop py
battery voltage (6 V, 12 V or 24 V).
t. rig
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Vo
co lksw
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Note


correct".

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2017 ➤ , Arteon 2018 ➤ , Atlas 2017 e o➤ , Bora 1999 ➤ , Bora Varian ...
ut
ss a Electrical System, General ra
c Information - Edition 01.2018
ce
e
nl
pt
du
an
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ab
ility
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Note
hole
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nf
ercia
orm
m
Note
atio
om
n in
or c
♦ When a battery is being charged in the maintenance mode and
thi
te
sd
a
an electrical consumer draws current from the battery, the

iv
o
r
rp
cu
battery charger - VAS 5903- automatically compensates the
o
m
f
charge.
en
ng
t.
yi Co
op py
♦ The maintenance mode can be continued for an unlimited pe‐ t. C rig
gh ht
riod. yri
p by
o Vo
by c lksw
cted
agen
Prote AG.
♦ Observe battery manufactures maintenance instructions!
WARNING

tions ⇒ page 3 !
WARNING

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


3.4.1 General description
Note

AG. Volkswagen AG d
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WARNING d by
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or eo
th
Danger of injury! Observe warning notices and
s ausafety regula‐ ra
c
tions ⇒ page 3 ! s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
WARNING
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
jump starting.
rrectness of i
l purpos
nf
ercia
o
Battery charger - VAS 5906- has been specially developed for
rm
m
charging in vehicle on-board supply during vehicle presentation.
atio
om
n in
c
It has an automatic charging characteristic for starter batteries, 3

or
thi
- 300 AH.
te
sd
iva
o
r
rp
cu
The maximum charging voltage 14.4 V is not exceeded. All elec‐

o
m
f
trical loads are supported by up to 30 A by the trickle charging.

en
ng
t.
yi Co
op py
For sustained operation, battery charger - VAS 5906- changes to t. C rig
gh ht
trickle charging once battery is fully charged. yri
p by
o Vo
by c lksw
cted
Tester starts fully automatically and does not require any settings.
agen
Prote AG.
All that is required is to connect crocodile clips and mains cable.
For further information, refer to the ⇒ operating manual VAS
5906 .


VAS 5906-
Note

WARNING

tions ⇒ page 3 !
WARNING

jump starting.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Overview of operating panel:

1- Charge condition display 25%.
5- Display ready
6- Start/Stop and Setup buttons for interrupting and resum‐
ing charging process. Entry to Letup menu and selection of
characteristic type (press for 10 sec.).
7- Malfunction display.
– Place charger in engine compartment or under vehicle.
– Connect mains cable to charger and plug it into mains.
Charger is in no-load operation - ready light is on.
WARNING

tions ⇒ page 3 !
AG. Volkswagen AG d
– Switch off ignition. agen oes
o lksw not
V gu
by
– Connect red charging cable
rised to positive terminal “+” on battery. ara
nte
ho eo
aut ra
ss c
Note
ce
le
un
pt
an
d
itte
y li

erm
ab

ility
ot p

wit
is n

h re
ole,
spec
– Connect black charging cable to negative terminal “-” on bat‐

t to the co
tery.
Charging starts after about 2 seconds.
rrectne
Number of LEDs lit indicates charge condition of battery. Battery

has been charged up once all lights are lit.
ss o
When battery is fully charged, battery charger - VAS 5906- auto‐

cial p
f in
matically switches over to trickle charging.

form
mer
atio
m
Caution
o
n
c
i
or
n thi
te
sd
a
Danger of sparking if charging terminals are removed too soon.

iv
o
pr
Terminate charging by pressing START/STOP button.

um
r
fo
en
ng
t.
yi Co
Cop py
t. rig
– Press start/stop button to terminate charging. gh ht
pyri by
Vo
o
by c lksw
– Disconnect black charging cable from negative terminal “-” on cted agen
Prote AG.
battery.
– Disconnect red charging cable from positive terminal “+” on
battery.


⇒ “3.5.1 General description - battery charger VAS 5908 ”,
page 55
⇒ “3.5.2 Auto mode on battery charger VAS 5908 ”, page 56
⇒ “3.5.3 Charging battery with battery charger VAS 5908 ”, page
58
⇒ “3.5.4 Charging battery in support mode with battery charger
VAS 5908 ”, page 60
⇒ “3.5.5 VAS I-CHECK current draw test with battery charger VAS
5908 ”, page 62
3.5.1 General description - battery charger -

VAS 5908-
Note

Battery charger - VAS 5908- has the following operating modes:

♦ AUTO MODE , trickle charge with automatic load detection (bat‐
tery or electrical consumer) ⇒ page 56
♦ CHARGE MODE , battery charging agewith
n AG.adjustable parameters
Volkswagen AG
does
ksw
⇒ page 58 by
Vol not
gu
a d ran
ise
♦ EPS MODE , externalho power supply (support mode)
r tee
ut or
⇒ page 60 ss
a ac
ce
le
♦ I-CHECK , current draw test with short circuit test between cells
un
pt
an
d
⇒ page 62
itte
y li
rm
ab
Technical data
pe
ility
ot
wit
, is n
♦ Input voltage: 100-240 VAC

h re
hole
spec
♦ Output voltage: 14.4 VDC (13.2 VDC with trickle charge)

es, in part or in w
t to the co
♦ Charge current: 90 A (max. 105 A)

♦ Weight: 8.2 kg
rrectness of i
Replacement parts
l purpos
♦ Charger cable 5m - VAS 5908/1-

♦ Charger coupling - VAS 5908/2-
nform
ercia
For additional information, refer to ⇒ Operating instructions for

m
battery charger - VAS 5908- .

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.

Equipment overview of battery charger - VAS 5908-

1 - “ON/OFF” mains switch
2 - Mains cable connection
3 - UP ▲ button for menu selection
4 - ENTER button for menu selection or start
5 - DOWN ▼ button for menu selection
6 - Battery charger clamp connection + (red clamp)
7 - Battery charger clamp connection - (black clamp)
8 - RS232 communication interface, 9-pin
9 - Signal interface, 25-pin
10 - Display for menu selection
11 - LED display for displaying operating and equipment status
LED display -11-
The LED display on the front of the equipment serves to indicate
the operating and equipment statuses. The relevance of the flash‐
ing or lit green, amber or red LEDs in the various operating
statuses is listed in a table ⇒ Operating instructions battery
charger - VAS 5908- , 8) Attachment for LED and remote indicator
signals .
Equipment menu
In the equipment menu, various parameters and basic settings
can be predefined to safeguard measured values and determine
the activation and deactivation behaviour of the battery charger -
VAS 5908- .
– Switch on battery charger - VAS 5908- .
– Using buttons ▲▼ , choose menu line »MENU« and confirm
with ENTER button. G. Volkswagen gen A AG do
swa es
– Using buttons ▲▼ , choose by
sub-menu
Volk »EQUIPMENT MENU«
not
gu
ara
ris button.
and confirm with ENTER ed
nte
ho eo
ut ra
For further information
ss about
the equipment menu, see ⇒ Oper‐
a c
ating instructions for battery charger - VAS 5908- .
ce
e
nl
pt
du
an
itte
y li
3.5.2 Auto mode on battery charger - VAS

erm
ab
ility
ot p
5908-
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co

rrectness of i

l purpos

nform
mercia
»AUTO MODE« serves to maintain the voltage in the vehicle

at
om
io
electrical system (trickle charge) during flashing or diagnostic

n
c
in t
r
work. In »AUTO MODE«, the battery charger - VAS 5908- auto‐

o
his
e
matically detects whether a battery or an electrical consumer with

at
do
riv
resistive load is connected by means of integrated load detection.

p
cum
for
en
g

n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
56
by lksw
cted agen
Rep. gr.27 - Starter, current supply, CCS Prote AG.
Starting supply process
Note
If the charger clamps are connected to an electrical consumer or

battery before the charger is switched on, the battery charger -
VAS 5908- starts trickling charging in »AUTO MODE« automati‐
cally once it is switched on.

– Using buttons ▲▼ , choose AUTO MODE and confirm with EN-
TER button.
n AG. Volkswagen A G do
wage es n
– Connect red terminal clamp “+” to positive olks
y V terminal of vehicle ot g
b ua
battery. ris
ed ran
tee
tho or
au ac
ss
Note ce
e
nl
pt
du
an
itte
♦ On vehicles installed with a start/stop system and battery y li

erm
ab
monitor control unit - J367- , the black charger terminal clamp ility
ot p
“-” must be connected to the body earth.

wit
, is n
h re
♦ If it is connected to the negative terminal of the battery, the

hole
spec
battery monitor control unit - J367- will be bridged. This could

es, in part or in w
result in malfunctions in the start/stop system.

t to the co
– On vehicles with start/stop system, fit the black charger clamp

rrectness of i
“-” to body earth.

l purpos
– On vehicles without start/stop system, fit the black charger

clamp “-” to the negative terminal of the vehicle battery.
nf
ercia
OR
orm
m
atio
– Fit the charger clamps with correct polarity to an electric con‐

om
sumer with resistive load.

n in
or c
thi
e
– Using buttons ▲▼ , choose menu START and confirm with EN-

t
sd
iva
TER button to start the supply.

r
rp
cu
o
m
f
en
ng
t.
yi Co
op py
Note
t. C rig
gh ht
pyri by
Vo
co lksw
by
The battery charger - VAS 5908- adapts the current and voltage cted agen
Prote AG.
thresholds automatically for auto mode.
Ending supply process

– Using buttons ▲▼ , choose menu STOP and confirm with EN-
TER button to stop the supply.

– Switch off battery charger - VAS 5908- .

– Disconnect black charger clamp “-” of battery charger from
negative terminal of vehicle battery or electrical consumer.
– Disconnect red charger clamp “+” of battery charger from pos‐
itive terminal of vehicle battery or electrical consumer.
– Pull out mains plug of charger.

VAS 5908-
Note

. Volkswagen AG
gen AG
♦ “VAS 5908” ⇒ “3.5 VBattery
wa charger VAS 5908o”,
espage 55 d
olks not
gu
y
db ara
rise nte
tho eo
au
WARNING
s
ra
c
s
ce
le
un
pt
Danger of injury! Comply with the warning notices and safety

an
d
itte
y li
regulations ⇒ page 3 !
erm
ab
ility
ot p
wit
is n
h re
ole,
WARNING
spec
t to the co
Do not test or charge batteries - A- whose magic eye is »col‐

ourless/light yellow«. Do not slave/jump start the vehicle!
rrectne
jump starting.
s

s o
cial p
f inform
mer
atio
om
Note
n
c
i
or
n thi
te
sd
a
♦ Follow instructions in chapter »Exhaustively discharged bat‐

iv
o
pr
teries« ⇒ page 69 .
um
r
fo
en
ng
t.
yi
Co
op py
exchanged prior to delivery. Preliminary damage cannot be t. C rig
gh ht
excluded. pyri by
Vo
co lksw
by
cted
agen
Prote AG.
♦ The minimum voltage “Uesp” of the battery to be charged must

be at least 5 V.

Charging battery
– Switch off ignition and all electrical consumers and withdraw
ignition key.
– Connect red terminal clamp “+” to positive terminal of vehicle
battery.
Note
♦ On vehicles installed with a start/stop system and battery

monitor control unit - J367- , the black charger terminal clamp
– On vehicles with start/stop system,

gen AG
. Volkswafit
gethe
n AGblack
does
charger clamp
“-” to body earth.Volkswa not
y gu
db ar
– On vehicles ris without start/stop system, fit the black charger
e an
tee
ho
clamp “-”
au to the negative terminal of the vehicle battery. r a
t o
ss c
– Using buttons ▲▼ , choose CHARGE MODE and confirm with
ce
e
nl
pt
du
ENTER button.
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
hole
♦ The battery charger - VAS 5908- adapts the current and volt‐
spec
age thresholds automatically for charge mode.

es, in part or in w
t to the co
♦ Predefine different current and voltage thresholds in the

charging menu if necessary ⇒ page 60 .
rrectness of i
Ending battery charging process

l purpos

nf
ercia

orm
negative terminal of vehicle battery.

m
atio
om

n in
or c
itive terminal of vehicle battery.

thi
te
sd
iva

r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Note
For sustained operation, the battery charger - VAS 5908- auto‐

matically changes to trickle charging once the battery is fully
charged.
Charging menu
The battery charger adapts the current and voltage thresholds
automatically for charge mode. The parameters for charging
mode can also be set manually.
– Using buttons ▲▼ , choose menu line »MENU« and confirm
with ENTER button.
– Using buttons ▲▼ , choose sub-menu »CHARGING MENU«
and confirm with ENTER button.
For further information about the charging menu, see ⇒ Operating
instructions for battery charger - VAS 5908- .

Note

AG. Volkswagen AG d
agen oes
♦ “VAS 5908” ⇒ “3.5 Battery charger VAS 5908 ”, page 55 olksw not
V gu
d by ara
ise nte
or eo
Support or backup mode (»EPS MODE«) serves to supply aut the
h
ra
vehicle electrical system with power if the battery is disconnected
ss c
ce
le
or removed.
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n

h re
ole,
♦ Ancillaries test without battery spec

t to the co
Caution
rrectne
In »EPS MODE«, only a resistive load (electrical consumer)

may be supplied.
ss
»EPS MODE« may not be used if a battery is connected.

o
cial p
f inform
Before using »EPS MODE«, disconnect or remove the battery.

mer
atio
om
n
c
i
or

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.

Performing support mode

– Switch off ignition gand all
en AG. Velectrical
olkswagen Aconsumers
G do and withdraw
ignition key.Volkswa es n
ot
b y gu
ara
– Remove ed
oris battery ⇒ Electrical system; Rep. gr. 27nte; Removing
eo
andautinstalling battery .
h
ra
ss c
– Switch on battery charger - VAS 5908- . ce
e
nl
pt
du
an
itte
y li
erm
Caution ab
ility
ot p
wit
, is n
Make absolutely sure that the red charger clamp does not
h re
come into contact with the body earth.

hole
spec
Make absolutely sure that the battery terminal clamps do not

es, in part or in w
t to the co
come into contact with each other.

rrectness of i
– Connect red terminal clamp “+” of charger to positive terminal

clamp of vehicle battery.
l purpos
nf
ercia
Note
orm
m
atio
m
♦ On vehicles installed with a start/stop system and battery

o
n in
c
monitor control unit - J367- , the black charger terminal clamp

or
thi
e

t
sd
iva
o
r
rp
cu

o
m
f

en
ng
t.
yi Co
t. Cop py
rig
gh ht
pyri by
– On vehicles with start/stop system, fit the black charger clamp
o Vo
by c lksw
cted agen
“-” to body earth. Prote AG.
– On vehicles without start/stop system, fit the black charger

clamp “-” to the negative terminal clamp of the vehicle battery.
Note
♦ The battery charger - VAS 5908- adapts the current and volt‐
age thresholds automatically for support mode.
♦ Predefine different current and voltage thresholds in the EPS
menu if necessary ⇒ page 62 .
– Using buttons ▲▼ , choose EPS MODE and confirm with EN-

TER button.
Ending support mode



negative terminal clamp of vehicle battery.
itive terminal clamp of vehicle battery.
EPS menu
The battery charger adapts the current and voltage thresholds
automatically for support mode. The parameters for support mode
can also be set manually.
. Volkswagen AG
gen AG does
– Using buttons ▲▼ , choose menu line »MENU«Vol
ksw and confirm
a
not
gu
with ENTER button. ed by ara
nte
ris
ho eo
– Using buttons ▲▼ , choose sub-menu
sa
ut »EPS MENU« and con‐ ra
c
firm with ENTER button. s
ce
le
un
pt
For further information about the EPS menu, see ⇒ Operating
an
d
itte
y li
instructions for battery charger - VAS 5908- .
erm
ab
ility
ot p
3.5.5 VAS I-CHECK current draw test with
wit
is n
h re
ole,
spec
t to the co
Note
rrectne
ss o
cial p
f inform
mer
atio
om
n
c
The current draw test serves as a means of quickly appraising the i

or
n thi
e
condition of a discharged battery. Based on the result of the cur‐

t
sd
va
rent draw test, it is possible to determine whether the battery must

i
o
pr
cum
r
be renewed or fully charged.

fo
en
ng
t.
yi Co
Cop py
t. rig
gh
Note
ht
pyri by
Vo
o
by c lksw
cted agen
For the battery current draw test, take measures to ensure that
Prote AG.
the battery is testing without electrical consumers attached in

parallel.

Perform current draw test

– Disconnect both battery terminal clamps so as not to falsify the
result from electrical consumers within the vehicle ⇒ Electrical

system; Rep. gr. 27 ; Battery; Disconnecting and connecting

battery .
– Switch on battery charger - VAS 5908- and connect to battery
with correct polarity using charger clamps.
– Using buttons ▲▼ , choose menu line »AUTO MODE« and
confirm with ENTER button (display flashes).
– Using buttons ▲▼ , choose I-CHECK and confirm with ENTER
button.
– Activate battery capacity input »Qbat:« by pressing ENTER
button (flashes).
– Using buttons ▲▼ , set capacity (Ah) of battery to be tested and
confirm with ENTER button.
– Using buttons ▲▼ , choose menu line »TEST START« and
confirm with ENTER button to start the current draw test. Note
possible connection error messages ⇒ page 64 .
While current draw test is running, »TEST« flashes in display.
Button lock is activated, active test can only be interrupted by re‐
moving charger clamps. Note possible abort error messages
⇒ page 64 .
End of test with result 'Current draw I less than 100%’ (battery
defective)
If the current draw »I« is <100% at the end of the test, the current
supply to the battery is interrupted and »FILL IN WARRANTY
APPLICATION« appears in the display.
– Using buttons ▲▼ , choose »OK« and confirm with ENTER but‐
ton to display the test results.
The current draw percentage is displayed in the results windows
under »I«. The displayed data can be copied over to the battery
test sheet.
. Volkswagen AG
– Using buttons ▲▼ , choose »TEST END« and confirm ksw
agen with
AG does
not
l
ENTER button to stop the current draw test.by Vo gu
ara
d e
ris nte
End of test with result 'Current draw I greater
ut
ho than 100%' (battery eo
ra
in order but insufficiently charged) ss a c
ce
le
un
If the current draw »I« is >100% at the end of the test, the current
pt
an
d
supply to charge the battery is continued.

itte
y li
erm
ab
– Using buttons ▲▼ , choose »RESULT« and confirm with EN-

ility
ot p
TER button to display the test results.

wit
is n
h re
ole,
The current draw percentage is displayed in the results windows

spec
under »I«.
t to the co
– Using buttons ▲▼ , choose »OK« or »TEST END« and confirm

with ENTER button to change to “I-Check charge mode” and
continue charging the battery.
rrectne
In I-Check charging mode, »CHARGING« flashes in the display

s
until the battery is fully charged. Once the charging process is

s o
complete, the equipment switches automatically to trickle charge.

cial p
f in
»TRICKLE« flashes in the display.

form
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
63
AG.
3. Charging the battery
Note
♦ While the battery is being charged in “I-Check charging mode”,

the short circuit between cells test is automatically active.
♦ When the short circuit between cells test is active, the battery
charge is interrupted twice for approx. 30 seconds in order to
perform a voltage measurement.
♦ If the short circuit between cells test is positive, the charging
process is interrupted and »CELL SHORT CIRCUIT« is dis‐
played. agen
AG. Volkswagen AG d
o
ksw es n
Vol ot g
by ua
Connection error messages rise d ran
tee
tho or
♦ »APPLICATION ERROR s au - CONTACT« = no battery detected ac
s
and no battery connected.
ce
le
un
pt
an
d
♦ »APPLICATION ERROR - POLARITY REVERSAL« = battery

itte
y li
was connected with polarity reversal.
rm
ab
pe
ility
♦ »APPLICATION ERROR - EXHAUSTIVE DISCHARGE« =
ot
wit
, is n
voltage level of connected battery is below the activation volt‐
h re
hole
age limit (Uesp) as defined in the charging menu.
spec
es, in part or in w
Abort error messages
t to the co
♦ »APPLICATION ABORT - CONTACT« = battery was discon‐
nected during the test.
rrectness of i
♦ »APPLICATION ABORT - SHORT CIRCUIT« = short circuit
l purpos
determined in battery cables.
3.6 Midtronics - INC 940- battery charger

nform
ercia
only for USA/Canada

m
a
com
tio
Warning and safety regulations ⇒ page 3

n in
r
te o
thi
General description ⇒ page 64

s
iva
do
r
rp
cum
Charge battery ⇒ page 65 .

fo
en
ng
t.
yi
Dealing with problems with Midtronics - INC 940- battery tester
Co
Cop py
⇒ page 67
t. rig
gh ht
pyri by
Vo
o
3.6.1 General description of Midtronics - INC
by c lksw
cted agen
Prote AG.
940- battery tester
Batteries in VW vehicles are only allowed to be charged with bat‐
tery chargers approved by VW. In the USA/Canada, it is permitted
for the Midtronics - INC 940- battery charger to be used.
Midtronics - INC 940- battery charger combines battery charging
with a charge condition checks and a battery test.
The following charging and analysis procedures apply to all bat‐
teries, all battery installation locations (engine compartment or
luggage compartment) and battery application purposes (starter
battery or second/convenience battery).
Always comply with the safety regulations, the regulations for
setting up the battery charger, the display menu/display buttons,
LEDs and the operating procedures described in the ⇒ operating
manual INC 940 .
Read through ⇒ operating manual INC 940 carefully.
Refer to ⇒ Self-study programme No. ; Vehicle batteries for more
information.

WARNING

tions ⇒ page 3 !
No naked flames, sparking or smoking in the vicinity of batter‐
ies. wage
e
olks s no
Battery charger must be switched off ebefore
y V cables are con‐ t gu
db ara
nected or disconnected. ho
ris nte
eo
t
au ra
Do not remove cell plugs duringsscharging. c
ce
le
un
Overcharging sulphated batteries can lead to explosions.
pt
an
d
itte
y li
Do not store precision tools in rooms where batteries are
rm
ab
pe
charged, because corrosion can ensue due to chemical reac‐
ility
ot
tions.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
WARNING
rrectness of i
l purpos

jump starting.
nform
ercia

m
a
com
tion in
r
te o
3.6.2 Charging battery
thi
s
iva
do
r
rp
cum
fo
en
g
Note
n
t.
yi Co
Cop py
t. rig
gh
To avoid problems when updating or flashing the vehicle soft‐
ht
pyri by
Vo
o
ware, a charger capable of outputting a charge current of at least by c lksw
cted agen
70 A (such as e.g. the “VAS 5903”) should be used. ⇒ page 40
Prote AG.
Prerequisites:
WARNING

jump starting.
INC 940 initial set-up performed (dealership number, date/time)

⇒ Operating manual INC 940 .
– Check general information ⇒ page 64 .
– Open bonnet or cover for other installation location of battery.
– Perform visual check of battery ⇒ page 7 .
– Determine whether battery type is “Standard” (wet battery) or
“AGM” (absorbent glass mat battery).
– Close all vehicle doors.

Note
♦ Battery temperature must be at least 10°C.

INC 940 .
Perform charging procedure:

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

– Connect black terminal clamp “–” of battery charger to nega‐

tive terminal. agen
AG. Volkswagen AG d
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olks ot
– Connect Midtronics
ed
by - INC 940- battery charger to an
V gu earthed
ara
socket. horis nte
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au a
– Set “ON/OFF”
ss switch of Midtronics - INC 940- battery charger
c
to “ON”.
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– Select “Automatic” or “Manual” charging mode.

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ility
– Select test “In vehicle” or “Outside vehicle”.

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– Select battery type “Standard” or “AGM” (absorbent glass

h re
hole
mat).
spec
es, in part or in w
– Select test type “Warranty” or “Miscellaneous”. Note additional

t to the co
details (depending on type of test).

rrectness of i
Note
l purpos

INC 940 .
nform
ercia
♦ If necessary, make a note of menu items required for “War‐

m
at
ranty” test type ⇒ Warranty service circular .

om
ion
c
in t
or
his
e
Midtronics - INC 940- battery charger tests battery and starts

at
do
riv
charging procedure. Display then shows one of three results, as

p
cum
or
well as approximate charging time.

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t.
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Result: Measures:
C py
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Battery OK Battery can be returned to op‐
cop Vo
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Prote AG.

Result: Measures:
Charging required ♦ Test found low charge level.
♦ Charging starts and approx‐
imate charging duration is
displayed.
♦ Achieved cold-start per‐
formance and remaining
charging time are displayed,
and are updated regularly.
Renew battery Battery defective. Charging

procedure is interrupted. Re‐
new battery.
Note
In case Midtronics - INC 940- shows fault messages or text dis‐

plays other than those listed above, please refer to
⇒ page 67 .
WARNING
Stop charging if battery is liberating a lot of gas. Press “Stop”

button on front.
When charging and testing procedure has finished, Midtronics -

INC 940- battery charger displays “Battery good” or “Renew
battery” and total charging time.
There are three possible messages depending on individual cir‐
cumstance (printout for warranty, repair job, evaluation and filing):
♦ Generate test code (only possible after automatic charging
and test). n AG. Volkswagen AG age does
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♦ Print last test
by result (for warranty).
Vol
not
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ara
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♦ Display
tho last test results.
r eo
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c
ss
ce
le
un
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Note
an
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itte
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ab
For additional information, refer to the ⇒ operating manual INC

ility
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940 .
wit
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3.6.3 Dealing with problems with Midtronics -

spec
INC 940- battery tester

t to the co
Under certain circumstances, the display may show errors or

messages according to status.
rrectne
The most frequent display messages are listed below, together

s
with suggested solutions.

s o
cial p
f inform
mer
Note
atio
om
n
c
For messages not listed here, please refer to ⇒ operating manual

or
n thi
e
INC 940 .
t
sd
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pr
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fo
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t.
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Cop py
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67
op Vo
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Prote
cted AG.
agen 3. Charging the battery
Display message Measure

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

tightened according to reg‐
ulations and do not have
corrosion.
Terminals connected? Safety function of tester.
– Connect terminals to battery
before starting charging pro‐
cedure.
System noise – Switch off all electrical con‐
sumers.
– Wait until all electrical loads

monitored by on-board sup‐
ply control unit have switch‐
ed off.
– Pull out ignition key.
– Disconnect any suspect

electrical equipment not
connected to on-board sup‐
ply as standard.
Wait a few minutes and repeat charging procedure ⇒ page 65 .
3.7 Solar charger module - VAS 6102B-

with solar panel - VAS 6102B-
AG. Volkswagen AG d
agen oes
Solar charger module VAS 6102B olksw not
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General description: rise nte
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Solar panel - VAS 6102B- supports onboard supply and
s prevents
s c
ce
spontaneous discharging of battery.
le
un
pt
an
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Solar charger module - VAS 6102B- achieves max. voltage of

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14.3 V and a charge current of max. 255 mA.
pe
ility
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Solar charger module - VAS 6102B- is allowed to be used for

, is n
h re
charging all rechargeable lead or lead gel batteries.

hole
spec
Solar charger module - VAS 6102B- is connected to diagnostic

es, in part or in w
t to the co
connection in vehicle.
A green LED is integrated in the frame to indicate its function. The
brighter the LED, the higher the charging current.
rrectness of i
Integrated electronics prevent battery overcharging.

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

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

– Place underside on dash panel -2-.
Note
wage es n
Solar charger module - VAS 6102B- is not allowed to lie fullyy Von olks ot g
dash panel. It is only allowed to be positioned with the bottom ed b ua
ran
ris
edge for support. Placing it fully on the surface can result
tho in dis‐
tee
or
colouration of the dash panel. ss
au ac
ce
e
nl
pt
du
– Pull attachment string tight so that solar charger module - VAS
an
itte
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6102B- is positioned close to windscreen.
erm
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ility
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– Connect solar panel - VAS 6102B- to diagnostic connection of
wit
vehicle. Connection procedure is as for vehicle diagnostic , is n
h re
tester ⇒ page 88
hole
spec
es, in part or in w
– Check function of solar panel - VAS 6102B- . Green LED in‐
t to the co
dicates function of solar panel - VAS 6102B- .
3.8 Totally discharged batteries
rrectness of i
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WARNING
nf
ercia
o
rm
m
tions ⇒ page 3 !
atio
om
n in
or c
thi
te
sd
A battery is designated “totally discharged” when the no-load volt‐
iva
o
r
age is less than 11.6 V.

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en
ng
t.
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op
WARNING C py
t. rig
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pyri by
Vo
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c by lksw
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Prote AG.

jump starting.
Caution
♦ Totally discharged batteries freeze prematurely.

♦ Frozen batteries should no longer be used.

AG. Volkswagen AG d
agen oes
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Note rise
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♦ Totally discharged batteries in unregistered svehicles must be
s c
ce
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nl
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excluded.
an
itte
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erm
ab
♦ Batteries that have not been used for a long period of time
ility
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discharge themselves, e.g. those fitted in stored vehicles.
wit
, is n
h re
♦ In totally discharged batteries, the electrolyte is comprised al‐
hole
most entirely of water because the acid content is so low.
spec
es, in part or in w
t to the co
♦ Totally discharged batteries sulphate, that means, the entire
plate surfaces of the battery harden.
♦ If a battery is recharged shortly after it has totally lost its
rrectness of i
charge, the sulphation will mostly dissipate.
l purpos
♦ If these batteries are not recharged, the plates continue to

harden and the ability to recharge is reduced. The result of
which is a reduction in the battery output.
nf
ercia
orm
m
atio
m
– Check battery no-load voltage ⇒ page 22 .

o
n in
or c
thi
te
sd
iva
o
r
rp
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o
m
f
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
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Prote AG.

4 Cruise control system

lksw
agen (CCS) AG does
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General description: risedb ara
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The functions of the cruise
aut control system are controlled by the ra
ss c
engine control unit.
ce
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un
pt
– The cruise control system can be activated/deactivated
an
d
itte
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⇒ page 71 .
erm
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ility
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Fault detection and fault display:
wit
is n
h re
Faults on the CCS are output via the engine control unit.
ole,
spec
For fault finding, use vehicle diagnosis, testing and information
t to the co
system in “Guided fault finding” mode.
4.1 Activating and deactivating cruise con‐
rrectne
trol system (CCS)
s
– Connect vehicle diagnostic tester ⇒ page 88 .
s o
cial p
f inform
– Select “Guided fault finding” mode in vehicle diagnostic tester .
mer
atio
– Using the “GoTo” button, select “Function/component selec‐
om
n
tion” and the following menu items in succession:
c
i
or
n thi
te
♦ Drive
sd
iva
o
pr
cum
r
♦ Engine code
fo
en
ng
t.
yi Co
♦ 01 - Systems capable of self-diagnosis t. Cop py
rig
gh ht
yri
♦ Engine management/diesel direct injection and glow plug sys‐ p by
co Vo
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by lksw
cted agen
Prote AG.
♦ Functions
♦ Activating and deactivating cruise control system (CCS)
4. Cruise control system (CCS) 71

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
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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
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by c lksw
cted agen
Prote AG.
72 Rep. gr.90 - Gauges, instruments

. Volkswage
AG n AG d
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92 – Windscreen wash/wipe system
ara
rise nte
tho eo
s au ra
c
s
ce
le
1 Washer fluid line hose couplings
un
pt
an
d
itte
y li
rm
The following hose coupling types are used to connect the hose
ab
pe
ility
connection to pumps and washer jets and/or as points of sepa‐
ot
wit
ration:
, is n
h re
hole
1.1 Windscreen and rear window washer
spec
es, in part or in w
system
t to the co
– Pull the two coupling sections apart (no securing device) to
loosen the connection.
rrectness of i
– To secure the connection, push the two coupling sections to‐
l purpos
gether, until you hear and feel them engage.
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
– To loosen the connection, rotate the lock ring -1- through 90°
yri
gh by
ht
-arrow- and pull off the hose connection. cop Vo
by lksw
cted agen
Prote
– To secure the connection, push on the hose connection and
AG.
rotate the lock ring -1- -arrow- until it engages.
– To loosen the connection, pull up the lock ring -1- by approx.

1 mm -arrow-, and pull off the hose connection.
– To secure connection, attach hose connection and press in
clip -1- until it engages.
1. Washer fluid line hose couplings 73

– To loosen the connection, pull up the lock ring -1- -arrow- and
pull off the hose connection.
lkswage es n
o ot g
byV ua
d ran
ir se tee
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u or
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un
pt
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1.2 Headlight washer system
rm
ab
pe
ility
ot
– To loosen the connection, push the lock ring -1- -arrow- and
wit
, is n
pull off the hose connection.
h re
hole
spec
– To secure the connection, push and hold the lock ring
es, in part or in w
-arrow- and push on the hose connection. Check that the se‐
t to the co
curing clip has correctly engaged by depressing and trying to
pull off without the clip.
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.
74 Rep. gr.92 - Windscreen wash/wipe system

2 Hose repair
A new repair concept has been developed for repair work on wash
system hoses. Various connectors, special EPDM hoses (ethyl‐
ene-propylene-diene monomer) and heat-shrink hose are avail‐
AG. Volkswagen AG d
able as spare parts. agen oes
o lksw not
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2.1 General description tho
rise nte
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au ra
c
♦ The replacement parts can be found
s in the electronic
s
parts
ce
e
catalogue (ETKA).
nl
pt
du
an
itte
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♦ Replacement parts are available for repair of both smooth and erm
ab
corrugated pipes.
ility
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wit
, is n
2.2 Repairing smooth pipe
h re
hole
spec
Smooth pipes with a diameter of 5x1 mm or 6x1 mm can be re‐
es, in part or in w
paired with EPDM hose.
t to the co
– Cut damaged section at right angles out of smooth pipe which
is to be repaired.
rrectness of i
– Select the appropriate EPDM hose -2- and cable ties accord‐
l purpos
ing to the electronic parts catalogue (ETKA).

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

m
at
om
ion
c
in t
or
– Secure the repair joints with cable ties -1-.
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
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co lksw
by
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Prote AG.
2.3 Repairing corrugated pipe

♦ Hot air blower - VAS 5179- or
♦ Hot air blower - V.A.G 1416/- or

♦ Hot air blower - VAS 1978/14-
2. Hose repair 75
Note
♦ Repair points must not be subjected to pulling or bending

forces.
♦ If the damaged section is longer than 20 mm, a new piece of
corrugated pipe must be used and the procedure described
below must be performed twice.
– Cut damaged section at right angles out of corrugated pipe

which is to be repaired.
– Select suitable end pieces -2- and -3- and correct sized shrink-
. Volkswagen AG
fit piping from the electronic parts catalogue (ETKA).
swa
gen AG does
olk not
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– Heat end of corrugated tube -1-. e db ara
nte
ris
ho eo
– Push connector -2- into corrugated atube
ut -2- -arrow A-. ra
c
ss
– Heat end of corrugated tube -1-.
ce
le
un
pt
an
d
itte
– Push connector -3- into corrugated tube -4- -arrow B-.
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
– Cut heat-shrink hose so that ends of corrugated tube are each
spec
covered by about 20 mm -dimension x- of heat-shrink hose.
t to the co
– Push heat-shrink hose over corrugated tube, join connectors
and secure repair joints with heat-shrink hose.
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
py by
co Vo
by lksw
cted agen
Prote AG.
76 Rep. gr.92 - Windscreen wash/wipe system

3 Distinguishing features of jointless

wiper blades
Distinguishing features of Bosch and Federal Mogul products.
When renewing wiper rubbers, note the make. When renewing
wiper blades, the same make must be used.
Wiper blades can be identified according to wiper arm fastening.
Bosch wiper blades -1 and 2-:
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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ut ra
Federal Mogul wiper blades -1-: ss a c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
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
py by
co Vo
by lksw
cted agen
Prote AG.
3. Distinguishing features of jointless wiper blades 77

94 – Lights, bulbs, switches - exterior

1 Operation and safety notes for gas
discharge lamps
– If repairs are to be made to the headlight with gas discharge
bulbs, observe the following:
♦ Notes on dangerous high voltage/currents ⇒ page 78
♦ Notes on pressure, temperature, radiation/arcs ⇒ page 79
♦ Assembly notes for gas discharge bulbs ⇒ page 80
♦ Disposal regulations for gas discharge bulbs ⇒ page 80
♦ Safety goggles
♦ Gloves
AG. Volkswagen AG d
WARNING agen oes
olksw not
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d by ara
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It is absolutely necessary horto
is
disconnect the battery earth strap eo
before working on parts aut of the gas discharge headlights ra
s c
marked with yellow high voltage symbols.
s ce
le
un
pt
Then switch dipped beam on and off again. This will eliminate
an
d
itte
y li
any possible residual voltage.
erm
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ility
ot p
The gas discharge lamp control unit must never be operated

wit
is n
without a gas discharge lamp.

h re
ole,
spec
Due to the high voltage (above 28000 V when igniting the gas
discharge bulb) and high temperatures, the gas discharge bulb

t to the co
must only be operated in the headlight housing.

rrectne
WARNING
ss o
cial p
♦ Never change bulbs if you are not familiar with the appro‐
inform
priate procedures, safety precautions and tools.

mer
atio
om
n
c
Notes on dangerous high voltage and current

or
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te
sd
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o
pr
cum
WARNING
r
fo
en
ng
t.
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op
Control units for light systems, connectors and components
C py
t. rig
gh
pertaining to bulb holders conduct lethally high voltage.
ht
pyri by
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by c lksw
Operating the control unit and the starter unit is permitted only cted agen
Prote AG.
with the bulb fitted.
78 Rep. gr.94 - Lights, bulbs, switches - exterior

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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Ameo 2017 ➤ , Arteon 2018aut ➤ , Atlas 2017 ➤ , Bora 1999 ➤ , Bora Varian
h
r a ...
s c
Electrical
s System, General Information - Edition 01.2018
ce
e
nl
pt
du
an
itte
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erm
WARNING
ab
ility
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wit
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• Switch off ignition and all electrical consumers and re‐
h re
move ignition key.
hole
spec
es, in part or in w
• When working on the headlight system, ensure that there
t to the co
is no voltage in any component, including 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
lights cannot be switched on. mercia
at
om
ion
c
Notes on pressure, temperature, radiation/arcs
in t
or
his
ate
do
priv
c
WARNING
um
for
en
ng
t.
yi Co
op
• The bulbs may be operated in the headlight housing only C py
ht. rig
(protection against contact due to very hot bulbs, absorp‐ rig ht
py by
tion of UV radiation, avoidance of dazzling light, protection
co Vo
by lksw
cted
against explosion).
agen
Prote AG.
• The glass of the bulbs can become very hot - danger of

burns!
• Avoid looking directly into the beam, as the UV rays from
the gas discharge bulb are about 2.5 times greater than
normal halogen bulbs.
• Avoid looking into the light beam (danger of glare); vision
may be impaired for a substantial time.
WARNING
• Avoid contact with burst glass part of the bulbs.

• H7 bulbs and gas discharge bulbs (xenon and bi-xenon)
are under pressure and can explode while being changed
– danger of injury.
• Always wear eye protection and gloves when removing
and installing gas discharge lamps!
1. Operation and safety notes for gas discharge lamps 79

Assembly notes for gas discharge bulbs
Caution
♦ Always switch off the affected consumers before exchang‐

ing a bulb.
♦ Switch off ignition and all electrical consumers and re‐
move ignition key.
♦ Do not touch the glass part of the bulb with bare fingers;
use clean cloth gloves. When the light bulb is switched on,
the heat would vaporise the oil of the finger prints which
would then settle on the reflector, impairing the brightness
of the headlight.
♦ A light bulb must always be renewed with a bulb of the
same sort. The designation appears on the base of the
bulb or on the bulb glass.
♦ Properly engage connectors during installation and the
connection is seated tightly.
Disposal regulations for gas discharge bulbs
WARNING
• Gas discharge bulbs must be disposed agenof as hazardous

AG. Volkswagen AG d
o
waste; never dispose of gas discharge
olksw bulbs as consumer es not
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waste. ris
ed
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tho
• Gas discharge bulbs scontain
au metallic mercury (Hg) and or
ac
traces of thallium; never
s destroy these bulbs.
ce
e
nl
pt
du
• These components must be recycled in the correct man‐

an
itte
y li
ner according to national law.

erm
ab
ility
ot p
• Only dispose of in containers intended for this purpose at

wit
, is n
an authorised collection point.

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
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m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
80 Rep. gr.94 - Lights, bulbs, switches - exterior

96 – Lights, bulbs, switches - interior

1 12 V socket
1.1 Removing and installing 12 V socket
Caution
If excessive force is exerted on sockets without illumination,

the retaining sleeve may be damaged.
Only illuminated sockets (cigarette lighter) can be removed
with the puller T 40148.
. Volkswag
The puller does not kmanage
swa
gen AG to release the
en AG
doelocking
s no lugs of
sockets without illuminated
b y Vol
retaining sleeve. t gu
a
d ran
ise
Usually socketsho
r
without illumination cannot be removedteewith‐
ut or
out beingss damaged.
a ac
ce
le
un
pt
an
d
itte
Refer to removing and installing cigarette lighter - U1-

y li
erm
ab
⇒ page 82 .
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1.2 Removing and installing socket illumi‐ wit

is n
h re
ole,
nation bulb - L42-

spec
t to the co
The removal of the socket illumination bulb - L42- is performed in

the same way as the removal of the cigarette lighter illumination
bulb - L28- ⇒ page 86 .
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.
1. 12 V socket 81
2 Cigarette lighter - U1-

The following descriptions apply to the rear left cigarette lighter -
U3- , rear right cigarette lighter - U7- , rear cigarette lighter - U9- ,
12 V socket 2 - U18- , 12 V socket 3 - U19- , 12 V socket 4 - U20- ,
cigarette lighter 2 - U25- and 12 V socket 5 - U26- so far as they
are illuminated.
Caution

The puller does not manage to release the locking lugs of
sockets without illuminated retaining sleeve.
Usually sockets without illumination cannot be removed with‐
out being damaged.
2.1 General description
Caution

Usually sockets without illumination cannot be removed
n AG. Vowith‐
lkswagen AG
out being damaged. wage does
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On some vehicles, the illuminations aisu not provided
by a light bulb, ra
c
but by an LED (light-emitting diode), depending on the equipment
s
ce
e
nl
level. This LED is permanently attached to the retaining sleeve

pt
du
an
and cannot be renewed separately.

itte
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erm
ab
Retaining sleeves with a light bulb are available in different ver‐

ility
ot p
sions. On the one version, the light bulb can be replaced sepa‐
wit
, is n
rately; on the other version, the light bulb cannot be replaced

h re
hole
separately. In this case, the bulb carrier has to be replaced to‐

spec
gether with the light bulb.

es, in part or in w
t to the co
Depending on the space requirement, the vehicles are equipped

with various electric sockets and cigarette lighter sockets. They
differ in length and have different electrical connections. In the
rrectness of i
case of electric sockets or cigarette lighter sockets with a wiring

tail, it may be necessary to perform additional work in order to
l purpos
gain access to the connector.

nform
mercia
at
om
ion
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in t
or
his
ate
do
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for
en
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Prote
82
AG.
Rep. gr.96 - Lights, bulbs, switches - interior
2.2 Assembly overview
Caution

out being damaged.
1 - Cigarette lighter socket with

wiring tail
2 - Cigarette lighter
3 - Electric socket
4 - Cigarette lighter socket
5 - Clamping sleeve
6 - Light bulb W 5 12 V 1.2 watt
7 - Bulb carrier
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es, in part or in w
t to the co
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nform
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tion in
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te o
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Prote AG.
2. Cigarette lighter U1 83
2.3 Removing and installing cigarette lighter

socket
Note
The removal and installation procedure is the same for all sockets
and is therefore described here only for the cigarette lighter sock‐
et.
Caution

out being damaged.

♦ Puller - T 40148-
AG. Volkswagen AG d
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Removing:
ce
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nl
pt
du
an
– Remove cigarette lighter, dummy cigarette lighter etc. from

itte
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socket if necessary.
erm
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ility
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wit
, is n
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Note
hole
spec
es, in part or in w
For reasons of clarity, the socket is removed in the illustration.

t to the co
Caution
rrectness of i
l purpos
The socket or the retaining sleeve can be damaged.

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

orm
m
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om
n in
or c
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84
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Rep. gr.96 - Lights, bulbs, switches - interior
agen
Prote AG.
– Push puller -arrow- into socket so that locking lugs -1- engage
in recesses -2-.
– Pull grip -3- in direction of -arrow- to release locking lugs of

retaining sleeve.
– Pull socket out of retaining sleeve using puller.
Caution
AG. Volkswagen AG d
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The socket wiring can be ydamaged.
Vol
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gu
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Take care not to stretchrise the wiring when pulling out the socket.ante
tho eo
s au ra
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s
ce
le
un
pt
an
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rm
ab
Depending on the fitting location, it is recommended to use the
pe
thrust piece 40148/1 -2- with the knurled nut -1-. ility
ot
wit
, is n
h re
hole
spec
Caution
es, in part or in w
t to the co
When using the thrust piece, ensure that no surrounding com‐

ponents are damaged.
rrectness of i
l purpos
– Pull off socket connector.

nform
ercia
Note
m
a
com
tio
Depending on the space requirement, the vehicles are equipped

n in
r
with various electric sockets and cigarette lighter sockets. They

te o
thi
differ in length and have different electrical connections. In the

s
iva
do
r
case of electric sockets or cigarette lighter sockets with a wiring

rp
cum
fo
tail, it may be necessary to perform additional work in order to

en
ng
t.
gain access to the connector.
yi Co
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Prote AG.
– Release puller locking lugs by pressing spindle -1- in direction

of -arrow B-. Then release puller -2- by turning it briefly to left
-arrow A-. Remove puller from socket.
Note
Ensure that the puller locking lugs are not spread.
Caution
The cigarette lighter might be ejected out of the socket after

the heating phase.
When the puller is mounted, the socket retaining springs are
pressed apart and the retaining force is reduced.
After removing the socket, carefully press the retaining springs
together and check if the cigarette lighter remains
AG. Volkswin
agethe
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moval position after the heating phase. agen does
olksw not
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au ra
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– Carefully press socketss retaining springs together -arrows-.
ce
le
un
pt
– Check if cigarette lighter remains in removal position after
an
d
itte
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heating phase and ensure it is not ejected in vehicle interior.
rm
ab
pe
ility
Installing:
ot
wit
, is n
h re
Installation is carried out in the reverse sequence of removal.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
2.4 Removing and installing cigarette lighter

nform
ercia
illumination bulb - L28-

m
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tion in
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Note
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thi
s
iva
do
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♦ On some vehicles, the illumination is not provided by a light

rp
cum
fo
bulb, but by an LED (light-emitting diode), depending on the

en
ng
t.
yi
equipment level. This LED is permanently attached to the re‐
Co
op py
taining sleeve and cannot be renewed separately.
t. C rig
gh ht
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Vo
♦ Retaining sleeves with a light bulb are available in different
o
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versions. On the one version, the light bulb can be replaced Prote AG.
separately; on the other version, the light bulb cannot be re‐
placed separately. In this case, the bulb carrier has to be
replaced together with the light bulb.
Removing:
– Remove socket ⇒ page 84 .
86 Rep. gr.96 - Lights, bulbs, switches - interior

– Press retaining lugs -arrows- and remove retaining sleeve to‐

gether with bulb carrier.
– Unclip bulb carrier from retaining sleeve.
– Separate bulb carrier in areas -A- and -B-.

– Open part -B- of bulb carrier.
AG. Volkswagen AG d
agen oes
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d by ara
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or eo
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– Remove light bulb in direction of -arrow-. ss c
ce
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un
pt
Installing:
an
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itte
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erm
Installation is carried out in the reverse sequence of removal.

ab
ility
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wit
is n
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
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Prote AG.
97 – Wiring
1 Vehicle diagnosis, testing and infor‐
mation systems
lksw
agen
AG. Volkswagen AG d
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WARNING
ho
tee
aut or
ac
ss
♦ During testing or measuring operations using a vehicle di‐
ce
e
nl
pt
agnostic information system there is a risk of serious or
du
an
itte
even fatal injury!
y li
erm
ab
ility
♦ If the vehicle diagnostic information system is situated in
ot p
wit
the activation area of an airbag during testing or measur‐
, is n
h re
ing operations, serious or even fatal injury may result if an
hole
spec
airbag is triggered!
es, in part or in w
t to the co
♦ During testing and measuring operations, work with a per‐
son who can operate the vehicle diagnostic and informa‐
tion system from one of the back seats.
rrectness of i
l purpos
Note
nform
ercia
♦ All the operations described, e.g. adaptation, coding, etc. can

m
at
om
be performed using the vehicle diagnostic tester .

on
c
in t
or
♦ All work procedures can be found in “guided fault finding” and

his
ate
“guided functions” modes.

do
priv
cum
or
♦ Additional information:
f
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⇒ Self-study programme No. 202 ; Vehicle diagnostic, testing gh ht
yri by
and information system VAS 5051 cop Vo
by lksw
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Prote AG.
⇒ Self-study programme No. 256 ; VAS 5052
⇒ Self-study programme No. 294 ; Online connection of VAS
5051
– Connect vehicle diagnostic tester ⇒ page 88 .
1.1 Connecting vehicle diagnostic tester
Note
Observe the latest operating instructions for vehicle diagnostic

tester , which are displayed after selecting the “Administration”
and “Operating Manual” keys.
88 Rep. gr.97 - Wiring

♦ Vehicle diagnostic tester
♦ Diagnostic cable - VAS 5051/6A- (5 m)
AG. Volkswagen AG d
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♦ Diagnostic cable - VAS
thor 5051/5A- (3 m) eo
au ra
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un
Note
pt
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Only these cables are to be used for diagnosis, as they are the
pe
ility
only ones fitted with CAN wiring and therefore allowing CAN di‐
ot
wit
, is n
agnosis and/or CAN communication.

h re
hole
spec
Connecting vehicle diagnostic tester :

es, in part or in w
t to the co
– Apply handbrake.
– Vehicles with automatic gearbox, move selector lever to posi‐
rrectness of i
tion “P” or “N”.

l purpos
– Vehicles with manual gearbox, move gear lever to neutral po‐

sition.
nform
ercia
– With ignition switched off, connect vehicle diagnostic tester

using diagnostic cable - VAS 5051/6A- to diagnostic interface
m
a
com
-arrow- in vehicle.
ion in
r
te o
thi
– Switch on ignition.
s
iva
do
r
– Switch off all electrical consumers.

rp
cum
fo
en
ng
t.
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Note
t. C rig
gh ht
pyri by
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co lksw
by
All other and the following vehicle diagnosis, testing and informa‐ cted agen
Prote AG.
tion systems or vehicle diagnostic and service information sys‐
tems are connected accordingly in the sequence described
above.
1. Vehicle diagnosis, testing and information systems 89

1.2 Connecting vehicle diagnostic tester

Golf Model Year 1998 - 2003
– Apply handbrake.
– Vehicles with automatic gearbox, move selector lever to posi‐
tion “P” or “N”.
– Vehicles with manual gearbox, move gear lever to neutral po‐
sition.
– Pull out trim -1- in direction of arrow.
– With ignition switched off, connect vehicle diagnostic tester
using diagnostic cable to diagnostic interface -arrow- in vehi‐
cle. gen AG
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d wa oes
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– Switch on ignition. byV gu
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ed nte
ris
– Switch off all electrical consumers. tho eo
au ra
c
ss
ce
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nl
pt
du
Note
an
itte
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erm
ab
All other and the following vehicle diagnosis, testing and informa‐
ility
ot p
tion systems or vehicle diagnostic and service information sys‐
wit
, is n
tems are connected accordingly in the sequence described
h re
hole
above.
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
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rig ht
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Prote AG.

2 Repairs to wiring harnesses and con‐

nectors
2.1 General notes concerning repairs to ve‐

hicle electrical system
Caution
When batteries are disconnected and reconnected, the proce‐

dure described in the workshop manual must be strictly ob‐
served.
WARNING
Some tools are equipped with a tool safety device. This must
be pushed over the tip of the tool after use in order to protect
the tip and prevent personal injury.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
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ce
e
nl
pt
du
an
itte
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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
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Prote AG.
2. Repairs to wiring harnesses and connectors 91

AG. Volkswagen AG d
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un
pt
an
d
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rm
ab
pe
ility
ot
wit
, is n
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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
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cum
fo
en
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t.
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Cop py
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rig ht
py by
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by lksw
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Prote AG.

♦ Observe the latest notes in the respective workshop manual

when carrying out repairs.
♦ Observe country-specific regulations.
♦ Always disconnect the battery earth strap before working on
the electrical system. Disconnecting the battery earth strap
(open circuit) provides a safe working environment for repairs
to the electrical system. The battery positive wire need only be
disconnected for removal of the battery.
♦ Before starting a repair, it is important to identify and rectify
AG. Volkswagen AG d
the cause of damage (e.g. kswsharp
agen edges on body panels,
oes
not
de‐
l
fective electrical components,
by
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a d ran
ise
♦ For additional information,
ut
ho
r
e.g. removal and installation of in‐
tee
or
dividual components,
ss
a please refer to the relevant workshop ac
manual.
ce
le
un
pt
an
d
♦ Soldering is not permitted for repairs to vehicle wiring.

itte
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rm
ab
♦ Wiring harness and connector repairs to vehicle electrical sys‐
pe
ility
tem should be carried out using wiring harness repair set - VAS
ot
wit
, is n
1978 B- and previous versions only. Only use yellow wires
h re
hole
from wiring harness repair set - VAS 1978 B- .
spec
es, in part or in w
♦ Wiring harness repairs may not be integrated in the vehicle's
t to the co
own wiring harness and must be marked with the use of yellow
adhesive tape. This indicates a previous repair.
rrectness of i
♦ Crimp connectors may never be repaired. If necessary, lay
wiring parallel to the defective wiring. After crimping, the crimp
l purpos
connector has to be shrink fitted using the hot air blower in

order to prevent any ingress of moisture.
nform
ercia
♦ It is essential that the supplementary information is observed

regarding repairs to wiring harnesses in airbag and belt ten‐
m
a
com
ti
sioner systems, fibre optic cables, CAN bus lines, aerial cables
on in
and wiring with cross sections up to 0.35 mm2 ⇒ page 102 .

r
te o
thi
s
iva
do
♦ Carry out a function test after every repair. It may be necessary

r
rp
cum
for the fault memory to be interrogated, erased and/or for the

fo
en
g
systems to be reset.
n
t.
yi Co
Cop py
♦ If possible, do not loosen any earth wires from the body (dan‐
t. rig
gh ht
yri
ger of corrosion).
p by
co Vo
by lksw
cted agen
♦ Wiring harness repair set - VAS 1978 B- and previous versions
Prote AG.
do not cover all wiring cross sections that occur in the vehicle.
If the required wiring cross section is not available, the next
largest one should be used.
♦ Screened wires can be repaired. Wiring for camera systems
are the exception. If damaged they must be replaced com‐
plete.
♦ Heat resistant wiring can be found in various places in the ve‐
hicle, mainly in the engine compartment. Heat resistant wiring
can be identified by its slightly matt and softer insulation. To
repair these wires, only heat resistant wiring may be used.

2.2 Wiring harness repair set
2.2.1 Wiring harness repair set - VAS 1978-

Wiring harness repair set - VAS 1978- allows optimal repair qual‐
ity to be achieved in the area of vehicle electrics. Using the tools,
repairs to connectors and wiring open circuits can be carried out.
To do this, complete repair wire sections with contacts already
crimped on are used and joined to the vehicle's own wiring har‐
ness with the aid of crimp connectors. A special set of pliers with
three different crimp recesses and a hot air blower for shrinking
the crimp connectors make a perfect electrical connection.
Note
AG. Volkswagen AG d
Additional information: olksw
agen oes
not
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d by ara
ise nte
⇒ Operating instructions Wiring harnesshor repair set - VAS 1978- eo
aut ra
ss c
2.2.2 Upgrade kit - VAS 1978/50-
ce
le
un
pt
an
d
itte
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Upgrade kit - VAS 1978/50- is required to bring the “old” wiring
rm
ab
harness repair set - VAS 1978- up to the latest standard of wiring
pe
ility
ot
harness repair set - VAS 1978A- . The upgrade kit comprises of
wit
, is n
4 assembly and 10 release tools, a new set of crimping pliers for
h re
hole
crimp connectors with head adapter 0.35 - 2.5 mm2 -VAS
spec
1978/1-1- , 4.0 - 6.0 mm2 -VAS 1978/2 A- and head adapter for
es, in part or in w
t to the co
JPT contacts - VAS 1978/9-1- . Also included are new stickers, a
new set of operating instructions, crimp connectors for 0.35
mm2 cable cross-section and a roll of black felt adhesive tape.
rrectness of i
l purpos
nform
ercia
2.2.3 Wiring harness repair set - VAS 1978A-

m
a
com
tion in
r
The new wiring harness repair set - VAS 1978A- allows optimal
te o
thi
repair quality to be achieved in the area of vehicle electrics. Using

s
iva
do
the new pliers, repairs to connectors and wiring open circuits can
r
rp
cum
fo
be carried out. To do this, complete repair wire sections with con‐

en
ng
t.
tacts already crimped on are used and joined to the vehicle's own
yi Co
op
wiring harness with the aid of four different types of crimp con‐
C py
t. rig
gh
nectors. A new set of crimping pliers with head adapters and a
ht
pyri by
Vo
o
hot air blower for shrinking the crimp connectors make a perfect by c lksw
cted agen
electrical connection. Prote AG.
Note
Additional information:
⇒ Operating instructions Wiring harness repair set - VAS 1978A-

2.2.4 Release tool set - VAS 1978/35-

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

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
2.3.1 Special pliers with insert
ed
ris nte
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aut ra
The special pliers without
s insert - VAS 1978/1- with insert for spe‐
s c
cial pliers - VAS 1978/2- is part of the wiring harness repair set -
ce
le
un
pt
VAS 1978- and is used to crimp connectors during wiring harness
an
d
itte
y li
repairs.
erm
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ility
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Colour of crimp Colour of crimp re‐ Wiring cross section
wit
is n
connector cess
h re
ole,
spec
Yellow Yellow 0.35 mm2
t to the co
Red Red 0.5 mm2 - 1.0 mm2
blue blue 1.5 mm2 - 2.5 mm2
rrectne
Yellow Yellow 4.0 mm2 - 6.0 mm2 ss o
Note
cial p
f inform
mer
♦ As an alternative, the connectors can also be crimped with

atio
m
crimping pliers (base tool) - VAS 1978/1-2- in conjunction with

o
n
c
head adapters -VAS 1978/1-1- or -VAS 1978/2A-

i
or
n thi
⇒ page 97 .
te
sd
iva
o
pr
♦ Ensure without fail that the correct crimp recess is chosen for
um
r
fo
the crimp connectors being used.

en
ng
t.
yi Co
op py
♦ The insulation on the wires must not be crimped.
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

2.3.2 Release tools for contacts

The various release tools serve as a means of detaching the dif‐
ferent contacts from the contact housings without damage.
A selection of release tools is included in wiring harness repair
set - VAS 1978- and wiring harness repair set - VAS 1978A- . The
complete set of release tools is included in release tool set - VAS
1978/35- ⇒ page 95 .
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.
Releasing and dismantling contact housings ⇒ page 139 .

G. Volkswagen nA AG do
wage es n
Volks ot g
2.3.3 Assembly tools for single wire seals
by ua
ed ran
oris tee
th o
The assembly stools
s serve as a means of au sliding the single wire r ac
seals fully into the contact housing without damage and thereby
ce
e
nl
assure complete sealing between single wire and contact hous‐ pt

du
an
itte
ing.
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erm
ab
Four assembly tools for single wire seals are included in each ility
ot p
wiring harness repair set - VAS 1978 B- and previous versions.

wit
, is n
h re
hole
Assembling single wire seals ⇒ page 136 .

spec
es, in part or in w
t to the co
rrectness of i
l purpos
2.3.4 Wire stripper - VAS 1978/3-

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

orm
lation off wires and cutting wires in the correct manner.

m
atio
om
n in
Wire strippers - VAS 1978/3- are included in wiring harness repair

or c
set - VAS 1978 B- and previous versions.

thi
te
sd
iva
o
r
The wire strippers have an adjustable limit stop within the pliers
rp
cu
o
jaws, with which the desired length of insulation to be removed

f
en
ng
t.
can be adjusted.
yi Co
Cop py
ht. rig
Stripping: rig ht
py by
co Vo
by lksw
– Adjust the sliding limit stop in the pliers jaws to the desired cted agen
Prote AG.
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.
AG. Volkswagen AG d
agen oes
ksw
2.3.5 Hot air blower 220 V/50 Hz - VAS
ol not
y V gu
d b ara
ise
1978/14- r nte
tho eo
au ra
ss c
ce
le
Caution
un
pt
an
d
itte
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rm
ab
When shrink-fitting, take care not to damage any other wiring,
pe
ility
plastic parts or insulating material with the hot air blower.
ot
wit
, is n
h re
Observe the operating instructions of the hot air blower without
hole
fail!
spec
es, in part or in w
t to the co
The hot air blower, 220 V / 50 Hz - VAS 1978/14- is used in con‐
junction with shrink element for hot air blower - VAS 1978/15- to
rrectness of i
shrink fit the crimp connectors. After crimping, the crimp connec‐
tor has to be shrink fitted using the hot air blower in order to
l purpos
prevent any ingress of moisture. nform

ercia
Hot air blower, 220 V/50 Hz - VAS 1978/14- is included in wiring

harness repair set - VAS 1978 B- and previous versions.
m
a
com
tion in
Shrink fitting crimp connectors using hot air blower, 220 V / 50 Hz

r
te o
thi
- VAS 1978/14- ⇒ page 115 , or ⇒ page 116 .

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2.3.6 Crimping pliers - VAS 1978/1A-

fo
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t.
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Crimping pliers - VAS 1978/1A- or crimping pliers (base tool) - t. C rig
gh ht
VAS 1978/1-2- together with head adapter 0.35 - 2.5 mm² - VAS yri
p by
o Vo
1978/1-1- or head adapter 4.0 - 6.0 mm² - VAS 1978/2A- are used
c by lksw
cted agen
to squeeze together crimp connectors from the wiring harness
Prote AG.
repair sets.
Crimping connectors using crimping pliers - VAS 1978/1A-
⇒ page 116 .
The following heads adapters are available for crimping pliers
(base tool) - VAS 1978/1-2- :
♦ Head adapter 0.35 mm2 - 2.5 mm2 - VAS 1978/1-1-
♦ Head adapter 4.0 mm2 - 6.0 mm2 - VAS 1978/2A-
♦ Head adapter for JPT contacts - VAS 1978/9-1-
In conjunction with head adapter for JPT contacts - VAS
1978/9-1- , the crimping pliers are used to crimp contacts to single
wires during repairs to wiring with cross sections up to 0.35
mm2 ⇒ page 102 .
Interchanging head adapter:
– Open up the crimping pliers fully.

– Unclip both locking pins -arrows- from the body of the crimping
pliers.
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– Insert the required head adapter from above -arrow- in the
es, in part or in w
body of the crimping pliers.
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ion
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ate
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– Lock the head adapter by engaging the pins -arrows- in the
um
for
body of the crimping pliers.

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t.
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Cop py
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Prote AG.
2.4 Repairs to wiring harnesses
Note
Observe the general notes on repairs to the vehicle electrical

system
⇒ “2.1 General notes concerning repairs to vehicle electrical sys‐
tem”, page 91 .
⇒ “2.4.1 Notes on repairs to airbag and belt tensioner wiring”,

page 99
⇒ “2.5 Repairs to fibre optic cables”, page 118
⇒ “2.4.2 Repairs to CAN bus wiring”, page 101
⇒ “2.6 Repair of aerial wires”, page 124
⇒ “2.4.3 Renewal of aerial wiring”, page 101
⇒ “2.4.4 Repairing 0.13 mm2/0.35 mm2/0.5 mm2 wire”,
page 102
⇒ “2.4.7 Wiring open circuit with one repair position”, page 115

⇒ “2.4.8 Wiring open circuit with two repair positions”, page 116
2.4.1 Notes on repairs to airbag and belt ten‐

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

AG. fail.
Volkswagen AG
ag does
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♦ Faulty repairs to thed bairbag
yV
o and seat belt tensioning sys‐
ot g
ua
tem can cause malfunctions
ris
e in the passenger protection rante
system. tho eo
au ra
c
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♦ For repairs to airbag and belt tensioner wiring harnesses,
ce
e
nl
only contacts, connectors and wiring designed specifically
pt
du
an
itte
for this purpose may be used ⇒ Electronic Parts Cata‐
y li
erm
ab
logue (ETKA) .
ility
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es, in part or in w
t to the co
rrectness of i
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orm
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Note
♦ Wires from airbag and belt tensioner wiring harness are only
allowed to be repaired using the wiring harness repair set -
VAS 1978 B- and previous versions.
♦ Observe the general notes on repairs to the vehicle electrical
system ⇒ page 91 .
♦ 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. en AG. V
olkswagen AG
ag does
lksw
♦ Repairs in the area of the airbag
by or belt tensioner should not gua
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Vo
be more than 30 cm fromorithese next contact housing. Together
d ran
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with the yellow insulating
au
t tape, this gives a clear indication of
h or
repairs that have already been carried out.
ac
ss
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un
♦ In series production, the wires leading to the triggering units

pt
an
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(airbags) are twisted with a length of lay of 20 mm ± 5 mm.

itte
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This length of lay is ensured in series production by means of

ab
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standard-part numbers for pairs of wires and must be adhered

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to under all circumstances when sections of twisted wires are

is n
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repaired.
ole,
spec
♦ During repairs, the wiring to the triggering units (airbags) must

t to the co
have the same length. When wires -1- and -2- are entwined,
the twine spacing of A = 20 mm ± 5 must be adhered to without
fail.
rrectne
♦ There must not be any section of wiring, for example in the

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

s o
cial p
f inform
mer
atio
om
n
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2.4.2 Repairs to CAN bus wiring
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♦ An unshielded two-wire line -1- and -2- with a cross section of
erm
ab
ility
0.35 mm2 or 0.5 mm2 is used for CAN bus wiring.
ot p
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♦ The colour codes of the CAN bus wiring can be gleaned from
h re
ole,
the following table:
spec
t to the co
Powertrain CAN, high wire Orange/black
Convenience CAN, high wire Orange/green
Infotainment CAN, high wire Orange/violet
rrectne
CAN low wire, (all) orange/brown
ss o
♦ Repairs to CAN bus wiring can be carried out either with sec‐
cial p
f in
tions of repair wiring with the correct cross section or with
form
mer
entwined wires “green/yellow” or “white/yellow” from the elec‐
atio
tronic parts catalogue (ETKA) ⇒ Electronic parts catalogue
om
(ETKA) .
n
c
i
or
n thi
e
♦ When repairs are performed, both bus wires must have the
t
sd
iva
o
same length. When twisting the wires -1- and -2- together, the
pr
cum
r
fo
length of each complete twist must be A = 20 mm.
en
ng
t.
yi Co
op
♦ There must not be any section of wiring, for example in the C py
t. rig
vicinity of crimp connectors -arrow-, longer than B = 50 mm gh ht
yri by
with the wires not twisted. cop Vo
by lksw
cted agen
Prote AG.
♦ Mark the area of repair with yellow insulation tape to make it
easy to identify.
2.4.3 Renewal of aerial wiring

A new approach to repair work on aerial wires has been devel‐
oped ⇒ page 124 .
Now connecting wires in different lengths and various adapter
cables are available as replacement parts instead of a complete
aerial wire.
General description:
♦ Replacement parts can be found in the ⇒ Parts catalogue
(ETKA): Special catalogue; Electrical connections; Genuine
accessories; Subgroup 35 from illustration No. 035-20 .
♦ These genuine parts are suitable for all aerial wires and wire
diameters which may need to be replaced.
♦ The connector housings for aerial wires are only available as
genuine parts in one colour. However, they can be used for all
colours of aerial connector.
♦ No provision has been made for replacement of individual
aerial connectors in the event of repair.
♦ The wires can be used retroactively for all VW models, with all
installed aerial wire diameters.
♦ All adapter and connection wires are suitable for all transmitter
and receiver signals.
♦ This repair method can also be used for testing or retrofitting.

Assembly overview of aerial cable:

Example: aerial wire between radio and aerial is defective. The
following wires are required for the repair:
1- Adapter cable, to radio connection. Length approx. 30 cm.
2- Connecting wire, available in different lengths.
3- Adapter cable, to aerial connection. Length approx. 30 cm.
Installing a new aerial cable:
Note
Note that the total length of an aerial wire, depending on vehicle

equipment level, can be divided into sections by aerial diversity
control unit, traffic information control unit or aerial amplifier. Only
the defective section of aerial wire must be replaced.
– Pull defective aerial wire connections off units.

– Determine the routing of the defective aerial wire in vehicle
and measure the total length of the aerial connecting wire to
be replaced.
The total length of aerial connecting wire is the sum of the length
of adapter cables required -1- and -3- and the connecting wire
-2-. wage
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– To determine the length of connecting wire required, ed subtract
by ara
60 cm from the measured total length of aerial tconnecting
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– Procure the required adapter cables -1- and -3- and connect‐
le
un
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ing wire -2- at length calculated as genuine part from the
an
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itte
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Electronic parts catalogue (ETKA).
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pe
ility
– Cut off connectors of defective aerial wire.
ot
wit
, is n
h re
The remainder of the defective aerial wire remains in the vehicle.
hole
spec
– Connect adapter cables -1- and -3- to equipment in vehicle.
es, in part or in w
– Route and attach the connection line -2- in the immediate vi‐ t to the co
cinity of the factory routing. rrectness of i
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Note
Do not kink or excessively bend aerial wires! The bending radius

nform
ercia
must not be below 50 mm.

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– Connect connecting wire to adapter cables.

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– Perform functional test.

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2.4.4 Repairing 0.13 mm2/0.35 mm2/0.5 mm2

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ElectricalthoSystem, General Information - Edition 01.2018
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♦ Hot air blower - VAS 1978/14A- from wiring harness repair set
ce
e
nl
pt
- VAS 1978 B-
du
an
itte
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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
♦ Crimping pliers (body) - VAS 1978/1-2- from wiring harness l purpos
nf
ercia
o
repair set - VAS 1978 B-
rm
m
atio
m
♦ Adapter head 0.13 - 0.5 mm² - VAS 1978/1-3-

o
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thi
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sd
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Note
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Repair wires with a cross section of 0.35 mm2 and 0.5 mm2 are
yi Co
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available for the repair. t. C rig
gh ht
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Procedure cted agen
Prote AG.
– Fit adapter head 0.13 - 0.5 mm² - VAS 1978/1-3- -1- on crimp‐
ing pliers (body) - VAS 1978/1-2- as follows:
– Open crimping pliers -VAS 1978/1-2- .
– Pull out locking pins -2- in direction of -arrow A- as far as stop.
– Fit adapter head -VAS 1978/1-3- -1- centrally on crimping pli‐
ers -VAS 1978/1-2- in direction of -arrow B-.
– Insert locking pins -2- again as far as stop.
– Clear the wire to be repaired about 20 cm either side of the
repair position.
Caution
Risk of damage to electrical wiring.

♦ Carefully lay wrapped wiring harnesses aside.
– If necessary, remove wrapping of wiring harness.

– Cut out the damaged piece of wiring using side cutters.
Note
♦ If, after the damaged wire has been cut out, both ends of the
vehicle's own wiring are too short for a repair using single butt
connectors, use a piece of yellow repair wire of the appropriate
length with two crimp connectors.
♦ When repairing a single wire with crimped/attached contact,
lay the yellow repair wire next to the damaged single wire of
the vehicle and cut to the required length.

– Fit end of wire -2- as far as stop -arrow- in receiver on adapter

head -VAS 1978/1-3- -1- with appropriate cross section.
. Volkswagen AG
gen AG does
– Press together crimping pliers completely and
Vol
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a
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– Pull out end of wire -2- from adapter
au
th head -VAS 1978/1-3- eo
ra
-1- to strip insulation. ss c
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un
pt
– Open crimping pliers again.
an
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itte
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• Insulation must be cut cleanly and removed from the wire
rm
ab
pe
ility
ot
• Do not leave any insulation on the stripped wires
wit
, is n
h re
• Single wires must not be damaged
hole
spec
es, in part or in w
– Choose a small transparent crimp connector from wiring har‐
t to the co
ness repair set - VAS 1978 B- .
– For 0.13 mm2 wires, also push a shrink tube onto one of the
rrectness of i
wires ⇒ Electronic parts catalogue (ETKA) .
l purpos
– Push crimp connector -2- in direction of -arrow A- as far as
nform
ercia
stop into crimp opening in adapter head -VAS 1978/1-3- .

m
a
com
t
– Push stripped wire -1- in direction of -arrow B- into crimp con‐
ion in
nector -2-.
r
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thi
s
iva
• All single wires must be pushed into crimp connector -2-
do
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rp
cum
fo
• Insulation on wire -arrow C- must not be crimped.
en
ng
t.
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op
– Press together crimping pliers completely and then open. C py
t. rig
gh ht
yri by
– Remove wire with crimp connector. cop Vo
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cted agen
Prote
– Crimp wire with crimp connector on other side as described.
AG.
– Pull out locking pin -1- in direction of arrow -A- as far as it will
go.
– Swivel upper part of adapter head -VAS 1978/1-3- -2- in di‐
rection of -arrow B-.
– Remove crimped crimp connector.

Correct crimping result

– After crimping, the crimp connector
wage
n AGhas
. Volkto be shrink
swagen AG
doefitted
s no
us‐
s
ing the hot air blower inyorder
Volk to prevent any ingress of t gu
moisture. ris
ed
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tho or
• For 0.13 mm2 swires,
sa
u
it is then necessary to shrink-fit the ad‐ ac
ditional shrink hose to ensure complete sealing.
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
– Fit shrink element for hot air blower - VAS 1978/15A- onto hot
air blower - VAS 1978/14A.-
rrectness of i
Caution
l purpos
nf
ercia
♦ When shrink-fitting the hose, take care not to damage any
or
other wiring, plastic parts or insulating material with the hot
m
m
atio
nozzle of the hot air blower.
om
n in
or c
♦ Observe the operating instructions of the hot air blower
thi
te
without fail!
sd
iva
o
r
rp
cu
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m
f
en
ng
t.
yi Co
op py
– For 0.13 mm2 wires, position heat-shrink hose -1- centrally t. C rig
gh ht
yri
over crimp connector -2- by feeling contours. p by
co Vo
by lksw
cted agen
• Dimension -a- must be approximately even on both sides. Prote AG.
– Heat up heat-shrink hose/crimp connector using hot air blower

along a straight line, working from centre outwards, until it is
sealed completely and adhesive escapes from the ends.
• This is how the finished repair point should look -3-.
Note
♦ Ensure that, where several wires have to be repaired, the

crimp connectors are not directly adjacent to each other. To
prevent the circumference of the wiring harness from becom‐
ing to great, position the crimp connectors so they are offset
slightly.
♦ If the repair position was already wrapped, this section has to
be wrapped again with yellow adhesive tape once the repair
has been carried out.
♦ Attach the repaired wiring harness with a cable tie, if neces‐
sary, to prevent it from generating noise when the vehicle is in
motion.

Electrical System, General Information -wEdition
agen 01.2018
AG. Volkswagen AG
doe
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Premature release ris
ed
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– Push release lever -1- upwardsssin direction of -arrow A-. au ra
c
ce
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– At same time, press together crimping pliers slightly and then
nl
pt
du
an
open.
itte
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erm
ab
ility
Caution ot p
wit
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hole
♦ Do not use the crimp connector after premature release.
spec
es, in part or in w
t to the co
rrectness of i
2.4.5 Repair of 10 mm2 or 16 mm2 wire with
l purpos
single butt connector
nform
ercia

m
at
om
io
- VAS 1978 B-
n
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
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Prote AG.
♦ Shrink element for hot air blower - VAS 1978/15A- from wiring
harness repair set - VAS 1978 B-
♦ Wiring harness repair set - VAS 631 003-
Note
♦ Repair wires (by the metre) with a cross section of 10 mm2 or

16 mm2 are available for the repair.
♦ Furthermore, single repair wires with a crimped/attached con‐
tact are available for repair work.
Procedure
– Attach the crimping anvil and crimping stamp relevant to the
wire thickness to the crimping pliers as follows:
– Open crimping pliers from wiring harness repair set - VAS 631
003- .
go.
– Open adapter -2- in direction of arrow -B-.

– Insert crimping stamp -1- until it is heard to engage in mounting

-2- on adapter -arrow A-.
– Insert crimping anvil -3- until it is heard to engage in mounting
-4- of crimping pliers -arrow B-.
– Close adapter -1- in direction of arrow -A-.

– Insert locking pin -2- onto stop in direction of arrow -B-.
repair position.
Caution

AG. Volkswagen AG d
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– If necessary, cut through wrappingsedof wiring harness with a
b ara
nte
knife. hori
eo
aut ra
– Cut out damaged section of swire with wire stripper from wiring
s c
ce
le
harness repair set - VAS 631 003- .

un
pt
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d
itte
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rm
ab
pe
Note
ility
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♦ If, after the damaged wire has been cut out, both ends of the
hole
spec
vehicle's own wiring are too short for a repair using single butt
es, in part or in w
connectors, use a piece of yellow repair wire of the appropriate

t to the co
length with two crimp connectors.

♦ When repairing a single wire with crimped/attached contact,
rrectness of i
lay the yellow repair wire next to the damaged single wire of
the vehicle and cut to the required length.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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cum
fo
en
ng
t.
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Cop py
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rig ht
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– Set the adjustable stop in the wire stripper from wiring harnessgen AG
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swa
repair set - VAS 631 003- to the length that needs yto V be strip‐
olk not
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ped. ris
ed b ara
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♦ 10 mm2 wires: 14 mm s au ac
s
ce
le
♦ 16 mm2 wires: 16.5 mm
un
pt
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– Insert the end of the wire from the front fully into the pliers jaws
rm
ab
and squeeze the pliers together completely.
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Use a suitable butt connector and heat-shrink hose from wiring
harness repair set - VAS 631 003- to perform repair.
l purpos
– Push heat-shrink hose onto one of the wires.
nform
ercia
– Position butt connector -1- with first crimping point centrally on

m
a
crimping anvil -2-.
com
tion in
r
• Dimension -a- must be even on both sides

te o
thi
s
iva
do
– Turn quick-action lever -3- in anti-clockwise direction -arrow-
r
rp
cum
until butt connector -1- is secure.
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Insert wire -2- with stripped end into butt connector -1- as far
as stop -arrow-.
• All single wires must be pushed into the butt connector
– Close and open the crimping pliers several times until the
crimping anvil moves downwards automatically to the start
position.
Note
The insulation on the wires must not be crimped.
– Crimping the wire with butt connector on the other side as de‐
scribed.

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G. V lkswage2018
n AG d ➤ , Atlas 2017 ➤ , Bora 1999 ➤ , Bora Varian ...
wage oes
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not
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b ua
ed ran
ris tee
– Pull out locking th pin in
o direction of arrow -A- as far as it will go.or
au ac
ss
– Open adapter in direction of arrow -B-.
ce
e
nl
pt
du
an
– Remove crimped butt connector.
itte
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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

A - 10 mm2, star crimp
nform
ercia
B - 16 mm2, B crimp
m
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.
After crimping, the heat-shrink hose over the butt connector has
to be shrink fitted using the hot air blower in order to prevent any
ingress of moisture.
air blower - VAS 1978/14A- .
Caution
Risk of damaging adjacent components.

without fail!
– Position heat-shrink hose -1- centrally over butt connector

-2- by feeling contours.
• Dimension -a- must be roughly even on both sides
– Heat up heat-shrink hose using hot air blower along a straight
line, working from centre outwards, until it is sealed completely
and adhesive escapes from the ends.
• This is how the finished repair point should look -3-.

AG. Volkswagen G d
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Electrical System, General Edition
oes 01.2018
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Note s au ra
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♦ Ensure that, where several wires have to be repaired, the butt
an
d
itte
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connectors are not directly adjacent to each other. To prevent
rm
ab
the circumference of the wiring harness from becoming too
pe
ility
great, position the butt connectors so they are offset slightly.
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
motion.
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Premature release
nform
ercia
– Push lever -1- downwards -arrow A-.

m
a
com
t
– Turn quick-action lever -2- in clockwise direction -arrow B- until
ion in
crimping anvil is in the start position.
r
te o
thi
s
iva
If premature release is not possible by hand:
do
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cum
fo
– Push lever -1- downwards -arrow A-.

en
ng
t.
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op
– Place wrench from wiring harness repair set - VAS 631 003- C py
t. rig
on bolt -3- on rear.
gh ht
pyri by
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– Turn wrench in anti-clockwise direction -arrow C- until crimp‐ Prote
cted AG.
agen
ing anvil is in the start position.
Caution
Do not use the butt connector after premature release.
2.4.6 Repair of 2.5 mm2, 4 mm2 or 6 mm2 alu‐

minium wire with single butt connector
- VAS 1978 B-
♦ Shrink element for hot air blower - VAS 1978/15A- from wiring
harness repair set - VAS 1978 B-
♦ Wiring harness repair set - VAS 631 001-

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Ameo 2017 ➤ , Arteonut 2018 ➤ , Atlas 2017 ➤ , Bora 1999 ➤ , BoraorVarian
ho e ...
a ac
s Electrical System, General Information - Edition 01.2018
s
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Note
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♦ Copper repair wires (by the metre) with a cross section of 2.5
h re
ole,
mm2, 4 mm2 or 6 mm2 are available for repair.
spec
♦ Furthermore, single copper repair wires with crimped contacts
t to the co
are available for repair work.
rrectne
Procedure
– Choose the crimping anvil, crimping stamp and contact posi‐
s
tioner with contact locking mechanism relevant to the wire
s o
cial p
thickness and attach to the hand pliers as follows:
f inform
mer
– Open hand pliers from wiring harness repair set - VAS 631
atio
001- .
om
n
c
i
or
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thi
e
go.
t
sd
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o
pr
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– Open support -2- in direction of arrow -B-.
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fo
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t.
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Cop py
t. rig
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pyri by
Vo
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– Place crimping anvil -1- in hand pliers in such a way that by c lksw
cted agen
crimping anvil -1- is flush with front of pliers. Prote AG.
– Secure crimping anvil with pins -2- -arrow A- and tighten

knurled screw by hand.
– Insert crimping stamp -3- that corresponds with crimping anvil
into support.
– Secure crimping stamp with pins -4- -arrow B- and tighten
knurled screw by hand.
– Close adapter -1- in direction of arrow -A-.

– Insert locking pin -2- onto stop in direction of arrow -B-.

AG. Volkswagen A
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Electrical System, eGeneral
db
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– Insert contact locking
ss
a mechanism
u
-1- in contact positioner ra
c
-2-.
ce
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nl
pt
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an
– Locate contact positioner with contact locking mechanism on itte
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hand pliers -5- and push hole in contact positioner -2- over
erm
ab
knurled screw -4-.
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wit
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– Screw in knurled screw -3- and tighten by hand.
h re
hole
spec
es, in part or in w
repair position.
t to the co
Caution
rrectness of i
l purpos
nf
ercia
orm
m
atio
– If necessary, cut through wrapping of wiring harness with a
om
knife.
n in
or c
thi
te
sd
a
– Cut out damaged section of wire using wire stripper from wiring
iv
o
r
rp
cu
harness repair set - VAS 631 001- .
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
Note
gh ht
pyri by
Vo
co lksw
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cted agen
If, after the damaged wire has been cut out, both ends of the ve‐ Prote AG.
hicle's own wiring are too short for a repair using single butt
connectors, use a piece of yellow copper repair wire of the ap‐
propriate length with two crimp connectors.
– Insert end of wire from front into matching adapter (relevant to

wire thickness) in jaws of pliers as far as it will go.
– Squeeze pliers together completely.
– Use a suitable butt connector and heat-shrink hose from wiring
harness repair set - VAS 631 001- to perform repair.
– Push heat-shrink hose onto one of the wires.

– Insert butt connector -1- in contact positioner -2-.

• Butt connector -1- must be flush with contact positioner -2-
-arrow A-
– Push contact locking mechanism -3- as far as stop in direction
of arrow -B- and, in doing so, secure butt connector -1-.
• Lugs -4- on butt connector -1- must engage in groove -5- on
contact locking mechanism -3-
– Insert wire -2- with stripped end into butt connector -1- as far
as stop -arrow-.
. Volkswagen AG
• All single wires must be pushed into the butt connector
swa
gen AG does
k not
Vol gu
• End of insulation should be no further than fronted edge of insu‐
by ara
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lation crimp oris eo
th
au ra
– Close hand pliers until hand pliers openssagain automatically. c
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erm
ab
ility
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ole,
spec
– Turn contact locking mechanism -2- onto stop in direction of
t to the co
-arrow-.
– Remove butt connector -1- from contact positioner -3-.
rrectne
– Rotate hand pliers for 2nd crimping.
– Crimping the wire with butt connector on the other side as de‐
scribed. ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
en
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t.
go. Cop
yi Co
py
t. rig
– Open support -2- in direction of arrow -B-. gh ht
pyri by
Vo
co lksw
by
– Remove crimped butt connector. Prote
cted AG.
agen


• End of wire must protrude 0.1 mm … 1.0 mm at front edge of
wire crimp, dimension -a-
• End of insulation must not be crimped with wire crimp
• Insulation should end no further than front edge of insulation
crimp -arrows-
AG. Volkswagen AG d
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After crimping, the heat-shrink hose over the butt connector has e d by gu
ara
to be shrink fitted using the hot air blower in order to preventhoris any nte
eo
ingress of moisture. s aut ra
c
s
ce
e
nl
pt
du
air blower - VAS 1978/14A- .
an
itte
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erm
ab
ility
ot p
Caution
wit
, is n
h re
Risk of damaging adjacent components.
hole
spec
es, in part or in w
t to the co
rrectness of i
without fail!
l purpos
nform
ercia
– Position heat-shrink hose -1- centrally over butt connector

m
-2-.
at
om
ion
c
• Dimension -a- must be roughly even on both sides
in t
or
his
ate
– Heat up heat-shrink hose using hot air blower along a straight
do
priv
c
line, working from centre outwards, until it is sealed completely
um
for
and adhesive escapes from the ends.

en
ng
t.
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op py
• This is how the finished repair point should look -3-. t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
♦ Ensure that, where several wires have to be repaired, the butt

connectors are not directly adjacent to each other. To prevent
the circumference of the wiring harness from becoming too
great, position the butt connectors so they are offset slightly.
motion.

2.4.7 Wiring open circuit with one repair posi‐

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

side of the repair position).
– If necessary, unbind the wiring harness using the folding knife.
AG. Volkswagen AG d
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– Cut out the damaged piece of wiring using theoriwire
se strippers - nte
eo
VAS 1978/3- . auth
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ss c
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an
Note
d
itte
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rm
ab
pe
ility
If, after the damaged wire has been cut out, both ends of the ve‐
ot
wit
hicle's own wiring are too short for a repair using single crimp
, is n
h re
connectors, use a piece of repair wire of the appropriate length
hole
with two crimp connectors ⇒ page 116 .
spec
es, in part or in w
t to the co
rrectness of i
– Strip the wire ends of insulation by 6 - 7 mm using the wire
l purpos
strippers.
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
– Push the crimp connector on both stripped wire ends of the cted agen
Prote AG.
vehicle's own single wire and crimp it on using the crimping
pliers.
Note
♦ Ensure without fail that the correct crimp recess is chosen for
the crimp connectors being used ⇒ page 95 .
After crimping, the crimp connector has to be shrink fitted using

the hot air blower in order to prevent any ingress of moisture.
– Place shrink element for hot air blower - VAS 1978/15- on hot
air blower, 220 V / 50 Hz - VAS 1978/14- .

– Heat up the crimp connector using the hot air blower along a
straight line, working from the middle outwards, until it is
sealed completely and the adhesive escapes from the ends.
Caution
When shrink-fitting, take care not to damage any other wiring, AG. Volkswagen AG d
plastic parts or insulating material with the hot air blower. olksw
agen oes
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Observe the operating instructions of the hot air blower without rised ara
nte
fail! ut
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ab
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Note
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ole,
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t to the co
slightly.
rrectne
be wrapped again with yellow insulation tape once the repair
ss o
cial p
f
inform
mer
motion.
atio
om
n
c
i
or
n thi
e
2.4.8 Wiring open circuit with two repair posi‐

t
sd
iva
o
pr
c
tions
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Repair position with interlinked wire. Cop py
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rig ht
– Place the wire to be repaired to the side at two points (about py by
co Vo
lksw
20 cm to both sides of the relevant repair position).
by
cted agen
Prote AG.
– If necessary, unbind the wiring harness using the folding knife.
– Place the yellow repair wire next to the damage wiring harness
and, using wire strippers - VAS 1978/3- , cut the repair wire to
the required length.
– Cut the damaged section of wire out of the vehicle's own single
wire.

– Strip the wire ends of insulation by 6 - 7 mm using the wire

strippers.
– Push the crimp connector onto one side of the vehicle's own
single wire and on the other side onto the repair wire.
– Crimp the connector using the crimping pliers to both wire

ends.
– Repeat this procedure on the other end of the repair wire.
Note
AG. Volkswagen AG d
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♦ Ensure without fail that the correct crimp recess isedchosen
by
V
for gu
ara
the crimp connectors being used ⇒ page 95 . horis nte
eo
ut ra
ss a c
ce
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nl
pt
du
an
After crimping, the crimp connector has to be shrink fitted using
itte
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the hot air blower in order to prevent any ingress of moisture.
erm
ab
ility
ot p
– Place shrink element for hot air blower - VAS 1978/15- on hot
wit
, is n
air blower, 220 V / 50 Hz - VAS 1978/14- .
h re
hole
spec
es, in part or in w
– Heat up the crimp connector using the hot air blower along a
t to the co
straight line, working from the middle outwards, until it is
sealed completely and the adhesive escapes from the ends.
rrectness of i
Caution
l purpos
When shrink-fitting, take care not to damage any other wiring,

plastic parts or insulating material with the hot air blower.
nform
ercia
Observe the operating instructions of the hot air blower without

m
at
om
fail! ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Note t. Cop py
rig
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cted agen
Prote AG.
slightly.
motion.

2.5 Repairs to fibre optic cables

It is very difficult to identify the exact location of the defect. Re‐
place the damaged fibre optic cable by laying a new cable parallel
to the defective fibre optic cable.
Note
♦ Via the menu options of the vehicle diagnostic tester “Guided

Fault Finding” or “Guided Functions”, it is possible to ascertain
the components between which the fibre optic cable has been
damaged.
♦ The colour “yellow” indicates a fibre optic cable that has al‐
ready been repaired.
Procedure:
– Select “Guided functions” or “Guided fault finding” in the vehi‐
cle diagnostic tester ⇒ Vehicle diagnostic tester.
– Prepare fibre optic cable ⇒ page 118
Caution
wage es n
Do not over-bend fibre optic cables. Minimum radius for bends y Vo lks ot g
ua
is 25 mm. ir se
d b ran
tee
tho
Do not route fibre optic cables over sharp edges. au or
ac
ss
ce
Make sure that the ends of the fibre optic cables are not dirty
e
nl
pt
du
and do not touch them with your bare hands.
an
itte
y li
erm
ab
Do not expose fibre optic cables to heat.
ility
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wit
It is not permissible to twist 2 fibre optic cables together or one
, is n
h re
fibre optic cable with a copper wire.
hole
spec
Protect connectors and connecting cables against dust. Use
es, in part or in w
t to the co
protective caps from the case.
rrectness of i
2.5.1 Preparing fibre optic cable
l purpos

♦ Fibre optic cable repair kit - VAS 6223A-
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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f
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ng
t.
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Cop py
t. rig
gh ht
pyri by
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by
cted agen
Prote AG.

♦ Cutting pliers - VAS 6228-
♦ Vehicle diagnostic tester
AG. Volkswagen AG d
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or eo
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ab
pe
ility
ot
wit
, is n
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Caution
hole
spec
es, in part or in w
Do not over-bend fibre optic cables. Minimum radius for bends
t to the co
is 25 mm.
Do not route fibre optic cables over sharp edges.
rrectness of i
Make sure that the ends of fibre optic cables are not dirty and
l purpos
do not touch them with your bare hands.

Do not expose fibre optic cables to heat.
nform
ercia
It is not permissible to twist 2 fibre optic cables together or one

m
fibre optic cable with a copper wire.

com
tion in
r
Protect connectors and connecting cables against dust. Use

te o
thi
protective caps from the case.

s
iva
do
r
rp
cum
fo
en
ng
t.
yi
Fit tool adapter for fibre optic cable pliers - VAS 6223/1- .
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Press locking pins -arrows- out.

– Fit tool adapter onto pliers -arrow- and press locking pins back
in.
Cutting fibre optic cable to size.

– Determine required length of fibre optic cable.
– Open fibre optic cable pliers and insert length of fibre optic
cable -1- to be cut.
– To cut the fibre optic cable to size, close fibre optic cable pli‐
ers .
Stripping off insulation

– Open fibre optic cable pliers - VAS 6223/1- .
– Push down the stripping lever -arrow-.
– Insert fibre optic cable into the stripping hole.
• The fibre optic cable must be flush with the rear
AG. Voof
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pliers. Volksw
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itte
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erm
– Close fibre optic cable pliers as far possible and hold closed.
ab
ility
ot p
– Push the stripping lever upwards -arrow-, and remove fibre

wit
, is n
optic cable.
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
o
by c lksw
cted agen
Prote AG.

Cut precisely (making a clean optic surface at end of cable).

– Insert fibre optic cable -1- into the cutting hole.
• The insulation must be lying against stop of cutting station.
– Close fibre optic cable pliers - VAS 6223/1- and remove cable.
– Visually inspect cable-1- to make sure that it has been cut
correctly and that there are no burrs on the cross-cut surface
at end of cable.
Note
♦ Place the fibre optic cable only on surface or material that is

absolutely clean or keep it in your hand.
. Volkswagen AG
gen AG does
♦ Use protective caps if there is a danger that the cross-cut
Vol
ksw
a
sur‐ not
face at the ends of the fibre optic cable will be
ed soiled.
by gu
ara
nte
ris
utho eo
ra
a c
ss
Fitting brass pin contact to fibre optic cable.
ce
e
nl
pt
du
an
itte
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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
– Change tool adapter -arrow-.

nform
ercia
– Move safety catch on fibre optic cable pliers -arrow- so that

the word “Pin” can be seen.
m
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.

– Insert a brass pin contact -1- into the hole.

– Close locking lever on fibre optic cable pliers -arrow-.
AG. Volkswagen AG d
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ara
ed
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itte
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ab
– Push fibre optic cable into brass pin contact -arrow- as far as
ility
ot p
spring-cushioned stop and close fibre optic cable pliers .
wit
, is n
h re
hole
– Open fibre optic cable pliers and remove fibre optic cable to‐
spec
gether with brass pin contact.
es, in part or in w
t to the co
Caution
rrectness of i
Do not kink or excessively bend fibre optic cables (min. bend‐
ing radius: 25 mm).
l purpos
nf
ercia
orm
m
atio
m
– Check that the brass pin contact -2- is correctly attached to

o
n in
c
fibre optic cable -1-.

or
thi
te
sd
iva
• 4 crimping points must be visible on the brass connecting pin.
o
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rp
cu
o
m
f
• Make sure that the brass pin contact cannot be pulled off fibre
en
ng
t.
yi
optic cable by hand.
Co
Cop py
ht. rig
ht
• The cross-cut end surface of the fibre optic cable is
rig by
opy Vo
0.01 … 0.1 mm behind the brass pin contact (visual inspec‐ by c lksw
cted agen
tion).
Prote AG.
Note
♦ There are push-on couplings that are used to connect fibre

optic cables ⇒ Electronic Parts Catalogue .
♦ Installation of the new fibre optic cable in the cable harness
connector ⇒ page 123 .

Fitting corrugated tube onto fibre optic cable.

– Cut corrugated tube to a suitable length.
• Use cutting pliers - VAS 6228- or a sharp knife for cutting.
• Do not cut the corrugated tube with a paper cutter.
• The corrugated tube must be cut at a crest -arrow- not in a
trough.
• When the corrugated tube is installed, it must engage audibly
in the housing of the fibre optic cable.
– Insert fibre optic cable into pliers for fitting the corrugated tube
- VAS 6223/10- as shown in the illustration.
– Position pliers in place on the groove ofnthe
AG. corrugated tube.
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– Push pliers in groove along the circumference
yV
ol of the corruga‐not gua
ted tube. This causes the fibreed boptic cable to be inserted in the ran
ris tee
corrugated tube. utho or
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ss
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erm
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ility
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is n
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ole,
2.5.2 Detaching fibre optic cable from cable

spec
harness connector
t to the co
Removing
rrectne
– Pull fibre optic cable connector off the relevant control unit.
– Release the locking mechanism in fibre optic cable connector
ss
-1- by pressing it.

o
cial p
f inform
– Release secondary locking element -2-, using a small screw‐

mer
driver.
atio
om
n
c
– Remove fibre optic cable.

i
or
n thi
te
sd
iva
o
r
Caution
p
cum
r
fo
en
ng
t.
yi Co
♦ Use protective caps from the case in order to protect the Cop py
fibre optic cable against dust and dirt.
t. rig
gh ht
pyri by
Vo
o
by c
♦ Use a new housing as the secondary locking element can
lksw
cted agen
Prote
be damaged when the fibre optic cable is removed.
AG.
♦ Take note of the arrows on the basic module for the as‐
signment of “IN” and “OUT”.
Installing
Install in reverse order of removal, observing the following:
– Install fibre optic cable in accordance with markings.

Note
♦ Push corrugated tube into plug-in housing until it engages au‐

dibly.
♦ Seal the open plug-in connection -2- for fibre optic cable with
the protective cap for cable harness connector - VAS 6223/9-
-item 1-.
♦ The protective cap prevents soiling and mechanical damage
at the cross-cut end of the fibre optic cable so that the trans‐
mission of light is not impaired.
2.6 Repair of aerial wires
2.6.1 Repair set, aerial cable VAS 6720

Checking the aerial wire: ⇒ page 125
Changing tool adapter: ⇒ page 125
Cutting aerial wire: ⇒ page 125
Stripping shielding: ⇒ page 126
Stripping outer sleeve: ⇒ page 128
Stripping inner insulation: ⇒ page 129
Crimping inner conductor: ⇒ page 130
Crimping outer conductor: ⇒ page 132
♦ Repair set, aerial cable - VAS 6720- AG. Volkswagen AG d
agen oes
o lksw not
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The repair set, aerial cable - VAS 6720- makesised b it possible to attain ara
nte
optimal repair quality in the repair of aerial
hor wiring RG 174 (blue) eo
ut
and RKT 031 (black). The set includesss a the respective stripping ra
c
tools and crimping tools for both aerial cables. In addition, the
ce
e
nl
case includes all the separate parts needed to connect the Gen‐
pt
du
an
uine plug in nearly production quality. In this case, only the 0-

itte
y li
erm
coded connector (green) is required. All other connecting wires

ab
ility
for the various infotainment systems can be found in ETKA (EL-

ot p
wit
electrical connection elements) in plate 035-XX. These various

, is n
h re
adapter aerial wires are specific to vehicle models and must al‐
hole
spec
ways be ordered separately. All the separate parts can be found

es, in part or in w
in the above-named plate for reordering. The compartments of

t to the co
the case are labelled with the part numbers of the consumable
materials. The repair set is based on the existing adapters and
pliers system of the VAS 1978B.
rrectness of i
l purpos
Note
nf
ercia
Additional information: ⇒ Operating manual, Repair set, aerial

orm
cable - VAS 6720-

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.

Checking the aerial wire:

Before beginning repairs, determine which aerial wire is affected
using the gauge.
♦ -1- System RG 174 = blue
♦ -2- System RTK 031 = grey
In both systems, the positioner of the adapters is colour-coded
accordingly.
Changing tool adapter:
– Select appropriate adapter according to check of aerial wire
⇒ page 125 .
– Open handles of pliers completely.
– Release the two locking pins -arrows- from handles of pliers

and pull them out.
AG. Volkswagen AG d
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– Insert required tool adapter from above -arrow- into handles
ce
le
un
pt
of pliers.
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
– Lock adapter into handles of pliers by pressing in pins

inform
-arrows-.
mer
atio
Cutting aerial wire:

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.

AG. Volkswagen AG d
agen oes
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Ameo 2017 ➤ , Arteon 2018 ➤ , Atlas 2017 ➤ aut, Bora 1999 ➤ , Bora Varian ...
h
ra
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Electrical System, General Information - Edition
s 01.2018
ce
le
un
pt
an
d
– Push aerial wire -2- into cutting mechanism -1-.
itte
y li
rm
ab
pe
– Close tool and open it again.
ility
ot
wit
, is n
– Pull aerial wire out of cutting mechanism.
h re
hole
spec
Stripping shielding:
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.
– Push locating pin -1- into rotary cutter to stop.

– Push aerial wire -2- into rotary cutter to stop. The locating pin
-3- is again entirely visible.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
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ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Push blade holder -1- against shaft of rotary cutter until it en‐
gages. The gap -2- beneath the blade holder is completely
closed.
– Hold aerial wire securely so that it cannot turn.
– Turn rotary cutter -3- approximately 2 times in direction of ar‐
row until it rotates easily.

AG. Volkswagen AG d
agen oes
olksw not
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ara
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aut ra
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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.
– Pull release pin -1-. The blade holder is released and sepa‐
rates from aerial wire.
– Push locating pin -2- into rotary cutter to stop. The aerial wire
is pressed out of rotary cutter.
– Remove shielding from aerial wire.
– Remove remnants of insulation from rotary cutter.
Stripping outer sleeve:

AG. Volkswagen AG d
agen oes
olksw not
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– Pushs aaerial
ut wire -2- through notch -3- into tool adapteror to ac stop
-1-.
s
ce
e
nl
pt
du

an
itte
y li
erm
ab
– Pull out aerial wire -4-.

ility
ot p
Stripping inner insulation:

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
129
by lksw
cted agen
Prote AG.
2. Repairs to wiring harnesses and connectors
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
– Push aerial wire -2- through notch -1- into tool adapter to stop.
erm
ab
ility
ot p
wit
, is n
h re
– Pull out aerial wire -3-.
hole
Crimping inner conductor: 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
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
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
o
by c lksw
cted agen
Prote AG.
– Select appropriate adapter according to check of aerial wire

⇒ page 125 ⇒ page 125 .
– Tilt back swinging positioner -2-.
– Open positioning piece -3-. Positioning piece swings upwards.
– Push inner contact -1- into swinging positioner to stop and
loosen positioning piece. The inner contact is fixed in place.
– Tip swinging positioner inwards. The inner contact -4- is posi‐
tioned in the tool adapter.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness
– Push aerial wire -1- into inner contact -2- in tool adapter. Hold
o
cial p
f i
swinging position in place while doing so.

nform
mer
– Close tool until it opens by itself.

atio
om
n
c
– Open positioning piece -3- and pull out aerial wire.

i
or
n thi
te
sd
a
Crimping outer conductor:

iv
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.

AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
– Push sleeve -2- and outer contact -1- over inner conductor.
pe
ility
ot
The knurled contact part must be pushed under shielding -3-

wit
, is n
but over the aluminium foil. h re

hole
spec
– Push on outer contact -4- completely. Ensure proper seating
es, in part or in w
of female connector and pin.

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.

AG. Volkswagen AG d
agen oes
olksw not
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ara
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ris nte
ho eo
aut ra
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ce
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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
ht. rig
rig ht
py by
co Vo
by lksw
cted
– Push on sleeve -3- to outer contact.
agen
Prote AG.
– Open tool and tilt out swinging positioner -1-.

– Position mounted outer contact -2- in tool adapter in middle
notch on contact edge -4-.
– Pull out aerial wire.

2.7 Repairs to contact housings and con‐

nectors
2.7.1 Notes on repairs to contact housings

and connectors
Note

♦ Allocation of the appropriate crimp contacts to the contact
housings is by way of the part number stamped on the contact
housing. Listed in illustration 198 (electrical connecting ele‐
ments) in ⇒ Electronic parts catalogue (ETKA) are the part
numbers for the contact housings in conjunction with the as‐
sociated crimp contacts.
♦ Damaged contact housings must always be replaced.
♦ New contact housings can be ordered from the OTC in Kassel.
2.7.2 Repairs to contacts in contact housings

– If necessary, first open or disengage the secondary locking
mechanism of the contact housing ⇒ page 139 .
– Disengage the contact (primary locking mechanism) using the
appropriate release tool ⇒ page 139 .
– Pull the contact by the single wire out of the contact housing.
– Select the yellow repair wire with the correct contact from the
wiring harness repair set .
– Place the wire to be repaired from the vehicle's own wiring AG. Volkswagen AG d
harness to one side (about 20 cm either side of the agen
kswrepair po‐
oes
ol not
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ara
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– If necessary, unbind the wiring harnessauusing the folding knife. eo
ra
ss c
ce
le
un
pt
an
d
itte
y li
– Push the new contact of the repair wire into the contact hous‐
erm
ab
ing until it engages.

ility
ot p
wit
is n
– Slide the single wire seal onto the repair wire.

h re
ole,
spec
Note
t to the co
The small diameter of the single wire seal must face the contact
housing.
rrectne
– Slide the single wire seal into the contact housing using the
ss o
correct assembly tool ⇒ page 136 .

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
135
Prote AG.
2. Repairs to wiring harnesses and connectors
– Trim the repair wire and the single wire of the vehicle's own
wiring harness accordingly using wire strippers - VAS 1978/3- .
– Strip the 6 - 7 mm of insulation from the end of the repair wire

and the vehicle's own single wire using the wire strippers.
– 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 115 .
Note wage
es n
olks ot g
byV ua
♦ Ensure that, where several wires have to be repaired, their se
d ran
tee
crimp connectors are not directly adjacent to each other.
uth To
o
or
prevent the circumference of the wiring harness from
ss becom‐
a ac
ce
e
nl
pt
slightly.
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
motion.
rrectness of i
2.7.3 Fitting single wire seals

l purpos
Note
nf
ercia
orm
m
♦ Single wire seals prevent the ingress of moisture and dirt in

atio
m
the contact housing. They are installed, for example, in the

o
n in
c
engine compartment and must always be reinstalled following

or
thi
e
repairs.
t
sd
iva
o
r
rp
cu
♦ As standard, the single wire seal is crimped together with the

o
m
f
en
ng
contact on the wire; this is not the case with the repair wires.
t.
yi Co
Before crimping the repair line, the single wire seal must there‐ Cop py
t. rig
fore first be pushed onto the wire. gh ht
pyri by
Vo
co lksw
by
♦ It is essential that the single wire seals are of the correct size Prote
cted AG.
agen
to fit the cross section of the repair wire. The outer diameter
of the single wire seal is based on the socket diameter of the
contact housing. Only carry out the repair using the correct
assembly tool.

Assembling single wire seal:

– Disengage the contact locking mechanism using the appro‐
priate release tool -A- and then pull the wire with the single
wire seal backwards -arrow- out of the contact housing.
– Cut off the old contact with the single wire seal from the vehi‐
cle's own wiring harness.
lkswage es n
o ot g
byV ua
ed ran
– Slide the repair wire with the new contact in the respective
horis tee
socket of the contact housing until it engages. aut or
ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Place the single wire seal -A- on the free end of the repair wire.
ss o
cial p
f
Note
inform
mer
The small diameter of the single wire seal must face the contact
atio
m
housing.
o
n
c
i
or
n thi
te
sd
a
– Slide the single wire seal -A- on the repair wire until it reaches
iv
o
pr
the contact housing.

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

– Slide the single wire seal -A- using the respective assembly
tool -B- fully into the contact housing.
– 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 115 g.en AG. Volkswagen AG d
wa oes
olks not
byV gu
ara
ed nte
ris
tho eo
au ra
c
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un
pt
an
d
itte
y li
rm
ab
pe
ility
2.7.4 Repairs to contact housings using cut-
ot
wit
, is n
and-clamp method
h re
hole
spec
es, in part or in w
t to the co
Note
♦ For technical reasons, the contact housings for cut-and-clamp
rrectness of i
method can be supplied only with the cut-and clamp-contacts
inserted.
l purpos
♦ These contacts can be removed just like any other contact

nform
ercia
housing if they are not needed.

m
♦ Repair wires can be supplied that already have the appropriate

a
com
tio
contacts crimped on ⇒ Electronics parts catalogue (ETKA) .

n 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.

2.8 Releasing and dismantling contact

housings
2.8.1 Notes on releasing and dismantling con‐

tact housings
Note

♦ To release, always use the correct release tools. Under no
circumstances should the contacts be pulled out of the contact
housings with force.
Volkswa
♦ Damaged contact shousings
wage
n AG. must always
gen AG
dbe
oes replaced. New
contact housings by
Vo can be ordered from the OTC
lk not
gin
ua Kassel.
d ran
ir se
♦ As an aidtho to disengage the secondary locking elements,
tee
or a
smallssscrewdriver
au can be used. ac
ce
le
♦ The socket/pin assignment can be found stamped on the sec‐

un
ondary locking mechanism or on the rear of the contact hous‐ pt

an
d
itte
ing. y li
erm
ab
ility
ot p
♦ For more detailed information about the locations of connec‐ wit

is n
tors, see ⇒ Current flow diagrams, Electrical fault finding and

h re
ole,
Fitting locations.
spec
t to the co

vices can be gleaned from the table in the ⇒ operating instruc‐
tions of -VAS 1978/35- .
rrectne
2.8.2 Secondary locking element

ss
The secondary locking mechanism is a housing catch (second

o
cial p
line locking mechanism) that secures all the wires in one contact
inform
housing. If a secondary locking mechanism is fitted to a contact

mer
housing, this must always be opened or removed using the ap‐

atio
m
propriate tool before releasing and pulling out individual crimp

o
n
c
contacts.
or
n thi
te
sd
va
The secondary locking mechanism is different in colour from the

i
o
pr
cum
rest of the contact housing. This makes it easier to identify the

r
fo
en
ng
secondary locking element and clarifies its intended function.

t.
yi Co
Cop py
The types of contact housing shown here are just a few examples
t. rig
gh ht
yri
to show the different functions of secondary locking mechanism.
p by
co Vo
by lksw
cted agen
Example 1: Prote AG.
The housing catch is disengaged by removing a “toothed ele‐

ment” -arrow-.

AG. Volkswagen
Ameo 2017 ➤ , lArteon
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agen 2018 ➤ , Atlas 2017
AG do
es n ➤ , Bora 1999 ➤ , Bora Varian ...
Vo ot g
Electrical System,
db
y General Information - Edition ua01.2018
ra
e nte
ris
or tho e
Example 2: s ac au
s
ce
le
The housing catch is disengaged by opening a “flap” -arrow-.
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
Example 3:
ss o
cial p
f
The housing catch can be disengaged by detaching a “slide”
inform
-arrow-.
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.
2.8.3 Primary locking element

The primary locking mechanism is what fixes an individual crimp
contact in the contact housing.
If necessary, any housing catches in place (secondary locking
elements) must be released or removed prior to disengaging the
contacts using the prescribed tool ⇒ page 139 .
The types of primary locking elements shown as follows are just
a few examples to show the different functions of primary locking
element.
♦ Round connector systems ⇒ page 140
♦ Flat connector systems ⇒ page 141
♦ Special connector systems ⇒ page 143
vice can be gleaned from the table in the ⇒ operating instructions
of -VAS 1978/35- .
2.8.4 Round connector systems
Note


– Insert the release tool appropriate for the contact housing in

the release port of the contact housing.
– Grab hold of the contact by the wire and push it lightly into the
contact housing -arrow-.
Note
By pushing the contact in the direction of the contact housing, the

locking tabs of the contact are lifted up by the housing edge and
disengaged using the release tool.
– At the same time, push the release tool nin

AGthe
. Voldirection
kswagen AGofd the
contact housing -arrow- and pullVout wage
olks the released contact from
oes
not
gu
the contact housing. ed by ara
n
ris tee
utho or
– The release tool can be
ss pulled out of the contact housing again
a ac
once the contact has been removed.
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
2.8.5 Flat connector systems
nform
mercia
Note
at
om
ion
c
in t
or

his
ate

do
priv

um
for
en
ng
t.
yi Co
op
Flat connector with one locking tab: C py
t. rig
gh ht
yri by
– Insert the release tool appropriate for the contact housing in cop Vo
by lksw
the release port of the contact housing. cted agen
Prote AG.
Note

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

AG. Volkswagen
Ameo 2017 ➤ , Arteon ksw 2018 ➤ , Atlas 2017 ➤
agen AG do
es n, Bora 1999 ➤ , Bora Varian ...
Vol ot g
Electrical System,
d b General Information - Edition 01.2018
y ua
ra
e nte
ris
o tho e
– At the same the release tool in the direction of the r ac time,
au push
ss
contact housing and pull out the released contact from the
ce
contact housing -arrow-. le
un
pt
an
d
itte
y li
– The release tool can be pulled out of the contact housing again
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
Flat connector with two locking tabs:
ss o
cial p
f
inform
mer
atio
– Grab hold of the contact by the wire and push it fully into the
om
n
c
i
or
n thi
te
sd
iva
o
pr
c
Note
um
r
fo
en
ng
t.
yi Co
op
By pushing the contact in the direction of the contact housing, the C py
t. rig
gh ht
pyri by
o Vo
by c lksw
cted agen
Prote AG.
– At the same time, push the release tool in the direction of the
Asymmetrical:
Note


– At the same time, push the release tool in the direction of the
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
h
aut ra
s c
2.8.6 Special connector systems
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Faston contacts:
rrectness of i
l purpos
contact housing.
nf
ercia
orm
m
atio
m
Note
o
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
yri
– At the same time, push the release tool in the direction of the p by
o Vo
by c lksw
contact housing and pull out the released contact from the Prote
cted agen
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.
The contact is ejected from the contact housing.

once the contact has been ejected.
Contacts without locking tabs:

– Insert the release tool under the locking tab ofAG
the
. Vocontact
lkswagen AG
housing. lkswagen does
no
Vo t gu
by
– Push through the release tool with
ris
ed a light upward movement
ara
nte
-arrow- onto the limit stop. utho eo
ra
a c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
The contact is ejected from the contact housing.

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.

3 Contact surface cleaning set - VAS

6410-
3.1 Using contact surface cleaning set -

VAS 6410- Volkswa AG. gen AG
agen does
The contact surface cleaning set - VAS 6410- olenables
ksw optimal not
yV gu
repair of the electrical systems and components
ed b in the vehicle. ara
nte
The tools allow performing repair work ris
ho in the area of the sensor eo
ut
in wiring harnesses for threaded connections
ss
a in the high-current ra
c
circuit (starting and charge current). The contact surface cleaning
ce
e
nl
set - VAS 6410- is matched to the structural features of the vehi‐
pt
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cles and ensures safe repairs while making the work easier at the
itte
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same time.
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hole
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The illustrations shown here are just a few examples of repair
t to the co
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rrectness of i
Contact surface cleaning set VAS 6410
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3.1.1 Repairing ring terminals

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♦ VAG 1331
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Cop py
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Prote AG.
Note
♦ The use of penetrating fluid, contact spray or grease etc. is

prohibited since the missing adhesion in the threads may
cause a torque excess and, therefore, the break of the threa‐
ded connection.
♦ The grey sanding pads are suitable for light dirt and "soft sur‐
faces". The red sanding pads are suitable for heavy dirt and
"hard surfaces".
3. Contact surface cleaning set VAS 6410 145

WARNING

tions ⇒ page 3 !
– Disconnect battery.
– Loosen cap nut and remove ring terminal from threaded con‐
nection.
– Check ring terminal for corrosion, dirt etc.
– Select suitable adapter and suitable sanding pad.
Note
As an alternative, the sanding block may also be used.

AG. Volkswagen AG d
agen oes
olksw not
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Caution ed by gu
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ut
Take care not to abrade excessively the tin
ss acoating and ensure ra
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that the copper does not appear. This could produce a galvanic
ce
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un
cell which destroys metal and causes faulty repair.
pt
an
d
itte
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ility
ot
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Note
hole
spec
es, in part or in w
As the thickness of the tin coating may differ according to the de‐
t to the co
sign, the cleaning process must be performed step by step and a
visual check of the ring terminal is necessary between the steps.
rrectness of i
– Insert adapter into ring terminal and grind off corrosion and dirt
l purpos
with circular movements.

– Check ring terminal and regrind if necessary. nform
mercia
a
com
tion in
r
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thi
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iva
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Cop py
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pyri by
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by c lksw
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Prote AG.

AG. Volkswagen
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ra
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– If necessary,s aremove
u punching burr on ring terminal using de‐ r ac
burrer. s
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nl
pt
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– Tighten ring terminal to specified torque ⇒ Current flow dia‐
an
itte
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grams, Electrical fault finding and Fitting locations.
erm
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Note
h re
hole
spec
es, in part or in w
Optimum contact is ensured when the components to be secured
t to the co
are tightened to the specified torque after cleaning.
– Apply suitable anti-corrosion treatment to connection
rrectness of i
⇒ page 150 .
l purpos
– Reconnect battery.
nform
ercia
WARNING
m
at
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io
n
c
in t
or
tions ⇒ page 3 !
his
ate
do
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cum
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en
– Teach in electric windows again, enter radio code, set clock
ng
t.
yi Co
and, if necessary, recode control units which emit code sig‐ t. Cop py
nals.
rig
gh ht
pyri by
Vo
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cted agen
3.1.2 Repairing threaded connections
Prote AG.

♦ VAG 1331
Note
♦ The use of penetrating fluid, contact spray or grease etc. is

prohibited since the missing adhesion in the threads may
cause a torque excess and, therefore, the break of the threa‐
ded connection.
♦ The grey sanding pads are suitable for light dirt and "soft sur‐
faces". The red sanding pads are suitable for heavy dirt and
"hard surfaces".
WARNING

tions ⇒ page 3 !

– Loosen cap nut and remove ring terminal from threaded con‐
nection.
– Check threaded connection for corrosion, dirt etc.
– Select suitable adapter and suitable sanding pad for threaded
connection.
Caution
Take care not to abrade excessively the tin coating and ensure
that the copper does not appear. This could produce a galvanic
cell which destroys metal and causes faulty repair.
Note
As the thickness of the tin coating may differ according to the de‐
sign, the cleaning process must be performed step by step and a
visual check of the ring terminal is necessary between the steps.
– Set adapter on threaded connection and grind off corrosion

and dirt with circular movements. en AG. V
olkswagen AG
does ag
not ksw
– Check threaded connection and
by regrind if necessary.
Vol gu
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– Tighten connection and,thoif necessary, locating element again
r eo
u
to specified torque ⇒ssCurrent flow diagrams, Electrical fault
a ra
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finding and Fitting locations.
ce
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un
pt
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ab
Note
ility
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h re
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spec
t to the co
– Apply suitable anti-corrosion treatment to threaded connection

⇒ page 150 .
– Reconnect battery.
rrectnes
WARNING
s o
cial p
f inform

mer
tions ⇒ page 3 !
atio
om
n
c
i
or
n thi
e
– Teach in electric windows again, enter radio code, set clock

t
sd
iva
and, if necessary, recode control units which emit code sig‐

pr
cum
r
fo
nals.
en
ng
t.
yi Co
Cop py
3.1.3 Cleaning battery clamp and battery ter‐

t. rig
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pyri by
Vo
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Prote AG.

en AG. Electrical
ag
Volkswagen System,
AG does
General Information - Edition 01.2018
ksw not
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♦ VAG 1331 ed
b ara
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au ra
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ss
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ab
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hole
spec
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t to the co
rrectness of i
l purpos
Note
nf
The use of penetrating fluid, contact spray or grease etc. is pro‐
ercia
o
hibited since the missing adhesion in the threads may cause a
rm
m
atio
torque excess and, therefore, the break of the threaded connec‐
om
tion.
n in
or c
thi
te
sd
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WARNING
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t.
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op
C py
t. rig
gh
tions ⇒ page 3 !
ht
pyri by
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co lksw
by
cted agen
Prote AG.
– Check battery clamp and battery terminal for corrosion or dirt.
– Clean battery clamp using wire brush of battery terminal clean‐
er with circular movements.

– Clean battery terminal using underside of battery terminal

cleaner with circular movements.
WARNING

tions ⇒ page 3 !
– Reconnect battery and tighten battery terminals to specified

torque.
Note

3.1.4 Anti-corrosion treatment
Caution
Missing anti-corrosion treatment results in damage to the on-

board supply.
Note
♦ All threaded connections must be tightened to specified tor‐

que.
♦ Always use hose supplied with anti-corrosive agent tin.
♦ Use protection wax for cold area. agen
AG. Volkswagen AG d
oes
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♦ Use cavity sealing agent for warm area. sed b ara
nte
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♦ The sealing agent independently reaches
aut
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the respective ra
points through capillary action. ss c
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nl
pt
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– Hold injector below ring terminal and spray pin all around.
itte
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ility
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hole
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t to the co
rrectness of i
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c
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or
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ate
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priv
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en
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Cop py
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rig ht
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150
Prote AG.
Rep. gr.97 - Wiring
– Hold injector above ring terminal and spray pin and wiring eye
all around.
lkswage es n
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r
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Cop py
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co lksw
by
cted agen
Prote AG.

4 Renewing Lambda probe
Note
♦ Do not repair Lambda probe wires, since this can result in

malfunctions.
♦ If necessary, replace attachment parts, cable ties or marking
rings to match the uniform probe to the defective probe as
specified.
♦ If necessary, identify the lambda probe by means of the pro‐
tective tube ⇒ page 154 .
4.1 Renewing LSF Lambda probe (4-pin)
Note
. Volkswagen AG
gen AG
♦ If necessary, replace attachment parts, cable
ksw ties or marking
a does
not
Vol
rings to match the uniform probe to the d b defective probe as
y gu
ara
specified. rise nte
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au ra
♦ Do not repair Lambda probe wires,
ss since this can result in c
malfunctions.
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nl
pt
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erm
ab
ility
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– Remove the defective Lambda probe.
wit
, is n
h re
– Place both Lambda probes next to each other so that the sen‐
hole
spec
sor housings are at the same height.
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
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f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Tie back any excess in the uniform probe length (approx. 50 -

250 mm) to the size of the defective probe and secure with
. Volkswagen AG
cable ties -1-. swa
gen AG does
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– Check that the connector d bhousing of the Lambda probe is ara
ise nte
compatible with the ton-board
ho
r supply side. eo
au ra
c
– If necessary, replace
ss the on-board supply system connector
ce
e
with the Lambda probe connector housing supplied
nl
pt
du
an
⇒ page 135
itte
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ab
ility
ot p
Note
wit
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hole
spec
♦ The connector housing should only be replaced on older ve‐
es, in part or in w
hicles. On new vehicles, the connector housing coding match‐
t to the co
es.
♦ Observe pin assignment. For reasons of clarity, respective
rrectness of i
pins in new connector housing have a colour marking.
l purpos
♦ Further notes can be found in the leaflet of the new Lambda

probe.
nf
ercia
o
– Install the new Lambda probe in the vehicle.
rm
m
atio
om
n in
c
4.2 Renewing LSU Lambda probe (6-pin)

or
thi
te
sd
iva
o
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m
Note
f
en
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t.
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Cop py
♦ If necessary, replace attachment parts, cable ties or marking
t. rig
gh ht
yri
rings to match the uniform probe to the defective probe as
p by
o Vo
by c lksw
specified. Prote
cted AG.
agen
♦ The wires should not be crimped or cut as otherwise the func‐

tion of the Lambda probe will be impaired.
– Remove the old Lambda probe.

– Place both Lambda probes next to each other so that the sen‐
sor housings are at the same height.
4. Renewing Lambda probe 153

– Tie back any excess in the uniform probe length (approx. 50 -

250 mm) to the size of the defective probe and secure with
cable ties -1-.
– Install the new Lambda probe in the vehicle.
lkswage es n
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4.3 Types of protective tube on uniform ir se
d b ua
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o
Lambda probes auth or
ac
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Note
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erm
ab
ility
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In addition to identifying by way of the part number, the protective
wit
is n
tube can also be used as a means of identification.
h re
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spec
Type D1, 6 openings at 3.5 mm each
t to the co
Only used on 4-pin LSF Lambda probes.
Type D2, 6 openings at 2 mm each
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mer
atio
om
n
c
i
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probes.
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Type D4, 12 openings at 1.4 mm each
by lksw
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te o
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Cop py
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4. Renewing Lambda probe 155

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Service

Golf Variant 2014 ➤ ,

Golfss aVariant 2017 ➤ , Lupo 1999 ➤,

Lupo 3L 1999 ➤ , Passat 1997 ➤ ,

Passat 2006 ➤ , Passat 2011 ➤ ,

Passat (NMS - US) 2012 ➤ ,

Passat (NMS - US) 2016 ➤ ,

Passat Variant 2011 ➤ ,

Passat Variant 2015 ➤ , Phaeton 2003 ➤ ,

Polo 1995 ➤ , Polo 2002 ➤ ,

Polo 2010 ➤ , Polo 2014 ➤ ,

Polo 2018 ➤ , Polo KH IN 2010 ➤ ,

Polo Lim IN 2011 ➤ ,

Polo Lim IN 2016 ➤ ,

Service Department. Technical Information

Polo Lim MY 2014 ➤ ,

Service Department. Technical Information

94 - Lights, bulbs, switches - exterior

Technical information should always be available to the foremen and mechanics,

All rights reserved.

Copyright © 2018 Volkswagen AG, Wolfsburg K0059101320

All rights reserved.

Copyright © 2018 Volkswagen AG, Wolfsburg K0059101320

27 - Starter, current supply, CCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4.1 Activating and deactivating cruise control system (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . . 71

92 - Windscreen wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

2.2 Repairing smooth pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

94 - Lights, bulbs, switches - exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

1 Operation and safety notes for gas discharge lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

96 - Lights, bulbs, switches - interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

1 Vehicle diagnosis, testing and information systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

2.5 Repairs to fibre optic cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

2.8 Releasing and dismantling contact housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

3 Contact surface cleaning set VAS 6410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

3.1 Using contact surface cleaning set VAS 6410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

27 – Starter, current supply, CCS

Danger of injury! Observe warning notices and safety regula‐

To prevent damage to the battery or vehicle, read the informa‐

1.1 Fundamentals for batteries

1.2 Types of lkbatteries

The description for the following batteries is for maintenance-

free batteries. No stickers may be removed and do not replen‐

ish with distilled water. Only perform a visual check. Refer to

chapter, Checking battery ⇒ page 6 .

1.2.1 Battery with »standard« colour indicator

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

It is not permissible to test or charge batteries whose colour

Danger of explosion when checking and charging or slave/

These batteries must be renewed.

1.2.2 Battery with »enhanced« colour indica‐

No stickers may be removed and do not replenish with distilled

It is not permissible to test or charge abatteries

equipped with a start/stop system. The battery can be identified

hanced flooded battery«.

An “EFB” battery may only be replaced with another “EFB” bat‐

Checking the colour indicator ⇒ page 9

start/stop systems and manual gearboxes as of 05.2011.

1.2.3 Absorbent glass mat battery

Always replace an absorbent glass mat battery with another ab‐

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

1.3 Warning notices and safety regulations

1.3.1 Dangers when handling vehicle batter‐

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

may escape through vent valves is explosive. In extreme