D3E800230E1-Electrical Equipment General Information

Service
Repair Manual olkswagen AG

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Lupo 3L 1999 ➤ , Passat 1997 ➤ ,
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Polo Lim IN 2011 ➤ ,
Polo Lim IN 2016 ➤ ,
Polo Lim MY 2014 ➤ ,
Polo Lim MY 2016 ➤ ,
Polo Lim RUS 2011 ➤ ,
Polo Lim RUS 2016 ➤ , Scirocco 2009 ➤ ,
Scirocco 2015 ➤ , Sharan 1996 ➤ ,
Sharan 2011 ➤ , Tiguan 2008 ➤ ,
Service Department. Technical Information

Service
Touareg 2003 ➤ , Touareg 2010 ➤ ,

Touareg 2015 ➤ , Touran 2003 ➤ ,
XL1 2015 ➤ , e-Golf 2014 ➤ ,
e-up! 2014 ➤ , up! 2012 ➤
Electrical Equipment General Information
Edition 04.2015
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
27 - Battery, Starter, Generator, Cruise Control
92 - Wiper/Washer Systems
94 - Exterior Lights, Switches
96 - Interior Lights, Switches
97 - Wiring
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Technical information should always be available to the foremen and mechanics,

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All rights reserved. Prote AG.
No reproduction without prior agreement from publisher.
Copyright © 2015 Volkswagen AG, Wolfsburg D3E800230E1

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All rights reserved.

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Copyright © 2015 Volkswagen AG, Wolfsburg D3E800230E1

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Electrical
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27 - Battery, Starter, Generator, Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.1 Battery General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.2 Types of Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
t to the co
1.3 Warnings and Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Battery Post/Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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2 Battery, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
l purpos
2.2 Batteries, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.3 Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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2.4 Visual Display in Battery Cover, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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2.5 Battery Tester VAS6161 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
com
tion in
2.6 Midtronics Battery Tester MCR340VKT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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2.7 Current Draw Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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3 Battery, Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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3.1 Battery Charger VAS5095A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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3.2 Battery Charger VAS5900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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3.3 Battery Charger VAS5903 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3.4 Battery Charger VAS5906 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3.5 Battery Tester Charger Kit GRX3000VAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.6 Solar Battery Maintainer VAS6102A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.7 Severely Discharged Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4 Cruise Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.1 Cruise Control System, Activating and Deactivating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
92 - Wiper/Washer Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1 Washer Fluid Line Hose Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1.1 Windshield and Rear Window Washer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1.2 Headlamp Washer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2 Hoses, Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.2 Smooth Tube, Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.3 Corrugated Tube, Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3 Joint-Free Wiper Blade Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
94 - Exterior Lights, Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

1 HID Headlamp Usage and Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
96 - Interior Lights, Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

1 12 V Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.1 12 V Socket , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.2 Socket Illumination Bulb L42 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2 Cigarette Lighter U1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.2 Overview - Cigarette Lighter U1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.3 Cigarette Lighter Socket, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.4 Cigarette Lighter Illumination Bulb L28 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 74
3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
97 - Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Contents i
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , CC 2012 ➤ , Eos 2006 ...
Electrical Equipment General Information - Edition 04.2015
1 Vehicle Diagnosis, Testing and Information Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

1.1 Vehicle Diagnostic Tester , Connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.2 Vehicle Diagnostic Tester , Connecting, Golf MY 1998 through 2003 . . . . . . . . . . . . . . . . 78
2 Wiring Harness and Connector Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.1 Vehicle Electrical System, General Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.2 Wiring Harness Repair Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2.3 Tool Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.4 Wiring Harnesses, Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.5 Fiber-Optic Cables, Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.6 Antenna Wires, Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.7 Contact Housings and Connectors, Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2.8 Contact Housings, Releasing and Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
3 Contact Surface Cleaning Set VAS6410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
3.1 Contact Surface Cleaning Set VAS6410 , Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
4 Heated Oxygen Sensor, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
4.1 4-Pin Heated Oxygen Sensor agen
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and Installing . . . . . . . . . . . . . . . . . . . . 131
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4.3 Oxygen Sensor rise Unit Protective Pipes . . . . . . . . . . . . t.e . . . . . . . . . . . . . . . . . . . . . . . . . . .
n 132
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5 Special sTools
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6 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
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ii Contents
27 – Battery, Starter, Generator, Cruise Control

1 Battery
(Edition 04.2015)
⇒ “1.1 Battery General Information”, page 1
⇒ “1.2 Types of Batteries”, page 1
⇒ “1.3 Warnings and Safety Precautions”, page 3
⇒ “1.4 Battery Post/Terminal”, page 5
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Risk of injury. Follow all Warnings and Safety Precautions.
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In order to prevent damage to the battery or vehicle, observe
battery type descriptions and notes. Refer to
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⇒ “1.2 Types of Batteries”, page 1 .
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To guarantee a long service life, the battery must be checked,
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serviced and maintained as described in this manual.
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In addition to supplying the power to start the engine, the battery
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The following batteries described are maintenance-free bat‐ Prote AG.
teries. Do not remove any of the labels on the battery and do

not add distilled water. Only perform a visual inspection. Note
the chapter on battery testing. Refer to
⇒ “2 Battery, Checking”, page 6 .
1. Battery 1
1.2.1 Battery with Visual Indicator, Standard

This is a maintenance-free battery with liquid electrolyte (wet bat‐
tery).
WARNING
Do not check or charge batteries that have a visual indicator

that is bright yellow. Jump starting must not be used!
There is a risk of explosion during testing, charging or jump
starting.
These batteries must be replaced.
This battery has a visual indicator. The visual indicator shows the
state of charge and the battery acid level. Visual indicator, check‐
ing. Refer to
⇒ “2.4 Visual Display in Battery Cover, Checking”, page 8 .
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1.2.2 Battery with Visual Indicator, Enhanced byV
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The battery is installed in certain Stop/Start vehicles due to spe‐

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An “EFB” battery has a visual indicator for checking the battery

electrolyte level.
Visual indicator, checking. Refer to
Note
“EFB” batteries are being installed in smaller gasoline engines

with the Stop/Start system and a manual transmission from
05/2011.
2 Rep. Gr.27 - Battery, Starter, Generator, Cruise Control

1.2.3 AGM Battery

Maintenance-Free Battery with Specific Electrolyte without a Vis‐
ual Indicator
Lead-acid battery, where the electrolyte is fixed in an absorbent
glass mat (AGM). The battery is closed and equipped with breath‐
er valves.
AGM is the English abbreviation for Absorbent Glass Mat.
These batteries do not have a visual indicator because the elec‐
trolyte level is predetermined. AGM is on the battery to identify it.
Note
Always replace an AGM battery with another AGM battery.
1.3 Warnings and Safety Precautions

⇒ “1.3.1 Battery Safety Precautions”, page 3
⇒ “1.3.2 Battery Safety Label”, page 4
⇒ “1.3.3 Working on Airbag System”, page 5
1.3.1 Battery Safety Precautions

Recognizing and Preventing Risks
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1. Battery 3
WARNING
♦ Personnel instructed in protection, such as a trainee or

apprentice, may only perform work on vehicle batteries
under the supervision of technical personnel such as a
master automotive mechanic or a master automotive elec‐
trician.
♦ Acid has strong corrosive properties. If batteries are han‐
dled inappropriately, there is a risk that personal injury
may result from exposure to harmful electrolyte influen‐
ces. Therefore, suitable remedies for acid damage must
be kept readily available. For example, soap solution is a
suitable material.
♦ If electrolyte drips out from the battery, skin can be burned
by acid or the vehicle may be affected by acid erosion and
corrosion. It is a possibility that safety-related vehicle com‐
ponents can be damaged.
♦ When charging and when resting after charging, explosive
gas is present. In extreme cases, if the battery is handled
inappropriately, the emitted gases may cause the battery
to explode.
♦ Batteries whose visual indicators are bright yellow must
be replaced. They may not be tested or charged and jump
starting may not be used. There is a risk of explosion dur‐
ing testing, charging or jump starting.
♦ Generating sparks by sanding, welding, separating work
and open flame, for example, smoking in vicinity of the
battery, is prohibited. Producing sparks through electro‐
static discharge must also be avoided. Always touch the
vehicle body before touching the battery.
♦ Only perform battery procedures in suitable and well-ven‐
tilated locations.
AG. Volkswagen AG d
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1. - When working in the area of batteries, fire, sparks, open flame

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2. - Wear protective eyewear when working on the battery.

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3. - Always keep acid and batteries out of the reach of children.

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4. - Disposal: old batteries require special disposal. They may

only be disposed of at a suitable collection facility and only in
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consideration of legal regulations.

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5. - Do not dispose of old batteries in household waste.

6. - When handling batteries, there is a risk of explosion. Battery
nform
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charging produces a highly explosive gas mixture.

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7. - Always observe notes on battery in ELSA "Electrical Equip‐

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ment - General Information" and in the Owner's Manual.

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from the ventilation openings.
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1.3.3 Working on Airbag System
WARNING
When working on the airbag system (pyrotechnic components,

Airbag Control Module - J234- , wiring), the ground cable must
be disconnected with the ignition switched on.
Exceptions: On vehicles with a battery in the passenger com‐
partment, the ignition must be switched off.
♦ Then cover the negative terminal.
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♦ After disconnecting the battery,Voalkwait
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If the ignition is not switched on after reconnecting the battery
spec
(the indicator lamps in the instrument cluster do not illuminate),
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the ignition (key/button) may only be switched on while sitting
t to the co
in the driver's seat in the rearmost position.
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1.4 Battery Post/Terminal
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WARNING
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Risk of injury. Follow all Warnings and Safety Precautions. atio

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Refer to ⇒ “1.3 Warnings and Safety Precautions”, page 3 .
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♦ Never use force to attach the battery terminals by hand.
♦ Do not apply grease to battery posts.
♦ The battery terminal clamps should be mounted so that
the battery terminal sits flush with the clamp or protrudes
out of it.
♦ After tightening the battery terminal clamps to the speci‐
fied torque, the threaded connections must not be tight‐
ened again.
1. Battery 5
AG. Volkswagen AG d
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2 Battery, Checking d b ara
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⇒ “2.1 General Information”, page 6 ss c
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⇒ “2.2 Batteries, Checking”, page 6
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⇒ “2.3 Visual Inspection”, page 7
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⇒ “2.4 Visual Display in Battery Cover, Checking”, page 8
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⇒ “2.5 Battery Tester VAS6161 ”, page 10
hole
spec
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⇒ “2.6 Midtronics Battery Tester MCR340VKT ”, page 15
t to the co
⇒ “2.7 Current Draw Test ”, page 19
2.1 General Information
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WARNING
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Note
For each respective vehicle. Refer to for information regarding the

battery.
2.2 Batteries, Checking

⇒ “2.2.1 Battery with Visual Indicator, Checking”, page 6
⇒ “2.2.2 AGM Battery, Checking”, page 7
2.2.1 Battery with Visual Indicator, Checking
WARNING

Perform Battery Checks in the Following Sequence:

1. Visual inspection. Refer to
⇒ “2.3 Visual Inspection”, page 7 .
2. Check the visual indicator: “3-color”. Refer to
⇒ “2.4.1 3-Color Visual Indicator, Checking”, page 8 ; or
“2-color”. Refer to
⇒ “2.4.2 2 Color Visual Indicator, Checking”, page 9 .

WARNING

starting.
3. Check the battery using the Battery Tester - VAS6161- .

Refer to ⇒ “2.5 Battery Tester VAS6161 ”, page 10 .
4. Depending on the battery test result, “perform a current draw
test”. Refer to ⇒ “2.7 Current Draw Test ”, page 19 .
2.2.2 AGM Battery, Checking

Perform Battery Checks in the Following Sequence:
1. Visual inspection. Refer to
2. Check the battery using the Battery Tester - VAS6161- .
Refer to ⇒ “2.5 Battery Tester VAS6161 ”, page 10 .
3. Depending on the battery test result, “perform a current draw
test”. Refer to ⇒ “2.7 Current Draw Test ”, page 19 .
2.3 Visual Inspection

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WARNING ir se
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Prior to performing any measurements or tests, perform a visual
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check of the battery condition, battery terminals and secure
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mounting of battery.
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Note
For each vehicle. Refer to for information regarding the battery.

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Caution
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♦ An improperly secured battery can lead to damage.

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♦ Excessive vibration due to an improperly secured battery

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will reduce the battery service life, and the battery hold-
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down bracket could damage the battery housing and lead

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to electrolyte leakage.
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♦ Check the battery for secure fitting, if necessary tighten

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the mounting bolt to the tightening specification.
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By Performing Visual Inspection, it can be Determined: cted agen
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♦ If the battery case is damaged. Acid can leak out if the case is
damaged. Battery acid that has leaked out can cause severe
damage to the vehicle. Acid that has leaked onto any part of
the vehicle should be immediately treated with acid neutralizer
or soap solution.
2. Battery, Checking 7
♦ If the battery terminals (battery wiring connections) are dam‐

aged. If the battery terminals are damaged, contact with bat‐
tery terminals clamps cannot be guaranteed. When connect‐
ing the battery pole shoes, keep in mind that the tightening
specification from the “Electrical Equipment” repair manual for
the corresponding vehicle is used. If the battery post clamps
are not correctly installed and secured, the wiring may burn.
Substantial malfunctions to the electrical system are a conse‐
quence. Safe operation of the vehicle can no longer be guar‐
anteed.
2.4 Visual Display in Battery Cover, Check‐

ing
⇒ “2.4.1 3-Color Visual Indicator, Checking”, page 8
⇒ “2.4.2 2 Color Visual Indicator, Checking”, page 9
2.4.1 3-Color Visual Indicator, Checking
WARNING

AG. Volkswagen AG d
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Visual Indicator Generald by Information gu
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Applies to allaoriginal
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equipment batteries with index “1J0” , “7N0” ra
and “3B0” and
ss to all replacement batteries, part number 191 915 c
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105 AB, and beginning with index “000 915 105 AX”.
un
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The visual indicator shows the electrolyte level and the battery
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state of charge.
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To obtain an accurate reading, gently tap the charge indicator with

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a screwdriver handle or rock vehicle slightly. By doing this, the air

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spec
bubbles that occur normally during battery charging (even during

es, in part or in w
vehicle operation) that adversely affect charge indicator reading

t to the co
will be displaced. The visual indicator will be more accurate.

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Note
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♦ Air bubbles can especially form under visual indicator when a

battery is charged, including when charged while driving. This
nform
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will cause an incorrect display.

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♦ The display is valid for only that one battery cell in which the
com
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visual indicator is located. An exact assessment of battery

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condition should always be confirmed by performing battery

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charge test ⇒ “2.5 Battery Tester VAS6161 ”, page 10 .

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♦ The visual indicator may be located on different locations on

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There Are Three Possible Color Indications:
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♦ »Green«: Battery is sufficiently charged.
Prote AG.
♦ »Black«: Insufficiently charged, less than 65% or discharged.

♦ »Colorless or light yellow«, battery must be replaced.

WARNING
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Do not check or charge olkbatteries that have a visual oindicator
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that is bright yellow.
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2.4.2 “2 Color” Visual Indicator, Checking
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WARNING
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Visual Indicator General Information

The general introduction of the “2-color” display began as a run‐
nform
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ning change in 2009. The color »green« for the state of charge
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was discontinued on the “2-color”.
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The visual indicator shows the battery acid level.
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It is no longer possible to read the battery state of charge using do

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the visual indicator. It is necessary to perform a battery test. Refer
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To obtain an accurate reading, gently tap the charge indicator with
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a screwdriver handle or rock vehicle slightly. By doing this, the air
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bubbles that occur normally during battery charging (even during
by lksw
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vehicle operation) that adversely affect charge indicator reading
AG.
will be displaced. Thereby, the color indicator of the visual indi‐

cator is more accurate.
Note
♦ Air bubbles can especially form under visual indicator when a

battery is charged, including when charged while driving. This
will cause an incorrect display.
♦ The display is valid for only that one battery cell in which the
visual indicator is located. An exact assessment of battery
charge is only possible by performing a battery test. Refer to
⇒ “2.5 Battery Tester VAS6161 ”, page 10 .
♦ The visual indicator may be located on different locations on
the battery.
Two Visual Indicators Are Possible:

♦ »Black«, the electrolyte level is OK
♦ »Bright yellow«, the electrolyte level is too low. The Battery
must be replaced.
WARNING

starting.
2.5 Battery Tester - VAS6161-

⇒ “2.5.1 Battery Tester VAS6161 Device Description”,
page 10
⇒ “2.5.2 Battery Test, Performing using Battery Tester VAS6161 agen
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⇒ “2.5.3 Warranty Test, Performing”, page 12 horise nte
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⇒ “2.5.5 Service Test, Performing”, page 13
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⇒ “2.5.6 Explanation of Test Results”, page 14
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⇒ “2.5.7 Evaluating Test Results”, page 14
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2.5.1 Battery Tester - VAS6161- Device De‐
hole
spec
scription
es, in part or in w
t to the co
1 - Integrated printer
2 - Operating lever for the paper tray
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3 - Paper slot
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4 - LCD screen with main menu
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5 - ON/OFF switch
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6 - Connection for the battery tester cable
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7 - Slot for the memory card
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General Description
WARNING
Risk of injury. Follow Aall Warnings

G. Volkswagen Aand Safety Precautions.
Refer to ⇒ “1.3olWarnings
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It is not
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All battery types are stored in the tester.
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The data can be stored on a SD memory card.
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The Battery Tester - VAS6161- can be updated via an interface
t to the co
or a SD card, so that all battery data from Volkswagen is always
current.
The integrated temperature sensor increases the quality of the
rrectne
measurements.
An optional 2D scanner is available to carry over the data from
ss
the battery 2D code.
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Note
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Read the Battery Tester - VAS6161- Operating Instructions.

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2.5.2 Battery Test, Performing using Battery

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Tester - VAS6161-
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Special tools and workshop equipment required
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♦ Battery Tester - VAS6161-
WARNING

Testing the Battery
WARNING

starting.
– Turn off the ignition and all electrical consumers.

– Battery with visual indicator, checking visual indicator. Refer
to ⇒ “2.2.1 Battery with Visual Indicator, Checking”, page 6 .
– Switch on the unit.
– Clamp the red clamp “+” of the tester to the positive terminal.
– Clamp the black clamp “-” on the tester to the negative termi‐
nal.
Note
Make sure the test clamps make good contact!
– Select the following:

♦ Check the original batteries in the warranty mode. Refer to
⇒ “2.5.3 Warranty Test, Performing”, page 12 .
♦ Check the replacement batteries in the service mode. Refer to
⇒ “2.5.5 Service Test, Performing”, page 13 .
Note
♦ The test is over after approximately 10 seconds.

♦ The results of the test are output through
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♦ It is not necessary to let the tester ir secool down before performing
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2.5.3 Warranty Test, Performing

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– Select “Warranty Test”.

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– Select “inside the vehicle” or “outside of the vehicle”.

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– Select “at the battery pole” or “at the battery jump start termi‐
com
tion in
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– Scan in the battery 2D code or manually select battery type

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– Measure the temperature. Hold the temperature sensor ap‐

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proximately 5 cm above the battery pole until the temperature C py
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– Start the test. cted agen
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– Print out the test report if necessary.
2.5.4 Maintenance Test, Performing
WARNING

starting.

– Select “Maintenance Test”.

– Connect the scanner.
Note
If there is no scanner, manually enter the VIN on the printed test

results.
– Scan the VIN.

nal”.
– Scan in the battery 2D code or manually select the type and
manufacturer in the menu.
proximately 5 cm above the terminal connection until the
temperature is stable.
– Start the test.
– Print out the test report if necessary.
2.5.5 Service Test, Performing
Note
♦ The printed test results can differ depending on the software

version.
♦ Read the Battery Tester - VAS6161-
agen Operating Instructions.
AG. Volkswagen AG d
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WARNING au
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– Select “Service Test”.

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– Select the type of battery: “standard”, “AGM”, “2*6V” or “Gel”.

– Select the “CCA”, “JIS”, “DIN”, “SAE”, “IEC” or “EN”.
nform
ercia
– Select battery value.

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tio

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proximately 5 cm above the battery pole until the temperature

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is stable.
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– Start the test.

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– Print out the test report if necessary. t. Cop py
rig
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2.5.6 Explanation of Test Results

1- Type of test.
2- Battery test result. n AG. Volkswagen AG do
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3- Measured voltage byV
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4- Measured cold start value. tho tee
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6- Measured battery temperature
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7- Batter installed location
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8- Location of the battery terminal set on the tester
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9- Selected battery.
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Note
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The printed test results are required for warranty claims.
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2.5.7 Evaluating Test Results
nform
ercia
Evaluating Battery Test Results for Warranty and Service Tests

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Battery Test Result Measure
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Battery good No measure on the battery

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Battery good - recharge Charge battery. Refer to
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⇒ “3 Battery, Charging”,
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page 21 . If necessary, Cop py
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Perform a current draw test Perform a current draw test. Prote AG.
Refer to
⇒ “2.7 Current Draw Test ”,
page 19 . Charge the battery
completely (refer to
page 21 ) and test again.
Replace the battery. Disconnect the battery and test
again. The result “replace the
battery” can occur due to a
weak cable contact.
Battery cell faulty - replace Replace the battery.
Check the connection Connect the cable directly to
the battery and not to the bat‐
tery jump start terminal.
Battery depleted Replace the battery.
Evaluating Battery Test Results for Maintenance Test
Battery good No measure
Charge the battery immediate‐ Fully charge the battery. Refer
ly. to
page 21 .
Mark as defective Mark as defective.

AG. Volkswagen AG d
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Battery Test Result olksw Measure oes
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Check the testerorconnection
ised
Disconnect the battery and ntetest
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Check the connection Connect the cable directly to
ab
ility
the battery and not to the bat‐
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tery jump start terminal.
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Noises Wait until the measured value
hole
spec
appears in the display.
es, in part or in w
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Battery depleted Replace the battery.
2.6 Midtronics Battery Tester -
rrectness of i
MCR340VKT-
l purpos
⇒ “2.6.1 General Information”, page 15
nform
ercia
⇒ “2.6.2 Battery, Testing using Midtronics Battery Tester

MCR340VKT ”, page 16
m
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io
⇒ “2.6.3 Evaluating Test Results”, page 17
n
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or
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⇒ “2.6.4 Midtronics Battery Tester MCR340VKT , Troubleshoot‐

at
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2.6.1 General Information

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WARNING
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Risk of injury.
Read and follow the Safety Precautions when working with
batteries. Refer to
⇒ “1.3 Warnings and Safety Precautions”, page 3 .
Dispose of electrolyte (sulfuric acid/water mixture) safely. Elec‐
trolyte must be taken to approved locations that accept it.
Follow local disposal ordinances.
Do not check gas batteries. Danger of explosion.
WARNING
Batteries that have a light yellow visual indicator do not have

to be tested or charged. Jump starting must not be used!
starting.
Note
To prevent damaging the battery or the vehicle, pay attention to

the battery type and notes. Refer to ⇒ “1 Battery”, page 1 .
Only Volkswagen approved battery testers may be used to test

batteries in Volkswagen vehicles. Use the Midtronics Battery
Tester - MCR340VKT- in the USA and Canada.
Read the safety precautions, setup and operating instructions

that come with the Midtronics Battery Tester - MCR340VKT- and
follow them exactly.
AG. Volkswagen
Refer to Self Study Program; Vehicle Batteries
lksw
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The following charging and analysis tho procedures apply to all bat‐ or
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teries, all battery installed locations (engine compartment or lug‐ ac
s
gage compartment) and all battery purposes (for the starter or for
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un
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the second/convenience battery).
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Always follow the Safety Precautions, the instructions for setting
erm
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up the battery tester, the display menu/display buttons, LEDs and
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the procedures in the MCR340V Operating Instructions.
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Always read all sub-chapters, notes and instructions for testing
batteries.
rrectne
2.6.2 Battery, Testing using Midtronics Bat‐
ss o
tery Tester - MCR340VKT-
cial p
f inform
mer
Requirements
atio
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WARNING
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Read and follow the Safety Precautions when working with
um
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batteries. Refer to
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⇒ “1.3 Warnings and Safety Precautions”, page 3 . Cop py
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starting.
– Read the General Description. Refer to

⇒ “2.6.1 General Information”, page 15 .
– Visually check the battery. Refer to
– Open the hood or open the cover if the battery is installed
somewhere else.
– Determine if it is a “Standard” battery or an “AGM” battery.
– Remove the covers on the battery positive and negative ter‐
minals.
– Use a fender protector or some type of cover before using any
equipment inside the engine compartment or inside the pas‐
senger compartment.
– Close all the doors.
Note
♦ The battery temperature must be at least 10 °C (50 °F).

♦ Refer to the Battery Tester Charger Kit - VASRX3000- Oper‐
ating Instructions for more information.

Performing the Test AG. Volkswagen AG d

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WARNING rise
d ara
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Batteries that
ss have a light yellow visual indicator do not have c
ce
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un
pt
an
d
itte
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erm
ab
starting.
ility
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wit
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h re
ole,
spec
t to the co
– Check the visual indicator. Refer to
⇒ “2.2.1 Battery with Visual Indicator, Checking”, page 6 .
rrectne
– Switch on the unit.
s
– Clamp the red clamp “+” of the tester to the positive terminal.
s o
cial p
f i
– Clamp the black clamp “-” on the tester to the negative termi‐
nform
nal.
mer
atio
om
n
c
i
or
n
Note
thi
te
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pr
Make sure the test clamps make good contact! cum

r
fo
en
ng
t.
yi Co
op
– Select “inside the vehicle” or “outside of the vehicle”.
C py
t. rig
gh ht
yri by
– Select “Warranty Test”. cop Vo
by lksw
cted agen
Prote AG.
Note
If the test results are needed to process a warranty claim, use the
print function on the Midtronics Battery Tester - MCR340VKT- .
– Determine if it is a “Standard” battery or an “AGM” battery.

– Enter the battery DIN value taken from the battery label. If the
label does not state a DIN value, then enter the SAE value.
– Enter the DIN value into the tester and then perform the battery
test. Refer to MCR340V Operating Instructions.
– If using an SAE value, go into the menu under “other” and
change “DIN” to “SAE”. Refer to MCR340VKT Operating In‐
structions.
Note
Always use the DIN value on the battery label. Otherwise the test
result will be incorrect.
2.6.3 Evaluating Test Results

Battery Test Result
Battery good None
Good - charge Charge battery. Refer to
⇒ “3.5 Battery Tester Charger
Kit GRX3000VAS ”,
page 52 .

Use in charge Charge battery. Refer to
⇒ “3.5 Battery Tester Charger
Kit GRX3000VAS ”,
page 52 .
Replace the battery. Replace the battery. Refer to ⇒
Electrical Equipment; Rep. Gr.
27 ; Battery, Removing and In‐
stalling
Battery cell defective Replace the battery. Refer to ⇒
Electrical Equipment; Rep. Gr.
27 ; Battery, Removing and In‐
stalling
2.6.4 Midtronics Battery Tester -

MCR340VKT- , Troubleshooting
Sometimes the display shows the malfunction or the messages
based on the condition.
The following is a list of the most frequent displayed messages
together with suggested solutions. wagen AG. Volkswagen AG doe
olks s no
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ris nte
Note tho eo
au ra
c
ss
Refer to the MCR340V Operating Instructions for messages not
ce
e
nl
pt
du
listed here. an
itte
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erm
ab
ility
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Display Message Measure

wit
, is n
h re
No display – Make sure the battery tester

hole
terminals are attached se‐

spec
curely to the battery termi‐

es, in part or in w
t to the co
nals.
– Make sure the battery pole

rrectness of i
is tightened to the tightening

specification and is not cor‐
l purpos
roded.
– Charge battery. Refer to

nform
ercia
⇒ “3.5 Battery Tester

m
Charger Kit GRX3000VAS

at
om
io
”, page 52 .
n
c
in t
or
System noises – Switch off all electrical con‐

his
ate
sumers.
do
priv
cum
for
en
g
– Wait until all electrical equip‐

n
t.
yi Co
ment, which are monitored
. Cop py
by the vehicle electrical sys‐
ht rig
rig ht
by
tem control module, are
copy Vo
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cted
switched off.
agen
Prote AG.
– Remove the key.
– Disconnect any doubtful or

standard production electri‐
cal equipment from the ve‐
hicle electrical system.
Wait a few minutes and then perform the test again. Refer to
⇒ “2.6.2 Battery, Testing using Midtronics Battery Tester
MCR340VKT ”, page 16 .

Note
If the test was performed at the battery jump start terminal and
the message still does not go away, then perform the test directly
on the battery.
2.7 Current Draw Test
agen
WARNING
AG. Volkswagen AG d
oes
olksw not
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by
Batteries that have a rlight
ised yellow visual indicator do not havearante
to be tested or charged.
tho Jump starting must not be used! eo
s au ra
c
s
ce
le
starting.
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
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h re
ole,
spec
Note
t to the co
♦ Make sure the correct charging mode is set on the charger so
the current draw test is not inaccurate.
rrectne
♦ Battery Charger - VAS5095A- . Refer to
⇒ “3.1.2 Battery, Charging with Battery Charger VAS5095A ”,
s
page 22 .
s o
cial p
f i
♦ Battery Charger - VAS5900- . Refer to
⇒ “3.2 Battery Charger VAS5900 ”, page 27 . nform
mer
atio
m
♦ Battery Charger - VAS5903- . Refer to

o
n
c
⇒ “3.3 Battery Charger VAS5903 ”, page 37 .

or
n thi
te
sd
iva
o
pr
In order to receive an indication as quickly as possible of the bat‐

cum
r
fo
tery condition of discharged batteries, a conclusion can be made

en
ng
t.
yi
during the charging process using the battery current draw as to
Co
Cop py
whether the battery should be replaced or charged completely.
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
In the case of the Battery Tester - VAS6161- , the current draw

test must always be conducted when the test result “conduct cur‐
rent draw test” appears in the display.
Always Perform A Current Draw Test When:

♦ the test result from the Battery Tester with Printer - VAS5097A-
shows the following:
1 - Starting power sufficient
2 - Starting power insufficient
3 - Starting power very insufficient
4 - Not able to test - charge the battery and test again
- and in cases in which the unit does not switch on (no LED, no
printout)
or
♦ the test result from the Battery Tester - VAS6161- shows the
following:
1 - Perform a current draw test

By checking a battery's current draw capacity during the charging
procedure, it can be determined in a short time whether a partially
discharged or severely discharged battery (refer to
⇒ “3.7 Severely Discharged Batteries”, page 56 ) can become
operable again by further charging.
Test Prerequisites
♦ When charging a battery, the battery temperature must be at
least ≥ +10 °C (+50 °F). wage
es ks not
Vol gu
♦ The charger must be able to deliver at least 30 Aedcharge
by cur‐ ara
nte
rent, for example as on the battery chargers t-VAS5095A-
horis ,- eo
VAS5900- and -VAS5903- . s au ra
c
s
ce
le
♦ When charging using the Battery Charger - VAS5095A- , the
un
pt
battery current draw must be measured with a current probe,
an
d
itte
y li
for example, Test Instrument Set - Current Clamp - 100A -
rm
ab
VAS6356/4A- . The Battery Charger - VAS5900- and the
pe
ility
ot
Battery Charger - VAS5903- indicate the current draw on the
wit
, is n
device. The Battery Charger - VAS5900- automatically per‐
h re
hole
forms the menu- guided current draw test.
spec
es, in part or in w
– Connect the battery to the battery charger and start the charg‐
t to the co
ing process.
– Measure the battery charge current after five minutes.
rrectness of i
Test Result
l purpos
When current draw A is greater than 10% of nominal capacity Ah

(for example, > 6.1 A at 61 Ah battery), fully charge the battery
nform
ercia
and retest.
m
a
com
tion in
Note
r
te o
thi
s
iva
do
On the Eos with two 6V AGM batteries, the charge current must
r
rp
cum
fo
only be greater than 5% of the battery nominal capacity in amp.

en
ng
t.
As an example for Eos: the 50 Ah battery must have a charge
yi Co
op
current greater than 2.5 A after charging for five minutes.
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
– Charge the battery completely when the charge current is Prote
cted AG.
agen
greater than 10% of the nominal capacity (note exception for
Eos in the note above).
– After resting the battery for two hours, perform a battery test.
Refer to
⇒ “2.5.2 Battery Test, Performing using Battery Tester
VAS6161 ”, page 11 .
If the charge current is less than 10% of the nominal capacity (two
6 V batteries in the Eos 5%) five minutes after starting the test
(that is, for a 50 Ah battery < 5A), then replace the battery. Fill out
the battery check sheet for warranty and goodwill cases.

3 Battery, Charging
⇒ “3.1 Battery Charger VAS5095A ”, page 21
⇒ “3.2 Battery Charger VAS5900 ”, page 27
⇒ “3.5 Battery Tester Charger Kit GRX3000VAS ”, page 52
⇒ “3.6 Solar Battery Maintainer VAS6102A ”, page 56
⇒ “3.7 Severely Discharged Batteries”, page 56
3.1 Battery Charger - VAS5095A-

⇒ “3.1.1 Battery Charger VAS5095A Device Description”,
page 21
page 22
⇒ “3.1.3 Severely Discharged Battery, Charging with Battery
Charger VAS5095A ”, page 23
⇒ “3.1.4 Support Mode with Battery Charger VAS5095A ”,
page 24
⇒ “3.1.5 Battery Charger VAS5095A Maintenance Charging”,
page 26
. Volkswagen AG
gen AG
3.1.1 Battery Charger ksw - VAS5095A- Device
a oes d
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Description d b ara
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o th e or
s au ac
s
WARNING
ce
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un
pt
an
d
itte
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erm
ab

ility
ot p
wit
is n
h re
ole,
spec
Caution
t to the co
In order to prevent damage to the battery or vehicle, observe

battery type descriptions and notes. Refer to
rrectne

ss o
cial p
f in
WARNING
form
mer
atio
m

o
n
c

i
or
n thi
te
sd
a

iv
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pr
starting.
um
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by
In this chapter, the base functions of the Battery Charger - Prote
cted AG.
agen
VAS5095A- are described. Refer to Battery Charger - VAS5095A-
Operating Instructions for additional information.
3. Battery, Charging 21
Note
♦ The effective charging current cannot be read out on this unit.

The charging current must be measured externally with a cur‐
rent probe.
♦ Pay attention to the Battery Charger - VAS5095A- Operating
Instructions.
The Battery Charger - VAS5095A- is designed to charge all 12 V

batteries in the VW group.
The battery is charged without amperage or voltage surges.
Thereby the on-board electronics will not be affected. It is not
necessary to remove the battery from the vehicle or be discon‐
nected from the electrical system during charging.
Battery Charger - VAS5095A-
1 - Switch ON/OFF (0 = Charger OFF)
olkswagen AG
en AG. V
2 - Charge current display
olks (I > 12 A)
wag does
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3- Charge current
rise display: battery partially charged > 90% nte
ho eo
ut
4- Charger
ss a sustain, lights up green when battery is charged ra
c
ce
e
5 - Interference indicator
nl
pt
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an
itte
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6 - Support mode indicator

erm
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ility
ot p
7 - Support mode/normal mode selector switch

wit
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h re
8 - Charger cables, red charging clamp “+”, black charging clamp

hole
“-”.
spec
es, in part or in w
t to the co
9 - Battery type selector switch (base of loading devices)
3.1.2 Battery, Charging with Battery Charger

rrectness of i
- VAS5095A-
l purpos

nform
ercia
♦ Battery Charger - VAS5095A-

m
at
om
io
WARNING
n
c
in t
or
his
ate

do
priv

um
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Caution
o Vo
by c lksw
cted agen
Prote AG.
While charging, always set the battery type to 2.4 V/C (Volts/
Battery Cell)! This applies to all batteries.
Note
The battery temperature must be at least 10 °C (50 °F).

WARNING

starting.

– Check the battery type setting onG.the battery type selector.
A Volkswagen AG d
Refer to kswagen oes
not
⇒ “3.1.1 Battery Charger Vol VAS5095A Device Description”, gu
d by ara
page 21 . It must
orisbe set to 2.4V/C (Volts/Cell).
e nte
th eo
– Clamp the redau ra
ss charging clamp “+” of the charger to the positive c
battery terminal.
ce
le
un
pt
an
d
itte
y li
erm
ab
Note
ility
ot p
wit
is n
In the case of vehicles with a start/stop function and an installed
h re
ole,
Battery Monitoring Control Module - J367- , the black charging
spec
clamp “-” must be connected to the body ground. The start/stop

system will malfunction if it is connected to the negative terminal
t to the co
on the battery.
rrectne
– Connect the black charging clamp “-” of the charger to the
negative battery terminal. ss
– Switch on the battery charger. Refer to

o
cial p

inform
page 21 .
mer
atio
m
Charge current displays. Refer to

o
n
c
⇒ Fig. ““ Battery Charger -VAS5095A- ”“ , page 22 -2- and -3- light

i
or
n thi
up yellow. When only the yellow LED -3- is lit, the battery is par‐
te
sd
a
tially charged (approximately 90%).

iv
o
pr
cum
r
fo
If the green LED. Refer to

en
ng
t.
yi
⇒ Fig. ““ Battery Charger -VAS5095A- ”“ , page 22 -4- is also lit,
Co
Cop py
the charger has switched to the charge sustain function. The bat‐
t. rig
gh ht
yri
tery is charged. p by
o Vo
by c lksw
cted agen
– Switch off the charger. Refer to Prote AG.
page 21 .
– Remove the charger clamps from the battery terminals.
3.1.3 Severely Discharged Battery, Charging

with Battery Charger - VAS5095A-
WARNING

The charger recognizes the severely discharged battery auto‐

matically and starts the charging process conservatively with low
charging current. The charge current is automatically adjusted to
the battery charge state.
AG. Volkswagen AG d
agen oes
olksw not
Note d byV gu
ara
ise nte
o r eo
th
♦ Observe the notes
s au in chapter. Refer to ra
c
⇒ “3.7 Severely Discharged Batteries”, page 56 . s
ce
e
nl
pt
du
♦ Severely discharged batteries in vehicles must be replaced
an
itte
y li
prior to delivery. Pre-existing damage cannot be ruled out.
erm
ab
ility
ot p
♦ The battery voltage must be at least 0.6 V!
wit
, is n
h re
hole
spec
WARNING
es, in part or in w
t to the co
rrectness of i
l purpos
starting.
nform
mercia
at
om
i
– Charge the battery. Refer to
on
c
in t
or
his
e
page 22 .
at
do
priv
3.1.4 Support Mode with Battery Charger - cum

for
en
ng
t.
VAS5095A-
yi Co
Cop py
ht. rig
rig ht
General Information py by
co Vo
by lksw
cted agen
The support mode provides the vehicle electrical system with Prote AG.
voltage when the battery is removed or disconnected.
For more information. Refer to Battery Charger - VAS5095A- Op‐
erating Instructions.
The support mode is used for the following situations
♦ Vehicle electrical system support mode with the battery not
installed
♦ Maintaining the voltage when the battery is being replaced
♦ Testing without the battery
WARNING

WARNING

starting.

Caution
♦ The polarity protection of the charger clamps is not active

in the operation mode “charging severely discharged bat‐
teries/Support mode”. Connect the charger clamps to the
battery terminals correctly according to polarity!
♦ It can result in sparks due to short circuit.
♦ This constitutes an explosion risk.
♦ Make sure the charger clamps are secure.
♦ Do not touch START/STOP when battery cables are incor‐
rectly connected! The charger can be damaged.
– Remove the battery.
Caution AG. Volkswagen AG d

agen oes
o lksw not
V
Whenever the battery is removed, be careful
ed by to prevent contact gu
ara
between the connected charge clamp horis
on the positive terminal nte
eo
and the body ground. Likewise prevent
s aut contact between the ra
c
battery terminals. s
ce
e
nl
pt
du
an
itte
y li
erm
– Connect the red charging clamp “+” to the vehicle positive ter‐
ab
ility
minal.
ot p
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
rrectness of i
l purpos
on the battery.
– Connect the black charging clamp “+” to the vehicle negative

nf
ercia
terminal.
rm
m
atio
m
– Check the battery type setting on the battery type selector

o
n in
c
normal mode/support mode. Refer to

or
thi
e

t
sd
iva
page 21 . Support mode must be on.

o
r
rp
cu
o
m
f
en
– Verify that the charger clamps are connected to the correct

ng
t.
yi Co
polarity. t. Cop py
rig
gh ht
– Switch on charging unit. pyri by
Vo
o
by c lksw
cted agen
The charger begins the support mode. Prote AG.
End Battery Support Mode

– Turn off the charger.
– Remove the black charging clamp “-” of the charger from the
negative battery terminal of the vehicle.
– Remove the red charging clamp “+” of the charger from the
positive battery terminal of the vehicle.
– Pull out the electrical system connector of the charger.
Electrical Equipment General Information - Edition 04.2015 agen
AG. Volkswagen AG d
o w es n
olks ot g
byV ua
3.1.5 Battery Charger - VAS5095A- Mainte‐ ho
ris
ed ran
tee
nance Charging
t or
au ac
ss
ce
le
un
pt
an
d
WARNING
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
WARNING
rrectne
s
s o
starting.
cial p
f inform
mer
atio
om
n
c
i
or
n thi
During maintenance charging, the Battery Charger - VAS5095A-
te
sd
a
provides safe charging and preserves the charge of the battery.

iv
o
pr
cum
r
fo
– Proceed as when charging the battery. Refer to
en
ng
t.
yi
Co
op py
page 22 .
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote
Note
AG.
♦ If the battery is discharged by an electrical consumer during

maintenance charging, the Battery Charger - VAS5095A- au‐
tomatically supplies the appropriate charge.
♦ Maintenance charging can be performed without time restric‐
tions.
♦ The battery can be used constantly.

3.2 Battery Charger - VAS5900-

⇒ “3.2.1 Battery Charger VAS5900 Device Description”,
page 27
⇒ “3.2.2 Battery, Charging with Battery Charger VAS5900 ”, page
28
⇒ “3.2.3 Service Charging with Battery Charger VAS5900 ”, page
29
wage es n
⇒ “3.2.4 Severely Discharged Batteries, Charging with Battery
yV
olks ot g
ua
Charger VAS5900 ”, page 32 ise
d b ran
r tee
ho
⇒ “3.2.5 Support Mode with Battery Charger VAS5900
au ”,
t or
ac
page 34 ss
ce
le
un
pt
⇒ “3.2.6 Battery Charger VAS5900 Maintenance Charging”, page
an
d
itte
y li
36 erm
ab
ility
ot p
3.2.1 Battery Charger - VAS5900- Device De‐
wit
is n
scription
h re
ole,
spec
t to the co
WARNING
rrectne
ss o
cial p
f in
WARNING
form
mer
atio
m

o
n
c
i
or
n thi
te
sd
a

iv
o
pr
c
starting.
um
r
fo
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
In this chapter, the base functions of the Battery Charger - cted agen
Prote AG.
VAS5900- are described. Refer to Battery Charger - VAS5900-
Note
♦ The effective charging current can be read out directly on this

charging device.
♦ Pay attention to the Battery Charger - VAS5900- Operating
Instructions.
The Battery Charger - VAS5900- is designed to charge all 12 V

Battery Charger - VAS5900-
1 - Display
2 - Adjustment button “Up” ↑
3 - Adjustment button “Down” ↓
4 - START/STOP
5 - INFO

- VAS5900-
♦ Battery Charger - VAS5900-
WARNING

WARNING

starting.
Note

– Plug in the electrical system connector of the charger. The alast
selected battery type is shown on the display. lksw ge es n
Vo ot g
by ua
ed ran
– Select battery type using INFO . oris tee
th or
au ac
The symbol -1- for “standard charge of wet the sym‐ batteries”
ss or
bol -2- for “standard charge of Gel/Absorbant Glass Mat (AGM)
ce
le
un
pt
batteries” is indicated in the display.

an
d
itte
y li
rm
ab
– Set the capacity (Ah) of the battery to be charged with the cor‐
pe
ility
responding button “Up” ↑ or “Down” ↓ .

ot
wit
, is n
h re
– Clamp the red charging clamp “+” to the positive battery ter‐
hole
spec
minal.
es, in part or in w
t to the co
Note
rrectness of i

l purpos
clamp (-) must be connected to the body ground. The start/stop

nform
ercia
on the battery.
m
a
com
tio
– Connect the black charging clamp “-” to the negative battery

n in
r
terminal.
te o
thi
s
iva
do
The battery charger recognizes the nominal voltage of the con‐

r
rp
cum
nected battery (6 V, 12 V or 24 V) and begins the charging process

fo
en
g
automatically.
n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

At a charge condition of approximately 80 - 85%, charging unit

begins the “Final-charging”. The fourth bar is indicated on the
display -1-. The battery is now ready to be used.
AG. Volkswagen
agen AG do
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y Vol ot g
ua
b
ed ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
With a charge status of 100%, all bars are indicated on the dis‐
es, in part or in w
play.
t to the co
Note
rrectness of i
l purpos
♦ With the battery type “standard charge”, parallel operation of

consumers during the charging process is possible. The
charging time is lengthened by this.
nf
ercia
orm
♦ Depending on battery type, the charger switches over to sus‐
m
atio
m
tain charging after approximately 1-7 hours. To achieve a

o
n in
c
100% charge status, the battery should remain connected to

or
thi
e
the charger for that long.

t
sd
iva
o
r
rp
cu
o
Possible malfunctions and how they are handled:

f
en
ng
t.
yi Co
op
1- Displayed voltage does not match the nominal voltage: C py
t. rig
gh ht
yri by
– Hold the appropriate button “Up” ↑ or “Down” ↓ until the
op Vo
by c lksw
charging process begins.
cted agen
Prote AG.
2- Displayed battery voltage does not match the nominal volt‐

age - the charging process has already begun:
– Press START/STOP twice.
charging process begins again.
3- The charger does not recognize a battery, when the battery
voltage is less than 2 V:
The display remains unchanged.
The selected battery type and Ampere hours (Ah) are displayed.
End Battery Charging Process
– Press START/STOP .
negative battery terminal.
positive battery terminal.
3.2.3 Service Charging with Battery Charger -

VAS5900-
WARNING

Caution AG. Volkswagen AG d

agen oes
olksw not
V
“Service charging” is not permitted for VW vehicles, ed by because gu
ara
voltage surges can damage the on-board electronics.
horis nte
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aut ra
If “Service charging” is still used, the battery
ss must always be c
separated from the vehicle electrical system.
ce
le
un
pt
an
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“Service Charging” is suitable for

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The “Service charge (SERV)” mode is only used with sulfated
batteries. The battery with voltages > 14.4 V is charged. A partial
removal of the sulfation layer can result from this. Check the visual
indicator after charging, immediately before the battery is used.
Refer to
Note

– Plug in the electrical system connector of the charger. The last
selected mode is shown on the display. Refer to
⇒ “3.2.1 Battery Charger VAS5900 Device Description”, page
27 .

– Select battery type using INFO .

The symbol -1- for “service charge of wet batteries” or the symbol
-2- for “service charge of Gel/Absorbant Glass Mat (AGM) bat‐
teries” is indicated in the display.
minal.
Note

on the battery.

terminal.
automatically.
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At a charge condition of approximately 80 - 85% of the battery

voltage, charging unit begins the “Final-charging”. The fourth bar
is indicated on the display -1-. The battery is now ready to be
used.
Note
swage es n
A successful “service charge” depends on the degree ofbysulfation
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The set operating mode and Ampere-hours (Ah) are displayed.

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3.2.4 Severely Discharged Batteries, Charg‐

ing with Battery Charger - VAS5900-
WARNING

WARNING

starting.

Caution

battery terminals correctly according to polarity! gen AG
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♦ During the charging process, always set the db
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mode corresponding with the battery. Refer
rise to the Battery nte
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Charger - VAS5900- Operating Instructions!
eo
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♦ The severely discharged battery is not recognized by the
ce
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charger. Refer to
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⇒ “3.7 Severely Discharged Batteries”, page 56 . itte
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It is not possible for the Battery Charger - VAS5900- to automat‐
t to the co
ically detect batteries with a voltage under 2 Volts.
rrectness of i
Note
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♦ Observe the notes in chapter. Refer to

⇒ “3.7 Severely Discharged Batteries”, page 56 .
nform
ercia

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– Plug in the electrical system connector of the charger. The last Cop py
selected operation mode is shown on the display. Refer to
t. rig
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27 . Prote
cted AG.
agen

minal.
Note

on the battery.

terminal.
– Press START/STOP for approximately 5 seconds. The menu
item “Charging severely discharged batteries/Support mode”
is activated.
– Press the corresponding button “Up” ↑ or “Down” ↓ , to set the
respective battery voltage (6 V, 12 V or 24 V).
Note
If no button is touched within five seconds, the battery charger will

return to the main menu (operating mode selection).
– Confirm the selected battery

agen
AG.voltage
Volkswagby
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– Confirm that the charger clamps are connected to the correct

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nform
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3.2.5 Support Mode with Battery Charger -

c
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VAS5900-
at
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General Information
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The support mode provides the vehicle electrical system with C py
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For more information. Refer to Battery Charger - VAS5900- Op‐

installed
WARNING

WARNING

starting.

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Caution
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nform
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27 .
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Co
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battery terminals. ht. rig
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minal.
Note

on the battery.
– Connect the black charging clamp “+” to the vehicle negative

terminal.
– Press START/STOP for approximately 5 seconds. The menu
item “Charging severely discharged batteries/Support mode”
is activated.
Note

– Confirm the selected battery

agen
voltage
AG. Volkswaby
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AG do START/
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STOP . Volksw ot g
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Then the inquiry
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the correct polarity of the charging clamps
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polarity.
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rm
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atio
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3.2.6 Battery Charger - VAS5900- Mainte‐

o
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or c
nance Charging
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Note
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Cop py
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maintenance charging, the Battery Charger - VAS5900- auto‐
co lksw
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matically supplies the appropriate charge. Prote AG.

tions.
♦ Observe the maintenance notes of the battery manufacturer.

AG. Volkswagen AG d
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WARNING d by gu
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Risk of injury.
ss a Follow all Warnings and Safety Precautions.r ac
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WARNING
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rrectness of i
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If the battery is fully charged, the Battery Charger - VAS5900-
nf
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starts maintenance charging.
orm
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⇒ “3.2.2 Battery, Charging with Battery Charger VAS5900 ”,

o
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or c
page 28 .
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⇒ “3.3.1 Battery Charger VAS5903 Device Description”,
page 37
38
⇒ “3.3.3 Refresh Charging with Battery Charger VAS5903 ”, page
40
⇒ “3.3.4 Severely Discharged Battery, Charging with Battery
Charger VAS5903 ”, page 43
⇒ “3.3.5 Support Mode with Battery Charger VAS5903 ”,
page 45
⇒ “3.3.6 Battery Charger VAS5903 Maintenance Charging”, page
47
3.3.1 Battery Charger - VAS5903- Device De‐

scription
WARNING

WARNING

starting.
In this chapter, the base functions of the Battery Charger -

VAS5903- are described. Refer to Battery Charger - VAS5903-
Note
Pay attention to the Battery Charger - VAS5903- Operating In‐

structions.
The Battery Charger - VAS5903- is designed to charge all 12 V

1 - Display
2 - Adjustment button “Up” ↑
3 - Adjustment button “Down” ↓
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4 - START/STOP agen oes
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nte
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- VAS5903-
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WARNING

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WARNING
orm
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Note


37 .
The symbol -1- for “standard charge of wet batteries” or the sym‐
bol -2- for “standard charge of Gel/Absorbant Glass Mat (AGM)
batteries” is indicated in the display.
minal.
Note

on the battery.

terminal.
automatically.
At a charge condition of approximately 80 - 85%, charging unit

begins the “Final-charging”. The fourth bar is indicated on theVolkswag
display -1-. The battery is now ready to be used. swagen AG. en AG
does
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orm
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♦ With the battery
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charging time is lengthened by this.
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♦ Depending on battery type, the charger switches over to sus‐
y li
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ab
tain charging after approximately 1-7 hours. To achieve a
pe
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100% charge status, the battery should remain connected to
ot
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the charger for that long.
h re
hole
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rrectness of i
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2- Displayed battery voltage does not match rated voltage -

charging process has already begun:
nform
ercia

m
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charging process begins again.
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te o
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The selected battery type and Ampere hours (Ah) are displayed.
gh ht
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End Battery Charging Process cted agen
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3.3.3 Refresh Charging with Battery Charger

- VAS5903-
WARNING


WARNING

starting.
Caution
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“Refresh charging” is ynot
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If “Refresh charging”
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separated from
ss the vehicle electrical system.
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Caution
ot p
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During the charging process, always set the operation mode
ole,
spec
corresponding with the battery. Refer to the Battery Charger -
VAS5903- Operating Instructions!
t to the co
“Refresh charging” is suitable for
♦ Wet batteries, which can be filled with distilled water.
rrectne
Do not use “Refresh charging” on maintenance-free wet bat‐
s
teries.
s o
cial p
f inform
mer
“Refresh charging (Refr)” mode is only used on batteries that are

atio
m
possibly defective (for example, sulfation). The battery is then

o
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c
charged to the maximum specific gravity of the electrolyte and the

i
or
n thi
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plates are reactivated (removal of sulfation layer).

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Note
t.
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The battery temperature must be at least 10 °C (50 °F). yri
p by
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cted agen
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selected mode is shown on the display. Refer to
37 .

The symbol -1- for “refresh - charging wet batteries” or the symbol
-2- for “refresh - charging of Gel/Absorbant Glass Mat (AGM) bat‐
minal.
Note

system will malfunction if it is connectedstowagthe
en Anegative terminal
G. Volkswagen AG
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on the battery. by
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– Connect the black charging
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ac
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automatically.
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co lksw
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At a charge condition of approximately 80 - 85% of the battery

voltage, charging unit begins the “Final-charging”. The fourth bar
is indicated on the display -1-. The battery is now ready to be
used.
Note
AG. Volkswagen AG d
agen oes
lksw not
A successful “Refresh charge” depends on the degree of sulfation Vo gu
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on the battery. orise nte
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charging process begins. ot p
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2- Displayed battery voltage does not match rated voltage -
hole
spec
charging process has already begun:
es, in part or in w
t to the co
rrectness of i
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nf
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orm
m
The set operating mode and Ampere-hours (Ah) are displayed.
atio
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n in
c

or
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f
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t.
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t. rig
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– Remove the red charging clamp “+” of the charger from the yri
p by
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c by lksw
cted agen
Prote AG.
3.3.4 Severely Discharged Battery, Charging

with Battery Charger - VAS5903-
WARNING

WARNING

starting.
Caution

♦ During the charging process, always set the operation
mode corresponding with the battery. Refer to the Battery
Charger - VAS5903- Operating Instructions!
♦ The severely discharged battery is not recognized by the
charger. Refer to
It is not possible for the Battery Charger - VAS5903- to automat‐

ically detect batteries with a voltage under 2 Volts.
Note
♦ Observe the notes in chapter. Refer to


⇒ “3.3.1 Battery Charger VAS5903 gDevice AG. VoDescription”,
lkswagen AG page
37 . a en does
olksw not
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an
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spec
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rrectness o
cial p
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mer
atio
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t.
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minal.
Note

on the battery.

terminal. n AG. Volkswagen A ge G do
swa es
– Press START/STOP
yV
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not
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item “Charging
rise severely discharged batteries/Support
nte mode”
tho
is activated. eo
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nl
pt

du
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Note
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spec

es, in part or in w
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– Confirm the selected battery voltage by pressing START/

STOP .
rrectness of i
Then the inquiry about the correct polarity of the charging clamps
l purpos
is made.
nf
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polarity.
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The charger begins charging the severely discharged battery.

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op
– Press START/STOP . C py
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Prote AG.
3.3.5 Support Mode with Battery Charger -

VAS5903-
General Information
The support mode provides the vehicle electrical system with
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , CC 2012 n➤
AG,. Eos 2006
Volksw ...G d
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For more information. Refer to Battery Charger - VAS5903-
tho Op‐ or
au
erating Instructions. ss
ac
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un
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an
d
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ab
pe
installed
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spec
es, in part or in w
t to the co
WARNING
rrectness of i
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nform
ercia
WARNING
m
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com
tion in
r
te o
thi
s
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c
um
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starting.
en
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t.
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op py
These batteries must be replaced. t. C rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
Caution


27 .
Caution
Whenever the battery is removed, be careful to prevent contact

between the connected charge clamp on the positive terminal
and the body ground. Likewise prevent contact between the
battery terminals.
minal.

Note

on the battery.
AG. Volkswagen AG d
agen
– Connect the black charging clamp “+” to the vehicle Vonegative
lksw
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s mode”
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nl
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Note
spec
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rrectness of i
– Confirm the selected battery voltage by pressing START/
l purpos
STOP .
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nform
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at
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polarity.
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The battery charger starts the battery support mode.

n
t.
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pyri by
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cted agen
Prote AG.
3.3.6 Battery Charger - VAS5903- Mainte‐

nance Charging
Note

maintenance charging, the Battery Charger - VAS5903- auto‐
matically supplies the appropriate charge.
tions.
♦ Observe the maintenance notes of the battery manufacturer.
WARNING
Risk of injury. Follow all Warnings and Safety APrecautions.

n G. Volkswagen AG do
Refer to ⇒ “1.3 Warnings and Safety Precautions”,
olks
wage page 3 . es n
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WARNING ss
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starting.
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If the battery is fully charged, the Battery Charger - VAS5903-
rrectness of i
starts maintenance charging.
l purpos
⇒ “3.3.2 Battery, Charging with Battery Charger VAS5903 ”,

page 38 .
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ercia
m
at
play.
om
ion
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or
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ate
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for
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t.
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Prote AG.


⇒ “3.4.1 General Information”, page 49
49
3.4.1 General Information

WARNING

WARNING

There is a risk of explosion duringlkstesting, charging or jump
starting. swagen AG
. Vo wagen AG
does
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Vol
These batteriessemust be replaced.
y gu
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utho eo
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The Battery Charger - VAS5906- was developed especially for
ce
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un
pt
charging the vehicle electrical system while the vehicle is on dis‐

an
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play.
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ility
It supplies for automatic charging of 3 - 300 Ah for starter batter‐

ot p
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wit
is n
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ole,
The 14.4 V maximum charging voltage is not exceeded. All elec‐

spec
trical consumers will be supported up to 30 A by the support

t to the co
charging.
After the battery is completely charged, the Battery Charger -
VAS5906- switches to maintenance charging for long-term oper‐
rrectne
ation.
The unit starts automatically and does not require any adjust‐
ss
ments. Only the charging terminals and the network cable need
o
cial p
f i
to be connected.
nform
mer
For more information. Refer to Battery Charger - VAS5906- Op‐

atio
m
o
n
c
i
or
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te
sd
a

iv
o
pr
cum
r
- VAS5906-
fo
en
ng
t.
yi Co
Cop py
t. rig
gh
WARNING
ht
pyri by
Vo
co lksw
by
cted agen
Prote
AG.
WARNING

starting.
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
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au ra
ss c
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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
iva
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rp
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f
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ng
t.
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Cop py
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pyri by
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Control Panel Overview

1- 25% charge display.
5- Ready-to-use display
6- Pushing the start/stop and setup buttons will stop and start
the charging process. Enter into the setup menu and select
characteristic line type (hold for 10 seconds)
7- Display malfunction lkswage es n
o ot g
byV ua
d
– Position the battery charger
o
ir se inside the engine compartment or
ran
tee
under the vehicle. au th or
ac
ss
– Connect the network cable to the battery charger and then
ce
e
nl
pt
connect it to the network.
du
an
itte
y li
When the battery charger is in idle - the ready-to-use lights up.
erm
ab
ility
ot p
wit
, is n
WARNING
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Turn off the ignition.
l purpos
– Connect the red charger cable to the positive terminal “+” on

the battery.
nf
ercia
orm
m
Note
atio
om
n in
or c

thi
te
sd
a

iv
o
r
rp
cu

o
m
f

en
ng
t.
yi
on the battery.
Co
Cop py
t. rig
gh ht
pyri by
– Connect the black charge cable to the negative terminal “-” on
co Vo
by lksw
cted
the battery.
agen
Prote AG.
Charging will begin after approximately 2 seconds.

LEDs show the battery charge level. When all the lamps illumi‐
nate, the battery is charged.
When the battery is completely charged, the Battery Charger -
VAS5906- automatically switches to maintenance charging.
Caution
Sparks can result if the charging terminals are removed too

early. Press the stop/start button to end the charging process.
– Press the start/stop button to end the charging.

– Disconnect the black charging cable from the negative termi‐
nal “-” on the battery.
– Disconnect the red charging cable from the positive terminal
“+” on the battery.
3.5 Battery Tester Charger Kit -

GRX3000VAS-
⇒ “3.5.1 Battery Tester Charger Kit GRX3000VAS General De‐
scription”, page 52
⇒ “3.5.2 Battery, Charging”, page 53
⇒ “3.5.3 Battery Tester Charger Kit GRX3000VAS Troubleshoot‐
ing”, page 55
3.5.1 Battery Tester Charger Kit -

GRX3000VAS- General Description
Only Volkswagen approved chargers may be used to charge bat‐
teries in Volkswagen vehicles. Only the Battery Tester Charger
Kit - GRX3000VAS- charger is used in the USA and Canada.
The Battery Tester Charger Kit - GRX3000VAS- battery charger
combines battery charging with checking the charge level and
testing the battery.
The following charging and analysis procedures apply to all bat‐
teries, all battery installed locations (engine compartment or lug‐
gage compartment) and all battery designated usage (for the
starter or for the second/convenience battery).
Always follow the Safety Precautions, the instructions for setting
up the battery charger, the display menu/display
. Volkswagen AG
buttons, LEDs
wagen AG
and the procedures in thekBattery Tester Charger doKit
es n-
s
GRX3000VAS- Operating Vol Instructions. ot g
by ua d ran
ise
Carefully read the
ut
ho Battery Tester Charger Kit - GRX3000VAS-
r tee
or
Operating Instructions.
ss
a ac
ce
e
Refer to Self Study Program - Vehicle Batteries for more infor‐

nl
pt
du
an
mation.
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
Keep open flame or sparks away from the batteries and do not
smoke.
rrectness of i
The battery charger must be switched off whenever connecting

or disconnect the cable.
l purpos
Do not remove the plugs while charging.

nf
ercia
Overcharging sulfated batteries can cause an explosion.

orm
m
atio
Precision tools may not be kept in areas where batteries are

om
n in
charged. Chemical reactions can lead to corrosion.

or c
thi
te
sd
iva
o
r
rp
cu
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m
f
en
ng
WARNING
t.
yi Co
Cop py
ht. rig
Batteries that have a light yellow visual indicator do not have rig ht
py by
Vo
co lksw
by
cted agen
Prote AG.
starting.

3.5.2 Battery, Charging

Requirements
WARNING

starting.
Battery Tester Charger Kit - GRX3000VAS- output - setup per‐

formed (unit number, date/time). Refer to Battery Tester Charger
Kit - GRX3000VAS- Operating Instructions.
– General information, checking. Refer to
⇒ “3.5.1 Battery Tester Charger Kit GRX3000VAS General
Description”, page 52 .
– Open the hood or open the cover if the battery is installed
somewhere else.
– Visually inspect the battery.AGRefer toagen A
. Volksw
⇒ “2.3 Visual Inspection”,
olkswage page 7 .
n G do
es n
o V t gu
by
– Determine ifriitseis
d a “standard” battery (wet battery) oraan
ran “AGM”
tee
battery. utho or
sa ac
– Close all
s
the vehicle doors.
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n

h re
hole
spec
♦ Refer to the Battery Tester Charger Kit - GRX3000VAS- Op‐

es, in part or in w
erating Instructions for more information.

t to the co
Perform Charging Procedure

rrectness of i
– Turn off all electrical consumers.

l purpos
– Turn off the ignition and remove the key.

– Clamp the red charging clamp “+” of the charger to the positive
nf
ercia
battery terminal.
orm
m
atio
om
n in
c
Note
or
thi
te
sd
iva
o
r

rp
cu
o

f
en
ng
t.
yi
Co
op py
system will malfunction if it is connected to the negative terminal t. C rig
gh ht
on the battery. pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Connect the black charging clamp “-” of the charger to the
– Connect the Battery Tester Charger Kit - GRX3000VAS- bat‐
tery charger to a grounded socket.
– Switch the “ON/OFF” switch on the Battery Tester Charger Kit
- GRX3000VAS- battery charger to “ON”.
– Select the charge mode “automatic” or “manual.”.
– Select the test: “inside the vehicle” or “outside of the vehicle”.

gen AG
. Volkswagen AG
d wa oes
olks not
– Determine if it is a “standard” battery or an “AGM” dbattery.
by
V gu
ara
e nte
ris
– Select the type of test: “Warranty” or “other”. uNote
tho any other eo
ra
additional details (depending on the type ofsstest).
a c
ce
e
nl
pt
du
an
itte
y li
Note
erm
ab
ility
ot p
♦ Refer to the Battery Tester Charger Kit - GRX3000VAS- Op‐
wit
, is n
erating Instructions for more information.
h re
hole
spec
♦ If necessary, go through all the menu points when performing
es, in part or in w
a “Warranty” test. Refer to Warranty Service Circulars.
t to the co
The Battery Tester Charger Kit - GRX3000VAS- battery charger
rrectness of i
checks the battery and starts the charging process. The display
then show one of three results with the exact charging time.
l purpos
Result: Measure:
nform
ercia
Battery good The battery can be used again.

m
Charging is required ♦ The test shows a low state
at
om
io
of charge.
n
c
in t
or
his
e
♦ The charging process be‐

at
do
riv
gins and the exact duration

p
cum
or
for the charging will be dis‐

f
en
g
played
n
t.
yi Co
Cop py
♦ The cold start performance
t. rig
gh ht
yri by
and the remaining charging op Vo
by c lksw
time are displayed and up‐ cted agen
Prote AG.
dated regularly.
Replace the battery. Battery faulty. The charging

process is interrupted. Replace
the battery.
Note
If other malfunction messages or text displays, other than the

ones already mentioned, appear in the display on the Battery
Tester Charger Kit - GRX3000VAS- battery charger, then refer to
chapter. Refer to
⇒ “3.5.3 Battery Tester Charger Kit GRX3000VAS Troubleshoot‐
ing”, page 55 .
WARNING
If the battery starts to vent gas heavily, stop the charging proc‐
ess. Press the “Stop” button on the front side.
After the charging and testing process is completed, the Battery

Tester Charger Kit - GRX3000VAS- battery charger will display
“battery good” or “replace the battery” and the total charging time.
Depending on the individual circumstance (Warranty Claim, Re‐
pair Order, Evaluation and File), there are three possible mes‐
sages
♦ Produce a test code (possible only after automatic charging
and testing).
♦ Print last test result (for Warranty)

♦ Display the last test result.
Note
Refer to the Battery Tester Charger Kit - GRX3000VAS- Operat‐

ing Instructions for more information.
3.5.3 Battery Tester Charger Kit -

GRX3000VAS- Troubleshooting
Sometimes the display shows the malfunction or the messages
based on the condition.
The following is a list of the most frequent displayed messages
together with suggested solutions.
Note
Refer to the Battery Tester Charger Kit - GRX3000VAS- Operat‐

ing Instructions for messages not listed here.
Display Message Measure

Check the connection – Make sure the battery
charger terminals are at‐
tached securely to the bat‐
tery terminals.
– Make sure the battery pole

is tightened to the tightening
olksspecification
does and is not cor‐
n AG. V wagen AG
wage
Volks roded. not
gu
by ara
Terminals connected?
oris
ed
Tester safety function. nte
auth – Connect the terminals to
eo
r a the
ss battery before charging. c
ce
e
nl
System noises – Switch off all electrical con‐

pt
du
an
sumers.
itte
y li
erm
ab
ility
– Wait until all electrical equip‐

ot p
wit
ment, which are monitored

, is n
h re
by the vehicle electrical sys‐

hole
tem control module, are

spec
es, in part or in w
switched off.
t to the co
– Remove the key.

rrectness of i
– Disconnect any doubtful or

standard production electri‐
l purpos
cal equipment from the ve‐

hicle electrical system.
nform
ercia
Wait a few minutes and repeat the charging process. Refer to

m
⇒ “3.5.2 Battery, Charging”, page 53 .

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.
3.6 Solar Battery Maintainer - VAS6102A-

⇒ “3.6.1 Solar Battery Maintainer VAS6102A Maintenance
Charging”, page 56
3.6.1 Solar Battery Maintainer - VAS6102A-

Maintenance Charging
Solar Battery Maintainer - VAS6102A-
General Description
. Volkswage
The Solar Battery Maintainer gen AG
-aVAS6102A- supports oethe
s no vehicle
n AG d
lksw
electrical system and prevents
by Vo the battery from self-discharging.
t gu
a d ran
ise
The Solar BatteryuthMaintainer
or - VAS6102A- reaches a maximum
tee
or
voltage of 14.3ssV and a maximum charge current of 255 mA.
a ac
ce
le
All chargeable lead- or lead gel batteries can be charged with the
un
pt
an
d
Solar Battery Maintainer - VAS6102A- .

itte
y li
erm
ab
The Solar Battery Maintainer - VAS6102A- is connected to the
ility
ot p
diagnostic connection in the vehicle.
wit
is n
h re
There is a green LED inside the frame, which displays the func‐
ole,
spec
tion. The brighter the LED, the higher the charging current.
t to the co
It is not possible to overcharge the battery due to the integrated
electronics.
rrectne
– Secure the Solar Battery Maintainer - VAS6102A- to the inte‐
rior rearview mirror -1-.
ss o
– Lay the bottom on the instrument panel -2-.

cial p
f inform
mer
atio
Note
om
n
c
i
or
n thi
The Solar Battery Maintainer - VAS6102A- must not touch the

te
sd
a
instrument panel completely. Only the bottom edge may be used

iv
o
pr
for support. If it touches completely, the color of the instrument

um
r
fo
en
ng
panel could change.

t.
yi Co
Cop py
t. rig
gh
– Pull the securing string together so that the Solar Battery
ht
pyri by
Vo
o
Maintainer - VAS6102A- is close to the glass.
c by lksw
cted agen
Prote AG.
– Connect the Solar Battery Maintainer - VAS6102A- to the ve‐
hicle diagnostic connection. Connecting is the same as with
the Vehicle Diagnostic Tester . Refer to
⇒ “1.1 Vehicle Diagnostic Tester , Connecting”, page 77 .
– Check the Solar Battery Maintainer - VAS6102A- function. The
green LED shows the functionality of the Solar Battery Main‐
tainer - VAS6102A- .
3.7 Severely Discharged Batteries
WARNING

For a battery to be indicated as “severely discharged”, the resting

voltage must be less than 11.6 V.

WARNING

starting.
Caution
♦ Severely discharged batteries freeze earlier.

♦ Batteries that have been frozen must no longer be used.
Note

prior to delivery. Pre-existing
gen AG
damage
. Volkswagen AG cannot be ruled out.
d
a oes
lksw no
♦ Batteries dwhich
by
Vo have not been used in driving
t gu operation for a
ar
long time,
ris for example vehicles in storage, discharge
e an
tee them‐
tho
selves. or
au a c
ss
♦ For severely discharged batteries, the electrolyte consists al‐
ce
e
nl
pt
most completely of water, because the acid portion has been

du
an
itte
greatly reduced.
y li
erm
ab
ility
♦ Severely discharged batteries become sulfated, meaning all

ot p
wit
the battery plate surfaces become hardened.

, is n
h re
hole
♦ The sulfating process may be largely reversed if a severely

spec
discharged battery is recharged immediately.

es, in part or in w
t to the co
♦ If the battery is not recharged, the plates will continue to hard‐

en, and the ability to accept a charge will decrease. This
results in reduction of battery performance.
rrectness of i
l purpos
– Check the battery resting voltage. Refer to

⇒ “3 Battery, Charging”, page 21 .
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.
4 Cruise Control System swage

es n
lk ot g
Vo
⇒ “4.1 Cruise Control System, Activating and Deactivating”, pageed by ua
ran
58 thoris tee
or
au ac
4.1 Cruise Control System, Activating and ss
ce
le
un
pt
Deactivating
an
d
itte
y li
erm
ab
General Description
ility
ot p
wit
Cruise control system functions are controlled by the engine con‐
is n
h re
trol module.
ole,
spec
– Cruise control system can be activated/deactivated. Refer to
t to the co
⇒ “4.1 Cruise Control System, Activating and Deactivating”,
page 58 .
DTC Recognition and Display
rrectne
Malfunctions in relation to the cruise control system are sent via
s
the engine control module.
s o
cial p
f
Use the Vehicle Diagnostic Tester in the “Guided Fault Finding”
inform
mode for fault finding.
mer
atio
m
– Connect the Vehicle Diagnostic Tester . Refer to

o
n
c
⇒ “1 Vehicle Diagnosis, Testing and Information Systems”,
i
or
n thi
e
page 77 .
t
sd
iva
o
pr
cum
r
fo
– On the Vehicle Diagnostic Tester , select “Guided Fault Find‐
en
ng
t.
yi
ing”.
Co
Cop py
t. rig
– Using the “GO TO” button, select “Functions/Component se‐
gh ht
pyri by
lection” and the following menu options in sequence:
co Vo
by lksw
cted agen
Prote AG.
♦ Powertrain
♦ Engine code
♦ 01 - On Board Diagnostic (OBD) capable systems
♦ Engine management system or Diesel Direct Injection & Glow
Plug System
♦ Functions
♦ Cruise Control System, Activating and Deactivating

5 Special Tools
♦ Battery Tester - VAS6161-
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
59
agen
Prote AG.
5. Special Tools
92 – Wiper/Washer Systems
1 Washer Fluid Line Hose Connections
⇒ “1.1 Windshield and Rear Window Washer System”,
page 60
⇒ “1.2 Headlamp Washer System”, page 61
1.1 Windshield and Rear Window Washer wagen AG. Volkswagen AG doe
System olks s no
yV t gu
db ar
e an
ris tee
The following hose connection types are used for connecting
tho ho‐ or
au
ses to pumps and spray nozzles or as separating points
ss ac
ce
le
– To loosen the connection, pulling both halves of the coupling un
pt
an
d
apart.
itte
y li
rm
ab
pe
– To secure the connection, push both halves of coupling to‐
ility
ot
gether until felt and heard to engage.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– To loosen the connection, turn the securing clip -1- 90°
nform
ercia
-arrow- and then pull the hose connection off.

m
a
com
ti
– To secure the connection, attach the hose connection and turn
on in
the securing clip -1- -arrow- until it engages.
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.
– To loosen the connection, lift the securing clip -1- approxi‐

mately 1 mm -arrow- and then remove the hose connection.
– To secure the connection, attach the hose connection and
press in the securing clip -1- until it engages.
60 Rep. Gr.92 - Wiper/Washer Systems

– To loosen the connection, pull the securing clip upward -1-

-arrow- and remove the hose connection.
1.2 Headlamp Washer System

The following hose connection types are used for connecting ho‐
ses to pumps and spray nozzles or as separating points
– Disconnect by depressing clip -1- -arrow- and then separating
coupling from jet.
– Reconnect by keeping clip -arrow- depressed while pushing
coupling onto jet until it engages. Check securing clip for se‐
cure locking by attempting to pull it off without depressing clip.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
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.
1. Washer Fluid Line Hose Connections 61

2 Hoses, Repairing
⇒ “2.1 General Information”, page 62
⇒ “2.2 Smooth Tube, Repairing”, page 62
⇒ “2.3 Corrugated Tube, Repairing”, page 62
2.1 General Information

A new repair concept has been developed for repairing washer
system hoses. Various individual hose connectors, adapters, Eth‐
ylene Propylene Diene Methylene (EPDM) rubber hoses and
shrink tubing will be offered as replacement parts.
♦ The replacement parts can be found in the Parts Catalog.
♦ The replacement parts are available both for the repair of a
smooth tube as well as for the repair of a corrugated tube.
2.2 Smooth Tube, Repairing

system hoses. Various individual hose connectors, adapters, Eth‐
ylene Propylene Diene Methylene (EPDM) rubber hoses and
Smooth hoses with a diameter of 5 x 1 mm or 6 x 1 mm can be
repaired with a EPDM repair hose section.
– Trim and remove damaged sections of hose.
– Select the corresponding EPDM hose -2- and cable ties ac‐
cording to the parts catalog.
. Volkswagen AG
gen AG does
– Extend the EPDM hose -2- so that the smooth tube oends
lksw -1-
a
not
and -3- can each be inserted approximately 10 mm by Vinto EPDM gu
ara
ed
hose -2-. ho
ris nte
eo
t
au ra
c
ss
– Secure with cable ties as illustrated -1-.
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
2.3 Corrugated Tube, Repairing

nform
ercia

m
a
com
tio
♦ Hot Air Blower - VAS5179- or

n in
r
te o
thi
♦ Hot Air Blower - VAG1416/- or

s
iva
do
r
rp
♦ Wiring Harness Repair Set - Hot Air Blower - VAS1978/14A-

um
fo
en
ng
t.
yi
Co
Cop py
system hoses. Various individual hose connectors, adapters, Eth‐ ht. rig
rig ht
ylene Propylene Diene Methylene (EPDM) rubber hoses and py by
co Vo
lksw
by
cted agen
Prote AG.

Note
. Volkswagen AG
gen AG does
swa
♦ Area to be repaired must not be under stress of ystretching
Volk or not
gu
bending. ised b ara
nte
or eo
h
♦ If the damaged area is longer than 20 mm,
s aut a new section of ra
c
corrugated hose must be inserted andsthe procedure descri‐
ce
le
bed in the following must be performed twice.
un
pt
an
d
itte
y li
erm
ab
– Trim and remove damaged sections of hose.
ility
ot p
wit
– Select the appropriate connecting pieces -2- and -3- as well is n
h re
as the corresponding heat-shrinkable tube according to the
ole,
Parts Catalog.
spec
t to the co
– Carefully warm end of hose -1-.
– Insert the connecting piece -2- into the corrugated tube -2-
-arrow A-.
rrectne
– Carefully warm the end of the corrugated tube -4-.
ss
– Insert the connecting piece -3- into the corrugated tube -4-
o
cial p
f
-arrow B-.
inform
mer
atio
– Trim the heat-shrinkable tube so that the corrugated tube is
om
covered with a minimum of 20 mm dimension -x- of heat-
n
c
i
or
n
shrinkable tube on both sides.
thi
te
sd
iva
o
– Slide the heat-shrinkable tube over the corrugated tube, attach
pr
cum
r
fo
the connecting pieces together and secure the repaired sec‐
en
ng
t.
tion with heat-shrinkable tubing.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Hoses, Repairing 63
3 Joint-Free Wiper Blade Characteris‐

tics
Characteristics for Bosch and Federal Mogul
Check the manufacturer when replacing the wiper blades. Always
replace them with blades made by the same manufacturer.
The wiper blades can be identified by the wiper arm mount.
Bosch Wiper Blades -1 and 2-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
Federal Mogul Wiper Blades -1-
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
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Prote AG.

4 Special Tools AG. Volkswagen AG d

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Special tools and workshop equipmentbrequired
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♦ Hot Air Blower - VAG1416- tho r eo
au ra
c
♦ Heat Gun - VAS1978/14- s s
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♦ Hot Air Blower - VAS5179-
an
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rrectness of i
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4. Special Tools 65
94 – Exterior Lights, Switches

1 HID Headlamp Usage and Safety
Precautions
Special tools and workshop equipment required AG. Volkswagen AG d
agen oes
♦ Protective Eyewear olksw not
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♦ Gloves horis
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– Note the following if working with HID headlamps: ss c
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♦ Notes on hazardous high voltage/currents. Refer to
du
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♦ Notes on pressure, temperature and radiation/electric arc. Re‐
ab
ility
fer to ot p
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, is n
♦ Assembly instructions for HID headlamp bulbs. Refer to
h re
hole
spec
♦ Disposal regulations for HID headlamp bulbs. Refer to
es, in part or in w
t to the co
WARNING
rrectness of i
Always make sure to disconnect the battery ground cable be‐
fore performing work on parts of the headlamp with a gas
l purpos
discharge lamp marked with yellow high voltage symbols.

Then switch the low beams on and back off. This removes any
nf
ercia
o
possible residual voltage.
rm
m
atio
m
The gas discharge lamp control module should not be operated

o
n in
c
without the gas-discharge lamp.

or
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Due to the high voltage (over 28000 V when igniting the lamp),
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the gas-discharge lamp should only be operated inside the
o
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en
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headlamp housing.
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WARNING Prote AG.
♦ Never replace bulbs if you are not familiar with the proce‐
dures, safety precautions and tools.
Notes on Hazardous High Voltage/Currents
WARNING
Light system control modules, connectors or components in

the bulb socket area conduct dangerous high voltage
Control module and igniter operation is only permitted with
lamp.
66 Rep. Gr.94 - Exterior Lights, Switches

WARNING
• Turn off the ignition and all electric consumers and remove
the key.
• Make sure all components have zero potential when work‐
ing on headlamp system, even residual voltage after
switching off headlamps must be discharged.
• Residual voltages are discharged by switching low beam
on and off again after ignition key was removed.
• Make sure lamps cannot be switched on when working on
headlamp system.
Notes on Pressure, Temperature and Radiation/Glare
WARNING
• Lamp must only be operated in headlamp housing (pro‐

tection against contact because of hot lamp, absorption of
ultraviolet radiation, avoiding danger of glare, explosion
protection).
• Glass cones of bulbs can become very hot – danger of
burns! agen
AG. Volkswagen AG d
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• Avoid looking directly into light beam, since UV radiation d by
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of the HID lamp is approximately 2.5 times higher thanorithat
se nte
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of standard Halogen lamps. aut
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• Avoid looking into light beam (danger of glare); vision can
ce
le
un
pt
be impaired for a longer period of time.
an
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WARNING
h re
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spec
• Avoid contact with burst glass cone.
es, in part or in w
t to the co
• H7 bulbs and HID bulbs (Xenon/Bi-Xenon) are under pres‐
sure and can burst when replaced - danger of injury!
rrectness of i
• When removing and installing HID bulbs, always wear
safety glasses and gloves.
l purpos
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Prote AG.
1. HID Headlamp Usage and Safety Precautions 67

Assembly Notes on HID Headlamp Bulbs
Caution
♦ Before replacing a bulb, the corresponding consumer

must always be switched off.
♦ Turn off the ignition and all electric consumers and remove AG. Volkswagen AG d
the key. lksw
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♦ Do not touch glass cone of bulb with bare fingers, use ised b ara
nte
clean cloth gloves. The remaining fingerprint would evap‐uthor eo
orate due to the heat of the operated bulb and condense a ra
ss c
on the reflector which would impair headlamp luminosity.
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♦ A bulb must only be replaced with one of the same version.
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Bulb identification can be found on bulb socket or glass
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cone.
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♦ Harness connectors must engage correctly when installed
h re
hole
and must be checked for proper connection.
spec
es, in part or in w
t to the co
Disposal Regulations for HID Headlamp Bulbs
rrectness of i
WARNING
l purpos
• HID lamps must be disposed of as hazardous waste, nev‐

er dispose of HID lamps via domestic waste.
nf
ercia
orm
• HID lamps contain metallic mercury (Hg) and traces of
m
atio
m
thallium, they must not be destroyed.

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or c
• These components must be returned for proper recycling
thi
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in accordance with national legislation.

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• Dispose of only in the designated containers at the re‐
f
en
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t.
sponsible collection point.
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68 Rep. Gr.94 - Exterior Lights, Switches

96 – Interior Lights, Switches

1 12 V Socket
⇒ “1.1 12 V Socket , Removing and Installing”, page 69
⇒ “1.2 Socket Illumination Bulb L42 , Removing and Installing”,
page 69
1.1 12 V Socket , Removing and Installing
Caution
Using force to remove cigarette lighter sockets without illumi‐

nation can result in damage to the mounting sleeve retainers.
The Cigarette Lighter Release Tool - T40148- can only be used
to remove cigarette lighter sockets
wage
n AG. Vowith
lkswagillumination.
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The puller is notecapable of releasing the retainers on
gu power
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sockets without
hor illumination.
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Sockets without
ss illumination usually cannot be removed with‐c
out damage.
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Cigarette Lighter - U1- , removing and installing. Refer to ility
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⇒ “2 Cigarette Lighter U1 ”, page 70 . wit

, is n
h re
1.2 Socket Illumination Bulb - L42- , Remov‐

hole
spec
es, in part or in w
ing and Installing

t to the co
The Socket Illumination Bulb - L42- is removed in the same man‐

ner as the Cigarette Lighter Illumination Bulb - L28- . Refer to
rrectness of i
⇒ “2.4 Cigarette Lighter Illumination Bulb L28 , Removing and

Installing”, page 74 .
l purpos
nform
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at
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Prote AG.
1. 12 V Socket 69
2 Cigarette Lighter - U1-

⇒ “2.1 General Information”, page 70
⇒ “2.2 Overview - Cigarette Lighter U1 ”, page 71
⇒ “2.3 Cigarette Lighter Socket, Removing and Installing”,
page 71 agen
AG. Volkswagen AG d
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⇒ “2.4 Cigarette Lighter
ed
by Illumination Bulb L28 , Removing
V t gu
araand
Installing”, pageho74
ris nte
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au ac
2.1 ss General Information
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The following descriptions also apply to Left Rear Cigarette Light‐
an
itte
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er - U3- , Right Rear Cigarette Lighter - U7- , Rear Cigarette
erm
ab
Lighter - U9- , 12 V Socket 2 - U18- , 12 V Socket 3 - U19- , 12 V
ility
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Socket 4 - U20- , Cigarette Lighter 2 - U25- and 12 V Socket 5 -
wit
, is n
U26- if they are illuminated.
h re
hole
spec
es, in part or in w
Caution
t to the co
rrectness of i
l purpos
to remove cigarette lighter sockets with illumination.

The puller is not capable of releasing the retainers on power nform
ercia
sockets without illumination.

m
at
om
Sockets without illumination usually cannot be removed with‐

on
c
out damage.
in t
or
his
ate
do
priv
cum
for
en
ng
t.
Caution
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Using force to remove cigarette lighter sockets without illumi‐ py by
co Vo
by lksw
cted agen
Prote AG.

The puller is not capable of releasing the retainers on power
out damage.
On some vehicle equipment levels, socket illumination is via Light

Emitting Diode (LED) instead of a bulb. These LEDs are integra‐
ted with the illumination housing and cannot be serviced or re‐
placed separately.
Various versions of illumination housing with bulb exist. One ver‐
sion allows separate replacement of the illumination bulb, and
another where the bulb cannot be serviced or replaced separate‐
ly. In this case, the entire illumination housing must be replaced.
There are different versions of the sockets and cigarette lighter
sockets due to different installation locations and construction.
The differences are primarily In the length and type of electrical
connectors. On sockets or cigarette lighter sockets with an elec‐
trical cable pig tail, additional work may be necessary to access
the connector.
70 Rep. Gr.96 - Interior Lights, Switches

2.2 Overview - Cigarette Lighter - U1-
Caution

out damage.
1 - Cigarette Lighter Socket

with Cable Pig Tail
2 - Cigarette Lighter
3 - Socket
4 - Cigarette Lighter Recepta‐
cle
5 - Mounting Sleeve
6 - Bulb W 5 12V 1.2 Watt
7 - Bulb Holder
AG. Volkswagen AG d
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nform
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ion
c
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ate
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cum
for
2.3 Cigarette Lighter Socket, Removing and

en
ng
t.
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Installing
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♦ Cigarette Lighter Release Tool - T40148-
2. Cigarette Lighter U1 71
Note
The removal and installation for all sockets is performed in the

same way and is only described for the cigarette lighter socket.
lkswage es n
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Caution orise
tee
th or
au ac
s
s
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un
pt
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spec
es, in part or in w
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out damage.
rrectness of i
Removing
l purpos
– Remove the cigarette lighter, blank plug, etc. from the socket,
if necessary.
nform
mercia
a
Note
com
tion in
r
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The illustration shows the socket removed. thi

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Caution
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The socket or mounting sleeve can be damaged. pyri by
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cted
Make sure the puller is seated properly or the mounting sleeve
agen
Prote AG.
retainers will not release.
– Insert puller -arrow- in receptacle so retainers -1- engage in

recesses -2-.

– Release the mounting sleeve retainers by pulling on grip piece

-3- in direction of -arrow-.
– Pull receptacle with puller out of mounting sleeve.
Caution
The wiring for the socket could get damaged.

Pay attention to the lengths of the electrical wires when re‐
moving the outlet.
Depending on installation location, it is recommended to use the

Thrust Piece - T40148/1- -2- withAknurled
G. Volkswanut
gen-1-.
A agen G do
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Caution ris
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Make sure none
ss of the surrounding components are damaged c
when using the thrust piece.
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un
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ab
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– Disconnect electrical connection.
ility
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, is n
h re
hole
Note
spec
es, in part or in w
t to the co
There are different versions of the sockets and cigarette lighter
sockets due to different installation locations and construction.
The differences are primarily In the length and type of electrical
rrectness of i
connectors. On sockets or cigarette lighter sockets with an elec‐

trical cable pig tail, additional work may be necessary to access
l purpos
the connector.
nform
ercia
– Release the puller retaining tabs by pressing the spindle -1- in

m
the direction of the -arrow B-. Then release the press -2- by
com
tion in
turning it slightly to left -arrow A-. Remove the puller from the
r
te o
thi
outlet.
s
iva
do
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fo
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Note
n
t.
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Make sure the puller retainers are not spread.
gh ht
pyri by
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cted agen
Prote AG.
Caution
The cigarette lighter can be ejected from the socket when the
heating cycle is complete.
Inserting the puller into the socket spreads the socket retainer
springs and reduces their ability to retain the cigarette lighter
insert.
After removing the socket, bend the retainer springs together
carefully to tighten them and make sure the insert remains in
the socket when the heating cycle is complete.
– Carefully bend retainer springs together -arrows-.

– Make sure the cigarette lighter insert is not ejected completely
into vehicle interior on completion of glow cycle, and remains
in receptacle.
Installing
Install in reverse order of removal.
AG. Volkswagen AG d
agen oes
olksw not
V
2.4 Cigarette Lighter Illumination Bulb - by gu
d ara
rise nte
L28- , Removing and Installing tho eo
au ra
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un
pt
an
d
Note
itte
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erm
ab
ility
ot p
♦ On some vehicle equipment levels, socket illumination is via
wit
Light Emitting Diode (LED) instead of a bulb. These LEDs are
is n
h re
integrated with the illumination housing and cannot be serv‐
ole,
spec
iced or replaced separately.
t to the co
♦ Various versions of illumination housing with bulb exist. One
version allows separate replacement of the illumination bulb,
and another where the bulb cannot be serviced or replaced
rrectne
separately. In this case, the entire illumination housing must
be replaced.
ss o
Removing
cial p
f inform
– Remove the socket. Refer to

mer
atio
m
– Depress retainers in direction of -arrows- and remove mount‐

o
n
c
ing sleeve with bulb holder.

or
n thi
te
sd
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– Unclip bulb holder from mounting sleeve.

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– Separate bulb holder sections -A and B-.

– Open bulb holder section -B-.

– Remove bulb in direction of -arrow-. AG. Volkswagen AG d

agen oes
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Installing by Vol not
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ise nte
Install in reverse order of removal. thor eo
au ra
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un
pt
an
d
itte
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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
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nform
mercia
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tion in
r
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thi
s
iva
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en
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t.
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3 Special Tools
♦ Release Tool for Cigarette Lighter - T40148-
AG. Volkswagen AG d
agen oes
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V gu
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or eo
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un
pt
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spec
t to the co
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cial p
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mer
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n
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Prote AG.

97 – Wiring
1 Vehicle Diagnosis, Testing and Infor‐
mation Systems
⇒ “1.1 Vehicle Diagnostic Tester , Connecting”, page 77
⇒ “1.2 Vehicle Diagnostic Tester , Connecting, Golf MY 1998
through 2003”, page 78
1.1 Vehicle Diagnostic Tester , Connecting

♦ Vehicle Diagnostic Tester
♦ Vehicle Diagnosis System - Diagnostic Cable - VAS5051/6A-
(5 m)
♦ Vehicle Diagnosis System - Updated Cable - 3m -
. Volkswagen AG
VAS5051/5A- (3 m) kswagen AG does
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WARNING
ho
tee
aut or
ac
ss
♦ During road tests using a vehicle diagnostic and informa‐
ce
e
nl
pt
tion system, there is the hazard of extreme to lethal inju‐
du
an
itte
ries!
y li
erm
ab
ility
♦ If vehicle diagnostic and information system is deposited

ot p
wit
in the action area of an airbag during a road test, here is

, is n
h re
the hazard of extreme to lethal injuries in the event the

hole
spec
airbag deploys!
es, in part or in w
t to the co
♦ During road tests, have a person sitting in the rear seat to

operate the vehicle diagnostic and information system.
rrectness of i
l purpos
Note
nform
ercia
♦ All of the procedures described such as adaptations and cod‐

ing can be performed with the Vehicle Diagnostic Tester .
m
at
om
ion
c
♦ All work instructions can be reached in the operating modes

in t
or
“Guided Fault Finding” and “Guided Functions”.

his
ate
do
riv
♦ Additional information:
p
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for
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ng
t.
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Self Study Program 202 C py
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Self Study Program 256
p by
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Self Study Program 294
Prote AG.
– Connect the Vehicle Diagnostic Tester . Refer to

⇒ “1.1 Vehicle Diagnostic Tester , Connecting”, page 77 .
Note
Follow the current operating instructions for the Vehicle Diagnos‐

tic Tester , which can be displayed by selecting the “Administra‐
tion” and “operator's handbook” buttons.
1. Vehicle Diagnosis, Testing and Information Systems 77

AG. Volkswagen AG d
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Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ u,thCC 2012 ➤ , Eos 2006 ...
o eo
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Electrical Equipment General Information - Edition
ss 04.2015 c
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un
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Note
ab
pe
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For the diagnosis, only the diagnostic cables listed above are to
h re
be used since only these are equipped with CAN wires and permit
hole
spec
a CAN diagnostic or CAN communication.
es, in part or in w
t to the co
Connect the Vehicle Diagnostic Tester .
– Apply the parking brake.
rrectness of i
– In vehicles with automatic transmission, move the selector
l purpos
lever to the “P” or “N” position.
– In vehicles with manual transmissions, move the shift lever to
nform
ercia
the neutral position.
m
a
com
t
– With the ignition switched off, connect the Vehicle Diagnostic
ion in
Tester with the Vehicle Diagnosis System - Diagnostic Cable
r
te o
thi
- VAS5051/6A- to the diagnostic connection -arrow- in the ve‐
s
iva
do
hicle.
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– Turn on the ignition.
en
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Note
AG.
The connection of all other and the following diagnostic operation

system or vehicle diagnosis and service system occurs in the
previously described sequence.
1.2 Vehicle Diagnostic Tester , Connecting,

Golf MY 1998 through 2003
– Apply the parking brake.
– In vehicles with automatic transmission, move the selector
lever to the “P” or “N” position.
– In vehicles with manual transmissions, move the shift lever to
the neutral position.
– Remove trim -1- in direction of -arrow-.
– With the ignition switched off, connect the Vehicle Diagnostic
Tester with the Diagnostic Cable to the diagnostic connection
-arrow- in the vehicle.
– Turn on the ignition.
Note
The connection of all other and the following diagnostic operation

system or vehicle diagnosis and service system occurs in the
previously described sequence.
78 Rep. Gr.97 - Wiring

2 Wiring Harness and Connector Re‐

pairs
⇒ “2.1 Vehicle Electrical System, General Repair Information”,
page 79
⇒ “2.2 Wiring Harness Repair Set”, page 82 agen
AG. Volkswagen AG d
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⇒ “2.3 Tool Descriptions”, page 84 ed by
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ara
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⇒ “2.4 Wiring Harnesses, Repairing”, page 88 aut
ho eo
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⇒ “2.5 Fiber-Optic Cables, Repairing”, page 98
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nl
pt
du
an
⇒ “2.6 Antenna Wires, Repairing”, page 104
itte
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ab
⇒ “2.7 Contact Housings and Connectors, Repairing”,
ility
page 115 ot p
wit
, is n
h re
⇒ “2.8 Contact Housings, Releasing and Disassembling”,
hole
spec
page 119
es, in part or in w
t to the co
2.1 Vehicle Electrical System, General Re‐
pair Information
rrectness of i
l purpos
Caution
Follow the procedure in the repair manual when disconnecting
nf
ercia
o
and connecting the battery.
rm
m
atio
om
n in
or c
thi
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sd
a
WARNING
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o
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f
en
Some tools are supplied with a tool safety clip, which is slid
ng
t.
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over the tool points after using the tool, in order to protect other t. Cop py
workers from injuries and tool points from damage.
rig
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pyri by
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Prote AG.
2. Wiring Harness and Connector Repairs 79

AG. Volkswagen AG d
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cial p
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mer
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♦ Observe the current notes in the corresponding repair manual

for all repairs.
♦ Observe country-specific regulations.
♦ Before working on the electrical system, the battery ground
cable must be disconnected.
agen
AG. VolkBy
swadisconnecting
gen AG
does the battery
ground cable (current
V olksw disruption), the electricalnot system is guar‐
g
y
anteed tosebe d b safe to work on. Disconnecting the ua
rpositive
an
batterythocable
ri is only required when removing the battery. tee
o
au ra
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♦ Before
ss commencing repair work, always eliminate cause of
ce
le
damage, for example, sharp body edges, faulty components,

un
pt
an
corrosion etc.
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♦ Further information, for example, installing and removing the
pe
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♦ Soldering is not permissible for repairs to the vehicle electrical
es, in part or in w
system.
t to the co
♦ Repair to the wiring harnesses and connectors on the vehicle
electrical system may only be performed using the Wiring Har‐
rrectness of i
ness Repair Set - VAS1978B- and with previous versions.
Only use the yellow wires from the Wiring Harness Repair Set
l purpos
- VAS1978B- .
♦ Wiring harness repairs may not be performed again in the
nform
ercia
wrapping of the vehicle-specific wiring harness and are to be

marked with yellow adhesive tape. This indicated a previous
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♦ Crimp connections must never be repaired. If necessary, lay

thi
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a wire parallel to the faulty wire. After crimping, crimp connec‐

do
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♦ Always observe also the supplementary notes for repairing
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cross-sections up to 0.35 mm2. Refer to
AG.
⇒ “2.4.4 Wires with Cross Section up to 0.35 mm 2, Repairing”,

page 92 .
♦ A function test must be performed after every repair. If nec‐
essary, check DTC memory, erase and/or bring systems into
basic setting.
♦ If possible, do not loosen grounding straps from the body
(danger of corrosion).
♦ Not all wire cross-sections in the vehicle are contained in the
Wiring Harness Repair Set - VAS1978B- and its previous ver‐
sions. If the required wire cross-section is not present, the next
greater cross-section must be used.
♦ Shielded harnesses may be repaired. Camera system wires
are the exception. If faulty, the entire harness must be re‐
placed.
♦ Heat-resistant wires have been installed in the vehicle at var‐
ious locations, mainly in the engine compartment. Heat-resist‐
ant wires can be recognized by their somewhat duller and
softer insulation. Only heat-resistant wires may be used to re‐
pair these wires.

2.2 Wiring Harness Repair Set

⇒ “2.2.1 Wiring Harness Repair Set VAS1978 ”, page 82
⇒ “2.2.2 Upgrade Kit For VAS1978 VAS1978/50 ”, page 82
⇒ “2.2.3 Wiring Harness Repair Set VAS1978A ”, page 83
⇒ “2.2.4 Release Tool Set VAS1978/35 ”, page 83
2.2.1 Wiring Harness Repair Set - VAS1978-

The Wiring Harness Repair Set - VAS1978- makes optimal repair
quality possible in the realm of vehicle electronics. Using the agen
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terminals already crimped on are used and can be connected hor to eo
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vehicle-specific wiring harness by the use of crimp connections.
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A pair of crimping pliers with three different crimp slots and a hot
ce
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air gun for shrinking the crimp connections provide trouble-free
pt
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Additional information:
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Refer to Wiring Harness Repair Set - VAS1978- Operating In‐
structions.
rrectne
2.2.2 Upgrade Kit For VAS1978 -
ss
VAS1978/50-
o
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f inform
The Upgrade Kit For VAS1978 - VAS1978/50- is required in order
mer
to bring the “old” Wiring Harness Repair Set - VAS1978- up to the
atio
m
new standard of the Wiring Harness Repair Set - VAS1978A- .

o
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The upgrade kit contains four assembly- and ten release tools as
thi
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well as new crimping pliers for crimp connections with Crimping
sd
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Heads for 0.35 - 2.5 mm 2 Wiring Harness Repair - Crimping Head

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- .35-2.5mm - VAS1978/1-1- , 4.0 - 6.0 mm² Wiring Harness Re‐
en
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pair Set - Crimping Head - 4-6mm - VAS1978/2A- and the Wiring Cop py
Harness Repair Set - Crimping Head - JPT - VAS1978/9-1- . Fur‐ ht. rig
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thermore it contains new stickers, a new set of user instructions,
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crimp connections for 0.35 mm2-wire cross sections and a roll of cted agen
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black felt adhesive tape.

2.2.3 Wiring Harness Repair Set -

VAS1978A-
The new Wiring Harness Repair Set - VAS1978A- makes optimal
repair quality possible in the realm of vehicle electronics. Using
the new pliers, repairs affecting harness connectors and for
breaks in wiring can be performed. For this purpose, complete
repair wires with terminals already crimped on are used and can
be connected to vehicle-specific wiring harness by the use of the
four different types of crimp connections. A pair of new crimping
pliers with crimping heads and a hot air gun for shrinking the crimp
connections provide trouble-free electrical connection.
Note
Additional information:
Refer to Wiring Harness Repair Set - VAS1978A- Operating In‐

structions.
2.2.4 Release Tool Set - VAS1978/35-

The Release Tool Set - VAS1978/35- is used to release the var‐
ious primary and secondary locking mechanisms on VW-group
vehicles. The set consists of 26 different tools which can be used
to professionally release or assemble e.g. round connector sys‐
tems, flat terminals with one or two locks as well as single wire
seals.
The allocation of the correct release tools to the respective locking
mechanisms can be found in the table in the Release Tool Set -
VAS1978/35- Operating Instructions.
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2.3 Tool Descriptions tho
or
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ss
⇒ “2.3.1 Crimping Pliers with Insert”, page 84
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⇒ “2.3.2 Contact Release Tools”, page 85
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⇒ “2.3.3 Single Wire Seal Assembly Tools”, page 85
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⇒ “2.3.4 Wiring Harness Repair Set - Wire Strippers VAS1978/3
h re
ole,
”, page 85
spec
⇒ “2.3.5 Wiring Harness Repair Set - Hot Air Blower
t to the co
VAS1978/14A ”, page 86
⇒ “2.3.6 Crimping Pliers - .35-2.5mm VAS1978/1A ”, page 87
rrectne
2.3.1 Crimping Pliers with Insert
ss
The Crimping Pliers without Insert - VAS1978/1- with Crimping
o
cial p
f i
Pliers - Insert 2 - VAS1978/2- is a component of the Wiring Har‐
nform
ness Repair Set - VAS1978- and is used to crimp the connector
mer
during the wiring harness repair.
atio
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Color of Crimp Color of Crimping Wire Cross-Section
thi
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Connectors Slot
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yellow yellow 0.35 mm2
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Red Red 0.5 mm2 - 1.0 mm2
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Blue Blue 1.5 mm2 - 2.5 mm2
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yellow yellow Prote
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Note
♦ The Wiring Harness Repair - Crimping Plier - Base Tool -

VAS1978/1-2- can also be used together with the Wiring Har‐
ness Repair - Crimping Head - .35-2.5mm - VAS1978/1-1- or
Wiring Harness Repair Set - Crimping Head - 4-6mm -
VAS1978/2A- to crimp the connectors as an alternative. Refer
to
⇒ “2.3.6 Crimping Pliers - .35-2.5mm VAS1978/1A ”,
page 87 .
♦ Always be sure to use the correct crimping slot for the crimping
connection used.
♦ Do not crimp wire insulation.

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Various release
ss tools are used to remove the different terminals c
from terminal housings without damage.
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A selection of release tools are a component of the Wiring Har‐
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ness Repair Set - VAS1978- and the Wiring Harness Repair Set
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- VAS1978A- . The Release Tool Set - VAS1978/35- contains the
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entire set of release tools. Refer to
h re
⇒ “2.2.4 Release Tool Set VAS1978/35 ”, page 83 .
hole
spec
es, in part or in w
t to the co
WARNING
Some tools are supplied with a tool safety clip, which is slid
rrectness of i
over the tool points after using the tool, in order to protect other
workers from injuries and tool points from damage.
l purpos
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Contact housings, releasing and disassembling. Refer to
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page 119 .
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2.3.3 Single Wire Seal Assembly Tools

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Assembly tools serve the purpose of allowing the single wire seals
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to be slid without damage into terminal housing up to stop, this
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Four assembly tools for single wire seals are components of the Prote AG.
Wiring Harness Repair Set - VAS1978B- and its previous ver‐
sions.
Assembly of single wire seals. Refer to
⇒ “2.7.3 Single Wire Seals, Installing”, page 117 .
2.3.4 Wiring Harness Repair Set - Wire Strip‐

pers - VAS1978/3-
The Wiring Harness Repair Set - Wire Strippers - VAS1978/3- is
used for professional stripping and cutting of wires.
The Wiring Harness Repair Set - Wire Strippers - VAS1978/3- is
a component of the Wiring Harness Repair Set - VAS1978B- and
its previous versions.
Wire stripper has an adjustable stop in its pliers-jaws which can
be set to the desired length of wire insulation to be removed.
Stripping
– Set the slideable stop in pliers-jaws to the desired length di‐
mension to be stripped.

– Insert wire end from front up to stop into jaws of pliers and
squeeze the pliers completely.
– Open pliers again and remove the stripped wire end.
– If necessary, cut wires using side-cutter function on the top of

the wire stripper.
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2.3.5 Wiring Harness Repair Set - Hot Air
, is n
h re
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Blower - VAS1978/14A-
spec
es, in part or in w
t to the co
Caution
rrectness of i
When heat-shrinking crimp connections, be careful not to dam‐
age any other wiring, plastic parts or insulating material with
l purpos
the hot nozzle of the hot air gun.

Always observe operating instructions of heat gun.
nform
mercia
a
com
tio
The Wiring Harness Repair Set - Hot Air Blower - VAS1978/14A-

n in
r
is used together with the Wiring Harness Repair - Blower - Shrink

te o
thi
Element - VAS1978/15A- to heat-shrink the crimp connectors.

s
iva
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After crimping, crimp connections must be heat-shrunk using hot

r
rp
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fo
air gun to prevent moisture penetration.

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The Wiring Harness Repair Set - Hot Air Blower - VAS1978/14A- ht. rig
rig ht
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is a component of the Wiring Harness Repair Set - VAS1978B- copy Vo
by lksw
and its previous versions. cted agen
Prote AG.
Crimp connectors, heat-shrinking using the Wiring Harness Re‐

pair Set - Hot Air Blower - VAS1978/14A- . Refer to or
⇒ “2.4.6 Wire Break with Dual Repair Point”, page 96 .

2.3.6 Crimping Pliers - .35-2.5mm -

VAS1978/1A-
The Crimping Pliers - .35-2.5mm - VAS1978/1A- or the Wiring
Harness Repair - Crimping Plier - Base Tool - VAS1978/1-2- to‐
gether with the Wiring Harness Repair - Crimping Head - .
35-2.5mm - VAS1978/1-1- , or the Wiring Harness Repair Set -
Crimping Head - 4-6mm - VAS1978/2A- from the wiring harness
repair set is used to compress the crimp connectors.
Crimp connectors, pressing using the Crimping Pliers - .
35-2.5mm - VAS1978/1A- . Refer to
The following crimping heads are available for the Wiring Harness
Repair - Crimping Plier - Base Tool - VAS1978/1-2-
♦ Crimping Head 0.35 mm 2 - 2.5 mm 2 Wiring Harness Repair
- Crimping Head - .35-2.5mm - VAS1978/1-1-
♦ Crimping Head 4.0 mm 2 - 6.0 mm 2 Wiring Harness Repair
Set - Crimping Head - 4-6mm - VAS1978/2A-
♦ Wiring Harness Repair Set - Crimping Head - JPT -
VAS1978/9-1-
In conjunction with Wiring Harness Repair Set - Crimping Head -
JPT - VAS1978/9-1- , the crimping pliers are used to crimp
contacts onto individual wires when repairing wiring cross-sec‐
tions up to 0.35 mm2. Refer to
page 92 .
Changing the Crimping Head
– Open crimp pliers completely. AG. Volkswagen AG d
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– Disengage both locking risepins in direction of -arrows- from crimp ante
d b ar
pliers basic tool. utho eo
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– Insert the required crimping head from above -arrow- in crimp

pliers basic tool.
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Electrical Equipment Generalhor Information - Edition 04.2015
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– Lock the crimping head by pressing in the pins -arrows- into
ce
le
crimp pliers basic tool.
un
pt
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2.4 Wiring Harnesses, Repairing
o
cial p
f inform
mer
⇒ “2.4.1 Airbag and Belt Tensioner Wire Repair Information”,
atio
page 88
om
n
c
i
or
n
⇒ “2.4.2 CAN Bus Wires, Repairing”, page 91
thi
te
sd
va
⇒ “2.4.3 Antenna Wires, Replacing”, page 91

i
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t.
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page 92 t. Cop py
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⇒ “2.4.5 Wire Break with Single Repair Point”, page 95 yri
p by
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cted
⇒ “2.4.6 Wire Break with Dual Repair Point”, page 96
agen
Prote AG.
2.4.1 Airbag and Belt Tensioner Wire Repair

Information
Note
Observe general notes for repairs on the vehicle electrical sys‐

tem. Refer to
page 79 .
In addition to the general repairs on wiring harnesses, the follow‐

ing methods and instructions must be observed for repairs on
airbag- and seat belt tensioner wires
WARNING
♦ The airbag and seat belt tensioner system can fail.

♦ Faulty repairs performed on airbag and seat belt tensioner
system can lead to malfunction in passenger protection.
♦ When performing repairs on airbag and seat belt tensioner
wiring harness, use only terminals, connectors and wires
designated for it. Refer to the Parts Catalog.

AG. Volkswagen AG d
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Note
♦ Air bag wires and the safety belt tensioner wiring harness may
repaired only with the Wiring Harness Repair Set - VAS1978B-
and previous versions.
♦ Observe general notes for repairs on the vehicle electrical
system. Refer to
page 79 .
♦ Pay attention to decals designating high voltage components.
When performing repairs, the residual voltage must be dis‐
charged. Refer to ⇒ Body Interior; Rep. Gr. 69 ; Passenger
Protection .
♦ A maximum of two repairs may be performed when repairing
wires of airbag- and seat belt tensioner system. Repairs in‐
crease the electrical resistance in the wire and may trigger
malfunctions in the system On Board Diagnostic (OBD).
♦ When repairing wiring harness of airbag- and seat belt ten‐
sioner system, the crimp connectors must always be heat-
shrunk to prevent corrosion.
♦ Do not wrap the repair point again into the vehicle-specific
n AG. Volkswagen A
wiring harness and mark the repair point quiteolkvisibly
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♦ Repairs in the area of the airbag or useat
tho belt tensioner should or
be performed a maximum of 30 cm ss from the next contact
a ac
housing. Together with the identification via yellow insulating
ce
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nl
pt
tape, this procedure makes it possible to obtain a quick over‐
du
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itte
view of previously performed repairs.
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♦ Wires to the deploying units (airbags) have a wire-twisting with
ot p
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a length of lay of 20 mm ± 5 mm in series production. This
, is n
h re
length of lay is guaranteed via the norm part numbers for wire
hole
spec
pairs in series production and must be observed strictly for the
es, in part or in w
repair lengths of twisted wires. t to the co
♦ During repair work, wires to deploying units (airbags) must

have the same length. When twisting together wires
rrectness of i
-1 and 2-, length of lay of -A- = 20 mm ±5 must be strictly

observed.
l purpos
♦ While doing this, no section of the wire, for example, in area

of crimp connectors -arrow-, may be greater than B = 100 mm
nf
ercia
without twisting of the wires.

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Electrical
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2.4.2 CAN Bus Wires, Repairing
an
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♦ Unshielded two-strand wiring -1- and -2- with a cross section
ility
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of 0.35 mm2 or 0.5 mm2 can be used as CAN bus wiring.
wit
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♦ The color coding of CAN bus wires can be found in the follow‐
hole
spec
ing table:
es, in part or in w
t to the co
CAN High wire, powertrain orange/black
CAN High wire, Convenience orange/green
rrectness of i
CAN High wire, Infotainment orange/violet
l purpos
CAN-Low lead (all) orange/brown
♦ Repairs on CAN-Bus wires can be performed with repair wire
nf
ercia
o
with matching cross section and also with twisted wires “green/
rm
m
yellow” or “white/yellow” from Parts Catalog.
atio
om
n in
c
♦ When repairing Bus leads, both wires must be of the same

or
thi
length. When twisting together wires -1- and -2-, the lay length
te
sd
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of -A- = 20 mm must be observed.
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♦ While doing this, no section of the wire, for example, in area
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of crimp connectors -arrow-, may be greater than -B- = 50 mm
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♦ Wrap repair points with yellow adhesive tape to mark a per‐
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formed repair.
Prote AG.
2.4.3 Antenna Wires, Replacing

A new repair concept has been developed for repairing antenna
wires. Refer to ⇒ “2.6 Antenna Wires, Repairing”, page 104 .
Instead of a complete antenna wire, connecting wires of different
lengths and various adapter leads are now available as replace‐
ment parts.
General Description
♦ Replacement parts can be found in Parts Catalog.
♦ These original replacement parts are suitable for all antenna
wires and wire cross sections to be replaced.
♦ Connector housing for antenna wires can be obtained as a
replacement part only in one color, but can be used for all an‐
tenna connector colors.
♦ The replacement of individual antenna connectors during re‐
pair work is not intended.
♦ The wires are appropriate for use on all VW models with
equipped antenna wiring cross-sections.
♦ All adapter leads and connecting wires are suitable for various
transmission and reception signals.
♦ This repair concept can also be used for testing or as an af‐
termarket solution.

Bora 1999 ➤ , Bora Variant 1999 ➤ , CCA2010 ➤ , CC 2012 ➤ , Eos 2006 ...
n G. Volkswagen AG do
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Electrical Equipment General Information es n
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Assembly Overview of Antenna Wire ho
ris
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aut ra
Example: antenna wire from thess radio to the antenna is faulty. The c
ce
le
following wires are required for repair
un
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d
itte
1- Adapter lead for connection to radio. Length approximately
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30 cm. pe
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2- Connecting wire, available in various lengths.
, is n
h re
hole
3- Adapter lead, for connection to antenna. Length approxi‐
spec
mately 30 cm.
es, in part or in w
t to the co
Installation of a New Antenna Wire
rrectness of i
Note
l purpos
Depending on vehicle equipment, make sure that the total length

of antenna wire can be divided into partial lengths by control
nform
ercia
modules for antenna selection, control modules for traffic moni‐

m
toring or antenna amplifier. Only the defective sections need to
a
com
tio
be replaced.
n in
r
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thi
s
iva
– Separate the connectors of the faulty antenna wiring from their
do
r
rp
c
components.
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ng
t.
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– Determine the path of the faulty antenna wire in the vehicle
Co
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and measure the total length of antenna wire to be replaced. t. C rig
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The entire length of the antenna wire consists of the length of the cted agen
Prote AG.
required adapter leads -1- and -3- as well as the connecting wire
-2-.
– Subtract 60 cm from the total length calculation for an antenna
wire to provide for the required length of connecting wire -2-
to be installed.
– Obtain the required adapter cables -1 and 3- as well as the
calculated length of connecting wire -2- as genuine replace‐
ment part according to the Parts Catalog.
– Cut the connectors off of the faulty antenna wiring.
Leave the rest of the defective antenna wire in the vehicle.
– Connect adapter leads -1- and -3- to modules in vehicle.
– Route and secure connecting wire -2- in the immediate vicinity
of the series-installed wire routing.
Note
Antenna wires must not be kinked or excessively bent! The bend‐

ing radius must not be less than 50 mm.
– Connect the connecting wire with the adapter leads.

– Perform a function test.
2.4.4 Wires with Cross Section up to 0.35 mm

2
, Repairing
♦ Crimping Pliers - .35-2.5mm - VAS1978/1A-
♦ Wiring Harness Repair - Crimping Head - .35-2.5mm -
VAS1978/1-1-

When repairing wires with a cross-section up to 0.35 mm2, new

contacts must always be crimped on using the Crimping Pliers -
JPT - VAS1978/9A- or the Wiring Harness Repair - Crimping Plier
- Base Tool - VAS1978/1-2- with the Wiring Harness Repair Set
- Crimping Head - JPT - VAS1978/9-1- installed. Due to the low
current strengths of these wires in the micro- to milli- range, con‐
tacts crimped on incorrectly lead to continuity resistances and
cause malfunctions or failure of the respective system. The most
frequent applications of these contacts are
♦ Heated Oxygen Sensor
♦ RPM sensor
♦ Mass Airflow Sensor
By using the Crimping Pliers - JPT - VAS1978/9A- or the Wiring n AG. Volkswagen AG
Harness Repair - Crimping Plier - Base Tool - VAS1978/1-2- with
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VAS1978/9-1- installed, the correct connection betweenorise
crimp nte
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contact, wire and single wire seal is guaranteed. aThe
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Contacts in a normal and a gold-plated version are crimped onto
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repair wires. The same version of the contact that was installed
hole
spec
at the factory must always be used for repairs.
es, in part or in w
t to the co
Crimping A New Contact with Single Wire Seal
– Insert the Wiring Harness Repair Set - Crimping Head - JPT -
rrectness of i
VAS1978/9-1- into the Wiring Harness Repair - Crimping Plier
- Base Tool - VAS1978/1-2- . Refer to
l purpos
⇒ “2.3.6 Crimping Pliers - .35-2.5mm VAS1978/1A ”,

page 87 .
nform
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– Place the single wire seal onto the repair wire.

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ate
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When doing this, the smaller diameter of single wire seal must be um
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facing in the direction of the contact to be crimped on.

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– Open crimp pliers and place the repair wire end into stripping
slot of crimp pliers.

– Close crimp pliers completely.

– Open crimp pliers again and remove the stripped wire end.
– Slide single wire seal in direction of stripped wire end until it

rests flush with the wire insulation.
– Place new crimp contact into mount on crimp pliers.
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– Insert the stripped wire end with positioned single wire seal
an
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into crimp contact until it makes contact on “wire stop”.

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– Crimp the contact, wire and single wire seal by closing crimp
wit
pliers completely.
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– Open crimp pliers again and remove the finished crimped-on

spec
contact.
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Rep. Gr.97 - Wiring
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Electrical
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A correctly performed crimp is distinguished
ss by a clean compres‐
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sion of wire and single wire seal in the contact and has an
nl
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impression on the rear side which identifies that the crimp was
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2.4.5 Wire Break with Single Repair Point
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Repair point with single crimp connection

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– Free up wire intended for repair (approximately 20 cm to both
on
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sides of repair point).
in t
or
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ate
– If required, remove wiring harness wrapping using a folding
do
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knife.
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– Cut out the damaged section of wire using the Wiring Harness
Repair Set - Wire Strippers - VAS1978/3- .
Note
If, by cutting out the damaged wire section, both ends of the ve‐
hicle-specific single wire are too short for a repair using a single
crimp connection, insert a repair wire section of matching length
with two crimp connections. Refer to
– Strip the wire ends using the 6 - 7 mm wire stripper.

– Slide crimp connection onto both stripped wire ends of vehicle-

specific single wire and crimp them using crimp pliers.
Note
connection used. Refer to
⇒ “2.3.1 Crimping Pliers with Insert”, page 84 .

– Place the Wiring Harness Repair - Blower - Shrink Element -
VAS1978/15A- on the Wiring Harness Repair Set - Hot Air
Blower - VAS1978/14A- .
– Heat crimp connection using hot air gun lengthwise from cen‐
ter outward until it is sealed completely and adhesive comes
out the ends.
Caution
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age any other wiring, plastic parts or insulating material with ed by V gu
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the hot nozzle of the hot air gun. ho
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♦ Make sure that crimp connections do not lie directly next to
es, in part or in w
each other when several wires need to be repaired. Arrange
t to the co
the crimp connectors at a slight offset so that the circumfer‐
ence of the wiring harness does not become too large.
rrectness of i
♦ In the event the repair point was previous taped, this point
must be taped anew with yellow insulating tape after repairs.
l purpos
♦ Secure the repaired wiring harness if necessary with a cable

tie to prevent flapping noises while driving.
nf
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2.4.6 Wire Break with Dual Repair Point

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Repair point with intermediate wire section

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– Free up wire intended for repair at two points (approximately

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20 cm to both sides of respective repair points).
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– If required, remove wiring harness wrapping using a folding rig ht
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knife.
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– Route the yellow repair wire next to the damaged wiring har‐
ness and cut the repair wire to the required length using the
Wiring Harness Repair Set - Wire Strippers - VAS1978/3- .
– Cut damaged wire section from the vehicle-specific single
wire.
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– Strip the wire ends using the 6 - 7 mm wire stripper.
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– Slide crimp connection onto vehicle-specific single wire at one
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side and onto repair wire at the other side.
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atio
– Crimp the crimp connection at both wire ends using crimp pli‐
om
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ers.
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– Repeat this procedure at the other repair wire end.

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connection used. Refer to cted agen
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⇒ “2.3.1 Crimping Pliers with Insert”, page 84 .

– Place the Wiring Harness Repair - Blower - Shrink Element -
VAS1978/15A- on the Wiring Harness Repair Set - Hot Air
Blower - VAS1978/14A- .
– Heat crimp connection using hot air gun lengthwise from cen‐
ter outward until it is sealed completely and adhesive comes
out the ends.
Caution
When heat-shrinking crimp connections, be careful not to dam‐

age any other wiring, plastic parts or insulating material with
the hot nozzle of the hot air gun.
Always observe operating instructions of heat gun.

Note

2.5 Fiber-Optic Cables, Repairing

⇒ “2.5.1 Fiber-Optic Cable, Assembling”, page 98
⇒ “2.5.2 Fiber-Optic Cable, Disconnecting from Wiring Harness
Connector”, page 103
2.5.1 Fiber-Optic Cable, Assembling

♦ Fiber-Optic Conductor Repair Set - VAS6223A-
♦ Hose Cutting Pliers - VAS6228-
♦ Vehicle Diagnostic Tester
It is very difficult to find the exact location of the problem. Replace
the damaged fiber-optic cable and lay a new wire parallel to the
defective fiber-optic cable.
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Select the damaged fiber-optic cable components with the
d
♦ orise nte
“Guided Fault Finding”
aut or “Guided Functions” from the Vehicle
h eo
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Diagnostic Testers menu options.
s c
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♦ A fiber-optic cable that needs repair is represented by a “yel‐

an
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low” color.
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Procedure
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– Choose “Guided Fault Finding” or “Guided Functions” in the

spec
Vehicle Diagnostic Tester. Refer to Vehicle Diagnostic Tester .

t to the co
– Assemble the fiber-optic cable. Refer to

⇒ “2.5.1 Fiber-Optic Cable, Assembling”, page 98 .
rrectness o
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Electrical Equipment General
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Information - Edition 04.2015
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Do not bend the fiber-optic cable too much.s The bending radius
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must be no less than 25 mm.
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Fiber optic cables must not be routed over sharp edges.
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The fiber-optic cable must not be dirty or touched with bare
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fingers.
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Fiber optic cables may not be heated.
spec
es, in part or in w
It is not permitted to twist together 2 fiber optic cables or one
t to the co
fiber optic cable with a copper wire.
Protect the connector and the connection box from dust. Place
rrectness of i
the cap on the trunk.
l purpos
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Caution
orm
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atio
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Do not bend the fiber-optic cable too much. The bending radius
o
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must be no less than 25 mm.

or
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Fiber optic cables must not be routed over sharp edges.

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The fiber-optic cable must not be dirty or touched with bare
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Fiber optic cables may not be heated.
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It is not permitted to twist together 2 fiber optic cables or one
agen
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fiber optic cable with a copper wire.
Protect the connector and the connection box from dust. Place
the cap on the trunk.
Mount the Tool Head for the Fiber-Optic Repair Set - Pliers -
VAS6223/1- .
– Remove the locking pin -arrows-.

– Remove the tool set -arrow- and pull the locking pin back.

Fiber Optic Cable, Cutting to Length

– Establish length of fiber optic cable required.
– Open the Fiber-Optic Repair Set - Pliers - VAS6223/1- and lay
the fiber-optic cable -1- in the mount.
– Close the Fiber-Optic Repair Set - Pliers - VAS6223/1- to cut
the fiber-optic cable lengths.
Stripping
– Open the Fiber-Optic Repair Set - Pliers - VAS6223/1- .
– Position the wire stripper in the lower position -arrow-.
– Insert fiber-optic cable into the stripping station.
• The end of the fiber-optic cable must be flush with the rear side
of the cutting pliers.
– Close the Fiber-Optic Repair Set - Pliers - VAS6223/1- until

the stop and keep closed.
– Bend the wire stripper upward -arrow- and remove the fiber- AG. Volkswagen AG d
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Precision Cutting (Production of Optical End Face)
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– Push the fiber-optic cable -1- into the cutting station.
• Insulation must make contact with cutting point stop. rrectness of i
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– Close the Fiber-Optic Repair Set - Pliers - VAS6223/1- and

remove the wire.
– Visually inspect the wire -1- to make sure that it was cut cor‐
rectly and that there are no burrs on the front surface.
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♦ Fiber-optic cable ais
ut only to be placed on an absolutely clean
h eo
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surface or held sin hand.
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♦ Use the cap if there is a risk of the fiber-optic cable surface
an
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Attaching Brass Pin Contact to Fiber-Optic Cable
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– Change tool head -arrow-.
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– Slide the safeguard on the Fiber-Optic Repair Set - Pliers -

p
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VAS6223/1- in direction of -arrow- so that the word “Stift” (pin)

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– Insert a brass pin contact -1- in the mount.

– Close the securing lever on the Fiber-Optic Repair Set - Pliers
- VAS6223/1- in direction of -arrow-.

– Insert the fiber-optic cable into the brass pin contact -arrow-
all the way up to the threaded stop and then close the Fiber-
Optic Repair Set - Pliers - VAS6223/1- .
– Open the fiber-optic cable pliers and remove the fiber-optic
cable along with the brass contact pin.
Caution
Do not excessively bend or kink the fiber-optic cables (mini‐

mum bending radius 25 mm).
– Make sure the brass pin contact -2- is secured properly on the
fiber-optic cable -1-.
• 4 crimped points must be visible on the brass connecting pin.
• The brass pin contact must not be able to be removed by hand
from fiber-optic cable.
• The front surface of the fiber-optic cable is 0.01 to 0.1 mm
behind the brass pin contact (visual check). AG. Volkswagen AG d
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Note utho or
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♦ Connector couplings are available for connecting the fiber-op‐

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tic cables. Refer to Parts Catalog.
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♦ To install the new fiber optic cable in wiring harness connector.
ility
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Refer to
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⇒ “2.5.2 Fiber-Optic Cable, Disconnecting from Wiring Har‐
h re
ness Connector”, page 103 .
hole
spec
es, in part or in w
t to the co
Corrugated Tube, Install on Fiber Optic Cable
– Cut corrugated tube to appropriate length.
rrectness of i
• Use the Hose Cutting Pliers - VAS6228- or a sharp knife for
l purpos
cutting.
• The corrugated tube must not be cut through using a side cut‐
nf
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ter under any circumstances

rm
m
atio
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• The corrugated tube must be cut on the wave peak -arrow-,

o
n in
c
not in the wave trough.

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• The corrugated tube must audibly engage in the fiber-optic

iv
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cable housing when installing.

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– Guide the fiber-optic cable into the Fiber-Optic Repair Set -

Tube Tool - VAS6223/10- as shown.
– Position corrugated tube assembly pliers on slot on the tube.
– Position crimping pliers for fiber-optic cable at slot of corruga‐
ted tube. The fiber optic cable is then routed in the corrugated
tube.
2.5.2 Fiber-Optic Cable, Disconnecting from

Wiring Harness Connector gen AG. Volkswagen AG d
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– Unplug connector for fiber opticutcable
ho from appropriate control eo
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unit. ss
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– Release the locking mechanism in the fiber-optic cable con‐
pt
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an
nector -1- by pushing on it.
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– Release the secondary lock -2- with a small screwdriver.
ility
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– Remove the fiber-optic cable.
h re
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spec
es, in part or in w
Caution
t to the co
♦ Install the cap on the trunk, in order to protect the fiber-
optic cable from dust and dirt.
rrectness of i
♦ Use a new housing since it is likely that the secondary lock
l purpos
was damaged during the removal of the fiber-optic cable.

♦ Note the arrows for allocation on the base module “IN” and
nform
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“OUT”.
m
at
om
ion
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Installing
o
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ate
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Install in reverse order of removal. Note the following

p
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en
– Install the fiber-optic cable according to the markings.

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♦ Push the corrugated tube into the connector housing until it

audibly engages.
♦ Cover the open connector -2- for the fiber-optic cable using
the Fiber-Optic Repair Set - Connector Protective Caps -
VAS6223/9- -item 1-.
♦ The protective cap prevents contamination of or mechanical
damage to end face of fiber optic cable which would impair
signal transmission.

2.6 Antenna Wires, Repairing

⇒ “2.6.1 Aerial Cable Repair Set VAS6720 ”, page 104
2.6.1 Aerial Cable Repair Set - VAS6720-

♦ Repair Set, Aerial Cable - VAS6720-
Checking the Antenna Wire. Refer to
Replacing the Tool Head. Refer to
Cutting the Antenna Wire. Refer to
Removing the Insulation from the Shield. Refer to
Removing the Outer Jacket of Insulation. Refer to
Removing the Inner Insulation. Refer to
Crimping the Inner Conductor. Refer to
Crimping the Outer Conductor. Refer to
The Repair Set, Aerial Cable - VAS6720- makes it possible to
perform a quality repair on antenna wires RG 174 (blue) and RTK
031 (black). The set contains the insulation removal tools and the
crimping tools for both antenna wires. Moreover, all the individual
parts needed are in the kit. Only the zero-coded coupler (green)
is needed. All other connection wires for the different Infotainment
systems can be found in the Parts Catalog in table 035-XX. These
adapter antenna wires must always be ordered separately de‐
pending on the vehicle type. All part numbers needed for reor‐
dering can be found in this table. The each compartment in the
kit has a part number. The repair kit is based on the Wiring Har‐
ness Repair Set VAS1978B.
Note
wage es n
Additional information: Repair Set, Aerial Cableb-y VVAS6720-
olks
Op‐ ot g
ua
erating Instructions. ir se
d ran
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Checking the Antenna Wire: ss
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Before starting the repair, determine which antenna wire using

an
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the gauge.
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ility
♦ -1- System RG 174 = blue

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♦ -2- System RTK 031 = gray

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spec
The adjusters on the heads of the tools are color coded on both
systems.
t to the co
Replacing the Tool Head:

rrectne
– Select the appropriate tool head based on the antenna wire

test. Refer to ⇒ page 104 .
ss
– Open the handle on the pliers all the way.

o
cial p
f inform
mer
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om
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c
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104
Prote AG.
Rep. Gr.97 - Wiring
– Release and remove both locking pins in direction of

-arrows- from the handle.
– Attach the necessary tool head to the handle from the top in
direction of -arrow-.
– Insert the pins in direction of -arrows- into the handle in order

to lock the tool head into place.
Cutting the Antenna Wire:
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– Slide the antenna wire -2- into the cutting device -1-.
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– Close the tool then open it again. ility

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– Pull the antenna wire out of the cutting device.
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Removing the Insulation from the Shield:

es, in part or in w
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– Push the locking pin -1- all the way into the rotating cutting
piece.
– Push the antenna wire -2- all the way into the rotating cutting
piece. The locking pin -3- can not be seen completely.

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– Push the blade holder -1- against the axle of the rotating cut‐
ting segment until it locks into place. The gap -2- under the
blade holder is completely closed.
– Hold the antenna wire so that it cannot turn.
– Turn the rotating cutting segment -3- 2 times in direction of
-arrow- until it starts to turn easily.

AG. Volkswagen AG d
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
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n
c
i
or
n thi
te
sd
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fo
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t.
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Cop py
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Prote AG.
– Pull the release pin -1-. The blade holder unlocks and sepa‐
rates from the antenna wire.
– Push the locking pin -2- all the way into the rotating cutting
piece. The antenna wire is pushed out of the rotating cutting
segment.
– Remove insulation from the antenna wire.
– Remove any insulation remaining on the rotating cutting seg‐
ment.
Removing the Outer Jacket of Insulation:

AG. Volkswagen AG d
agen oes
olksw not
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es, in part or in w
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rrectness of i
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– Slide the antenna wire -2- in the mount -3- into the tool head nform
ercia
until it stops -1-.

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a
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– Close the tool then open it again.

tion in
r
te o
– Remove the antenna wire -4-.

thi
s
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Removing the Inner Insulation:

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– Push the antenna wire -2- in the mount -1- all the way into the
pe
ility
ot
tool head.
wit
, is n
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hole
spec
es, in part or in w
– Remove the antenna wire -3-.

t to the co
Crimping the Inner Conductor:

rrectness of i
l purpos
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rig ht
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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
e
– Select the appropriate tool head based on the antenna wire

at
do
riv
test. Refer to ⇒ page 104 .

p
cum
for
en
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– Unfold the positioner -2-.

n
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op py
– Open the positioning plate -3-. The positioning plate swivels
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upward. p by
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– Push the inner contact -1- all the way into the positioner and Prote AG.
loosen the positioning plate. The inner contact is attached.
– Fold the positioner back in. The inner contact -4- is positioned
inside the tool head.

AG. Volkswagen AG d
agen oes
olksw not
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pt
du
an
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
– Slide the antenna wire -1- into the inner contact -2- in the tool
head. Hold the positioner tight while doing this.
rrectness of i
– Lock the tool until it opens by itself.

l purpos
– Open the positioning plate -3- and pull out the antenna wire.
nf
ercia
Crimping the Outer Conductor:

orm
m
atio
om
n in
or c
thi
te
sd
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o
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cu
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t.
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co lksw
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AG. Volkswagen AG d
agen oes
olksw not
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or eo
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aut ra
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ce
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un
pt
an
d
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rm
ab
pe
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Slide the sleeve -2- and outer contact -1- over the inner con‐
ductor. The knurled contact piece must be pushed under the
nform
ercia
shield -3-, but over the aluminum foil.

m
– Slide the outer contact -4- all the way on. Make the bushing/
com
tion in
pin fit correctly when doing this.

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AG. Volkswagen AG d
agen oes
olksw not
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nl
pt
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ab
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spec
es, in part or in w
t to the co
– Push the sleeve -3- up to the outer contact.

rrectness of i
– Open the tool and fold out the positioner -1-.

l purpos
– Position the outer contact -2- in the tool head on the contact
edge -4-.
nform
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m
at
– Pull out the antenna wire.

om
ion
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or
his
ate
do
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for
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t.
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Prote AG.

2.7 Contact Housings and Connectors, Re‐

pairing
⇒ “2.7.1 Contact Housings and Connectors, Repair Information”,
page 115
⇒ “2.7.2 Contacts in Contact Housing, Repairing”, page 115
⇒ “2.7.3 Single Wire Seals, Installing”, page 117
⇒ “2.7.4 Contact Housings, Repairing Wire Terminals”,
page 118
2.7.1 Contact Housings and Connectors, Re‐

pair Information
Note
Volkswa
♦ Observe general
swanotes for repairs ondo
gen AG
. gen AG
the
es vehicle electrical
system. Refer by
V to
olk not
gu
⇒ “2.1riVehicle
se
d Electrical System, General Repair
ara
ntInformation”,
ee
page ut 79 .
ho
or
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♦ Allocation of crimp contacts with correct fit to contact housing
ce
e
nl
is performed according to the part number stamped in on the

pt
du
an
contact housing. Part numbers of contact housing are listed in

itte
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conjunction with the respective crimp contacts with correct fit

ab
ility
in plate 198 (electrical connecting elements) in Parts Catalog.

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♦ Damaged contact housings must always be replaced.

h re
hole
spec
♦ New contact housings may be ordered via OTC Kassel.

es, in part or in w
t to the co
2.7.2 Contacts in Contact Housing, Repairing

rrectness of i
– First, open or release if necessary the secondary lock of the

contact housing. Refer to
l purpos

page 119 .
nform
ercia
– Release contact (primary lock) using the appropriate release

m
tool. Refer to
at
om

on
c
in t
page 119 .
or
his
ate
do
riv
– Pull contact at single wire out of contact housing.

p
cum
for
– Take the yellow repair wire with the correct contact out of the
en
ng
t.
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Wiring Harness Repair Set - VAS1978- .
Co
Cop py
t. rig
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– Free up repair point of vehicle-specific wiring harness (ap‐
ht
pyri by
Vo
o
proximately 20 cm to both sides of repair point).
c by lksw
cted agen
Prote AG.
– If required, remove wiring harness wrapping using a folding
knife.

– Insert new contact of repair wire into contact housing until it

engages.
– Slide a single wire seal onto the repair wire.
Note
When doing this, small diameter of single seal must point toward
contact housing.
– Slide single wire seal into contact housing using the correct
assembly tool. Refer to
⇒ “2.7.3 Single Wire Seals, Installing”, page 117 .
– Shorten the repair wire and the vehicle-specific wiring harness

single wire as needed using the Wiring Harness Repair Set -
Wire Strippers - VAS1978/3- .
– Strip ends of repair wire and of vehicle-specific single wire us‐

ing 6 - 7 mm wire stripper. . Volkswage n AG n AG d
wage oe
– Crimp the stripped ends yV
olkof
s repair wire and single wire
s no of ve‐
t gu
hicle-specific wirings ed harness
b using crimp pliers and a crimp
ara
nte
ri
connection asutdescribed
ho in chapter “Wire break with single re‐ eo
pair point”. sRefer
sa to ra
c
⇒ “2.4.5 Wire Break with Single Repair Point”, page 95 .
ce
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nl
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du
an
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ab
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es, in part or in w
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Note
rrectness of i

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2.7.3 Single Wire Seals, Installing
Note
♦ Single wire seals prevent the penetration of water and dirt into
the contact housing. They are installed, for example, in the
engine compartment and must be reinstalled after a repair.
♦ Single wire seal is crimped on at the factory together with con‐
tact on the wire, this is not the case for repair wires. Single wire
seal must be slid onto wire first before crimping the repair wire.
♦ Single wire seals must always fit with the repair wire cross-
section. Outer circumference of single wire seal is aligned
according to chamber circumference of the contact housing.
Perform assembly using only the assembly tool with correct
fit.
Assembling Single Wire Seal

– Release contact lock using assembly tool with correct fit -A-
and then pull wire with single wire seal toward rear -arrow- out
of contact housing.
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– Cut off the old contact with single wire seal from the vehicle-
es, in part or in w
specific wiring harness.
t to the co
rrectness of i
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nform
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c
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ate
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– Slide repair wire with new contact into corresponding chamber

p
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or
of contact housing until it engages.

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t.
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Cop py
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– Put single wire seal -A- onto free end of repair wire.
Note
AG. Volkswagen AG d
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When doing this, small diameter of single wire seal must by point
Vol not
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toward contact housing. rised ara
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– Slide single wire seal -A- onto repair wire up to the contact s
ce
le
housing.
un
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– Slide single wire seal -A- into contact housing until it stops
h re
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using the corresponding assembly tool -B-.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
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tion in
r
te o
thi
– Shorten the repair wire and the vehicle-specific wiring harness
s
iva
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single wire as needed using the Wiring Harness Repair Set -
r
rp
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Wire Strippers - VAS1978/3- .
fo
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t.
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– Crimp the stripped ends of repair wire and single wire of ve‐ t. Cop py
hicle-specific wiring harness using crimp pliers and a crimp
rig
gh ht
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connection as described in chapter “Wire break with single re‐ op Vo
by c lksw
pair point”. Refer to cted agen
Prote AG.
⇒ “2.4.5 Wire Break with Single Repair Point”, page 95 .
2.7.4 Contact Housings, Repairing Wire Ter‐

minals
Note
♦ For technical reasons, the contact housing for the wire termi‐
nals can be supplied only with the contacts pushed in.
♦ These contacts can be removed at every other contact hous‐
ing in the event they are not required.
♦ Repair wires which have already been equipped with corre‐
sponding contacts crimped on are available. Refer to Parts
Catalog.

AG. Volkswagen AG d
agen oes
olksw not
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2.8 Contact Housings, Releasing and Dis‐
ce
le
un
pt
an
d
assembling
itte
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ab
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⇒ “2.8.1 Releasing and Disassembly Contact Housings, General
ot p
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Information”, page 119
is n
h re
ole,
⇒ “2.8.2 Secondary Lock”, page 119
spec
⇒ “2.8.3 Primary Lock”, page 120 urposes, in part or in wh
t to the co
⇒ “2.8.4 Round Connector Systems”, page 121
rrectne
⇒ “2.8.5 Flat Connector Systems”, page 121
⇒ “2.8.6 Special Connector Systems”, page 123
ss o
2.8.1 Releasing and Disassembly Contact
cial p
f inform
Housings, General Information
mer
atio
om
n
c
i
or
n
Note
thi
te
sd
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♦ Observe general notes for repairs on the vehicle electrical
r
fo
en
ng
system. Refer to
t.
yi Co
op
⇒ “2.1 Vehicle Electrical System, General Repair Information”, C py
t. rig
page 79 . gh ht
pyri by
Vo
co lksw
by
♦ Always use the release tools intended for the releasing proc‐ Prote
cted AG.
agen
ess. Under no circumstances may terminals be pulled force‐
fully out of terminal housings.
♦ Damaged contact housings must always be replaced. New
contact housings may be ordered via OTC Kassel.
♦ Small screwdrivers may be used as an aid to release the sec‐
ondary locks.
♦ Chamber/pin assignment is located partially stamped in on
secondary lock or rear side of terminal housing.
♦ Detailed information on component locations of harness con‐
nectors. Refer to ⇒ Wiring diagrams, Troubleshooting & Com‐
ponent locations.
The allocation of the correct release tools to the respective locking

mechanisms can be found in the table in the Release Tool Set -
VAS1978/35- Operating Instructions.
2.8.2 Secondary Lock

The secondary lock is a housing securing mechanism (second
locking mechanism) that secures all wires in one contact housing.
If a secondary lock is installed at a contact housing, it must always
be opened or removed using specified tool before releasing and
pulling out individual crimp contacts.
Secondary lock is distinguished by a different color from the rest
of the contact housing. It simplifies recognizing the secondary
lock and clarifies its function.
The shapes of the terminal housings depicted here are only a
selection which, as an example, should make clear the various
functions of the secondary lock.

Example 1
Housing securing mechanism is released by removing a “comb”
-arrow-.
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olksw not
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Example 2 ss c
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nl
pt
Housing securing mechanism is released by opening a “flap”
du
an
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erm
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ility
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rrectness of i
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Example 3
nform
ercia
Housing securing mechanism can be released by disengaging a

“slider” -arrow-.
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
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pyri by
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co lksw
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Prote AG.
2.8.3 Primary Lock

The primary lock is the locking mechanism of an individual crimp
contact in the contact housing.
If necessary, housing securing mechanisms (secondary locks)
must be released or removed using specified tool before releasing
the contacts. Refer to ⇒ “2.8.2 Secondary Lock”, page 119 .
The shapes of the primary locks depicted in the following are only
a selection which, as an example, should make clear the various
functions of the primary lock.
♦ Round connector systems. Refer to
⇒ “2.8.4 Round Connector Systems”, page 121 .
♦ Flat connector systems. Refer to
⇒ “2.8.5 Flat Connector Systems”, page 121 .
♦ Special connector systems. Refer to
⇒ “2.8.6 Special Connector Systems”, page 123 .
The allocation of the correct release tool for the respective locks
can be found in the table in the Release Tool Set - VAS1978/35-
Operating Instructions.

2.8.4 Round Connector Systems
Note

– Guide the release tool which fits the contact housing into re‐
lease channel on contact housing.
– Grasp contact at wire and push it gently into contact housing
-arrow-.
Note
. Volkswage
By pushing the contact in the lksw
direction
agen
AG
of the contact
n AG d
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contact retaining tabs areby Volifted off the housing shoulder t gand
ua can
be released using othe
ris release tool.
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– At the same time,
push release tool in direction of contact
s
ce
le
housing -arrow- and pull the released contact out of contact

un
pt
an
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housing.
itte
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– After removing the contact, release tool can be pulled out of
ot
wit
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the contact housing again.

h re
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
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2.8.5 Flat Connector Systems

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must be released or removed using specified tool before releasing py by
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Prote AG.
Flat Connector System with One Retaining Tab

-arrow-.
Note
By pushing the contact in the direction of the contact housing, the

contact retaining tab is lifted off the housing shoulder and can be
released using the release tool.

– At the same time, push release tool in direction of contact

housing and pull the released contact out of contact housing
-arrow-.
Flat Connector System with Two Retaining Tabs

until it stops in direction of -arrow-.
Note n AG. Volkswagen AG do

lkswage es n
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By pushing the contact in the ir sedirection of the contact housing, the
d ran
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contact retaining tabs areuthlifted off the housing shoulder and can
o
or
be released using the srelease
s a
tool. ac
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un
pt
an
d
itte
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ab

pe
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in direction of -arrow-.
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Asymmetrical
m
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Note yri
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AG.
contact retaining tabs are lifted off the housing shoulder and can
be released using the release tool.


-arrow-.
2.8.6 Special Connector Systems
Note

Faston Contacts
– Grasp contact at wire and push it gently into contact housing.
Note

contact retaining tabs are lifted off the housing shoulder and can
be released using the release tool.
AG. Volkswagen AG d
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olksw not
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– At the same time, push release tool in direction of isedcontact ara
nte
housing and pull the released contact out of contact
ut
hor
housing eo
ra
-arrow-. ss a c
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t to the co
rrectness of i
GT 150/280 Contacts
l purpos
– Guide the release tool which fits the contact housing under
retaining tab into contact housing.
nform
ercia
– Push tool into contact housing until it stops -arrow-.

m
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tion in
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123
AG.
2. Wiring Harness and Connector Repairs
Contact is ejected from the contact housing.

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gen AG does
– After ejecting the contact, release tool can be pulled out ofVolkswa not
contact housing again. ed
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Contacts without Retaining Tabs
– Insert release tool under retaining tab of terminal housing.
rrectness of i
– Push release tool through until it stops by gently lifting
l purpos
-arrow-.
nform
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Contact is ejected from the contact housing
Co
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3 Contact Surface Cleaning Set -

VAS6410-
⇒ “3.1 Contact Surface Cleaning Set VAS6410 , Using”,
page 125
3.1 Contact Surface Cleaning Set -

VAS6410- , Using
⇒ “3.1.1 Wiring Eyelets, Repairing”, page 125olkswage es n
ot g
V
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⇒ “3.1.2 Threaded Connections, Repairing”,
rised page 127 ran
tee
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ut or
⇒ “3.1.3 Battery Terminal Clamp and
ss
a Battery Terminal, Cleaning”, ac
page 128
ce
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nl
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⇒ “3.1.4 Protecting”, page 130
itte
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3.1.1 Wiring Eyelets, Repairing
ility
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♦ Torque Wrench 1331 5-50Nm - VAG1331-
es, in part or in w
t to the co
Note
rrectness of i
♦ Do not use rust remover, contact spray or grease because the
l purpos
lack of friction will cause the torque to be exceeded when in‐

stalling and this will lead to the threaded connection breaking.
nf
ercia
♦ The gray sanding pads are for slight contamination and suit‐
orm
able for "soft surfaces". The red sanding pads are for heavy
m
atio
m
contamination and suitable for "hard surfaces".

o
n in
or c
thi
te
sd
iva
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WARNING
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t.
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Co
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pyri by
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Prote AG.
– Disconnect battery.
3. Contact Surface Cleaning Set VAS6410 125

– Loosen the cap nut and remove then Awiring

G. Volkeyelet from the
swagen A
threaded connection. olkswage G do
es n
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– Check the wiring eyelet
ris for corrosion, contamination, etc.
ed nte
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– Select the corresponding
ss
au adapter and the corresponding ra
c
sanding pad.
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pt
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Note
ility
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The sanding block can be used instead.
h re
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spec
es, in part or in w
t to the co
Caution
Make sure the tin layer is not worn down too much and the
rrectness of i
copper is not visible. A galvanic element can form from this,
destroying the metal and causing incorrect repairs.
l purpos
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mercia
Note
at
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ion
c
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r
Due to the different thicknesses of the tin layer, the cleaning proc‐
o
his
te
ess must be performed in several steps and a visual inspection

a
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of the wiring eyelet between steps is necessary.

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– Insert the adapter in the wiring eyelet and sand off the corro‐
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– Check the wiring eyelet and sand it again if necessary. Prote AG.

– If necessary, remove the burr on the wiring eyelet with the de‐
burring tool.
– Reinstall the wiring eyelet with the specified torque. Refer to
Note
G. Volkswagen
Optimal contact is ensured if the bolted
lksw
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are tightened
AG do
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to the specified torque afterdcleaning.
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– Apply protection material
to the connection. Refer to
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⇒ “3.1.4 Protecting”, page 130 .
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– Reconnect the battery.
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WARNING
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t to the co
– Reprogram the window regulators, enter the radio code, set
rrectness of i
the clock and, if necessary, code control modules that have
error messages.
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3.1.2 Threaded Connections, Repairing
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♦ Do not use rust remover, contact spray or grease because the Cop py
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lack of friction will cause the torque to be exceeded when in‐ gh ht
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stalling and this will lead to the threaded connection breaking. cop Vo
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♦ The gray sanding pads are for slight contamination and suit‐
able for "soft surfaces". The red sanding pads are for heavy
contamination and suitable for "hard surfaces".
WARNING

– Disconnect battery.

– Loosen the cap nut and remove the wiring eyelet from the
threaded connection.
– Check the threaded connection for corrosion, contamination,
etc.
– Select the corresponding adapter and the corresponding
sanding pad for the threaded connection.
Caution
Make sure the tin layer is not worn down too much and the
copper is not visible. A galvanic element can form from this,
destroying the metal and causing incorrect repairs.
Note
Due to the different thicknesses of the tin layer, the cleaning proc‐
ess must be performed in several steps and a visual inspection
of the wiring eyelet between steps is necessary.
– Place the adapter on the threaded connection and sand off the
corrosion and contaminants with circular movements.
– Check the threaded connection and sand it again if necessary.
– Retighten the connection and, if necessary, the anti-rotation
protection to the specified torque. Refer to ⇒ Wiring diagrams,
Troubleshooting & Component locations.
AG. Volkswagen AG d
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Optimal contact is ensured if the bolted
s aucomponents are tightened ra
c
to the specified torque after cleaning.
s
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– Apply protection material to the threaded connection. Refer to

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⇒ “3.1.4 Protecting”, page 130 .

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– Reconnect the battery.

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hole
spec
WARNING
es, in part or in w
t to the co

rrectness of i
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– Reprogram the window regulators, enter the radio code, set

the clock and, if necessary, code control modules that have
nform
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error messages.
m
at
om
3.1.3 Battery Terminal Clamp and Battery

on
c
in t
or
Terminal, Cleaning
his
ate
do
priv

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The Contact Surface Cleaning Set - VAS6410- makes optimal
ht
pyri by
repair quality possible in the realm of vehicle electronics. Using
o Vo
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the tools, service work can be performed in the area of the contact Prote AG.
sensor on the threaded connection wiring harnesses in the high
current circuit (starter and charging current). The Contact Surface
Cleaning Set - VAS6410- is adapted to the vehicle structural

measurements and ensures correct servicing and a comfortable

procedure.
Note
The illustrations of the service work only serve as examples.
Contact Surface Cleaning Set VAS6410
Note
Do not use rust remover, contact spray or grease because the

lack of friction will cause the torque to be exceeded when instal‐
ling and this will lead to the threaded connection breaking.
WARNING
AG. Volkswagen AG d
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Risk of injury.risFollow
ed all Warnings and Safety Precautions. ara
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Refer to ⇒ “1.3
ut
ho Warnings and Safety Precautions”, page 3e o.r
s a ac
s
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un
– Disconnect battery. pt
an
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itte
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– Check the battery terminal and the battery pole for corrosion ab
ility
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or dirt. wit
is n
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ole,
– The battery terminal clamp is cleaned with the battery terminal

spec
cleaner wire brush using circular motions.

t to the co
rrectness o
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f inform
mer
atio
om
n
c
i
or
n thi
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sd
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– The battery terminal is cleaned with the bottom side of the ter‐
i
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pr
cum
minal cleaner using circular motions.

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WARNING
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Prote AG.
– Reconnect the battery and tighten the terminals to the speci‐

fied torque.
Note
Optimal contact is ensured if the bolted components are tightened

to the specified torque after cleaning.

3.1.4 Protecting
Caution
Missing protection leads to the electrical system damage.
Note
swage es n
♦ All threaded connections must be tightened to thebspecified
yV
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torque. ir se
d ran
tee
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or
♦ When applying protection, always use the saccompanying
s au hose ac
on the protection container.
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un
pt
♦ Protection wax is used in the cool area.
an
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♦ Cavity protection wax is used in the warm area.
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♦ The protection material draws itself into the affected places by
is n
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capillary action.
ole,
spec
– Hold the injector under the wiring eyelet and spray all around
t to the co
the pins.
rrectness o
cial p
f inform
mer
atio
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n
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pr
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– Hold the injector above the wiring eyelet and spray all around
t.
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op
the pins and wiring eyelet. C py
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pyri by
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Prote AG.

4 Heated Oxygen Sensor, Replacing

⇒ “4.1 4-Pin Heated Oxygen Sensor (HO2S), Removing and In‐
stalling”, page 131
⇒ “4.2 6-Pin Universal Oxygen Sensor, Removing and Installing”,
page 132 AG. Volkswagen AG d
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⇒ “4.3 Oxygen Sensor Unit Protective Pipes”, page 132 d by V gu
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4.1 4-Pin Heated Oxygen Sensor (HO2S), tho eo
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Removing and Installing
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Note
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♦ Do not repair the heated oxygen sensor wires. Repairing may , is n
h re
hole
result in malfunctions.
spec
es, in part or in w
♦ Use the faulty sensor as a guide for installing all of the ac‐
t to the co
companying attachments, cable ties or marking bands.
♦ If necessary, identify the heated oxygen sensor (HO2S) using
rrectness of i
the protective tube. Refer to
⇒ “4.3 Oxygen Sensor Unit Protective Pipes”, page 132 .
l purpos
– Remove the faulty oxygen sensor.
nform
ercia
– Lay both of the oxygen sensor next to each other so the sensor
m
a
housings are the same level.
com
tion in
r
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s
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fo
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t.
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Cop py
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gh ht
pyri by
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co lksw
by
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Prote AG.
– Tie the excess length of the sensor (approximately 50 to 250

mm) back so it is the same length as the faulty sensor and
secure it with cable ties -1-.
– Check if the oxygen sensor connector housing is compatible
with the vehicle electrical system side.
– If necessary, replace the vehicle electrical system connector
with the provided oxygen sensor connector housing. Refer to
⇒ “2.7 Contact Housings and Connectors, Repairing”,
page 115 .
Note
♦ Only replace the connector housing on older vehicles. The

connector housing is correct on new vehicles.
♦ Check the pin assignment. The pins in the new connector
housing are color coded.
♦ The packaging for the new heated oxygen sensor contains
additional information.
– Install the new oxygen sensor in the vehicle.
4. Heated Oxygen Sensor, Replacing 131

4.2 6-Pin Universal Oxygen Sensor, Re‐

moving and Installing
Note
♦ Use the faulty sensor as a guide for installing all of the ac‐
companying attachments, cable ties or marking bands.
♦ Do not crimp or cut the wires otherwise the functionality of the
heated oxygen sensor (HO2S) will be diminished.
– Remove the old heated oxygen sensor (HO2S).

– Lay both of the oxygen sensor next to each other so the sensor
housings are the same level. Volkswa AG. gen AG
agen does
olksw not
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– Tie the excess length of the sensor (approximately 50 to 250
t to the co
mm) back so it is the same length as the faulty sensor and
secure it with cable ties -1-.
rrectness of i
– Install the new oxygen sensor in the vehicle.
l purpos
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4.3 Oxygen Sensor Unit Protective Pipes

t.
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Note
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In addition to using the part number, the protective pipe can also
be used for identification.
Version D1, 6 openings, 3.5 mm each

Only used with the 4-pin oxygen sensor

Version D2, 6 openings, 2 mm each
AG. Volkswagen AG d
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Used with 4-pin and 6-pin universal oxygen sensors.
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Version D4, 12 openings, 1.4 mm each
h re
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spec
es, in part or in w
t to the co
rrectness of i
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Used with 4-pin and 6-pin universal oxygen sensors. n in
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4. Heated Oxygen Sensor, Replacing 133

5 Special Tools
wage
♦ Crimping Pliers, Complete - VAS1978/1A- olks es n
ot g
byV ua
ed ran
♦ Exchangeable Head, 0.35mm² - 2.5mm² - VAS1978/1-1-
horis tee
ut or
a ac
ss
ce
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un
pt
an
d
itte
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pe
ility
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, is n
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spec
es, in part or in w
t to the co
rrectness of i
♦ Diagnostic Cable - VAS5051/5A- (3 m) (10 ft.)
l purpos
♦ Diagnostic Cable - VAS5051/6A- (5 m) (16 ft.)
nform
mercia
a
com
tion in
r
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thi
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do
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Cop py
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♦ Fiber Optic Pliers Repair Set - VAS6223A-

Bora 1999 ➤ , wBora
agen Variant 1999A➤
AG. Volkswagen G d, CC 2010 ➤ , CC 2012 ➤ , Eos 2006 ...
oes
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by
Vol Electrical Equipment General
not
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ara
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♦ Air Hose Pliers - VAS6228-
au
th e or
ac
ss
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un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
♦ Repair Set, Aerial Cable - VAS6720-
ss o
cial p
f inform
mer
atio
m
Edition: K0059101321 - FU - 5/8/2014 – JLH

o
n
c
i
or
n thi
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sd
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cum
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t.
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Cop py
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Prote AG.
5. Special Tools 135

6 Revision History
Re Dat Job Type Feedback # Notes Editor
vi‐ e
sio
n
4 5/8/ Factory Up‐ Jim

201 date Harder
5
3 10/ Factory Up‐ Tom
20/ date Perry
201
4
AG. Volkswagen AG d
2 08/ Factory Up‐ l
Yam‐
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not
14/ date by
V brick
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201 orised
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4 aut
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1 6/1 Factory Up‐ s
Yam‐
ce
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1/2 date CO brick

un
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an
d
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itte
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Cautions & Warnings
Please read these WARNINGS and CAUTIONS before proceeding with maintenance
and repair work. You must answer that you have read and you understand these
WARNINGS and CAUTIONS before you will be allowed to view this information.
•= If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this manual, we
suggest you leave such repairs to an authorized Volkswagen retailer or other qualified shop. We especially urge
. Volkswagen AG
you to consult an authorized w gen AG
aVolkswagen retailer dbefore
oes beginning repairs on any vehicle that may still be covered
olks not
wholly or in part by any
db
y Vof the extensive warranties issuedgua by Volkswagen.
e ran
ris tee
tho or
•= Disconnect negative terminal (ground strap) thea battery
u whenever
you work on the fuel system or the electrical ac
ss
system. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.
ce
le
un
pt
an
d
itte
y li
•= Volkswagen is constantly improving its vehicles and sometimes these changes, both in parts and specifications,
rm
ab
are made applicable to earlier models. Therefore, part numbers listed in this manual are for reference only. Always
pe
ility
ot
check with your authorized Volkswagen retailer parts department for the latest information.
wit
, is n
h re
hole
spec
•= Any time the battery has been disconnected on an automatic transmission vehicle, it will be necessary to
es, in part or in w
reestablish Transmission Control Module (TCM) basic settings using the VAG 1551 Scan Tool (ST).
t to the co
•= Never work under a lifted vehicle unless it is solidly supported on stands designed for the purpose. Do not support
a vehicle on cinder blocks, hollow tiles or other props that may crumble under continuous load. Never work under a
rrectness of i
vehicle that is supported solely by a jack. Never work under the vehicle while the engine is running.
l purpos
•= For vehicles equipped with an anti-theft radio, be sure of the correct radio activation code before disconnecting the
nform
ercia
battery or removing the radio. If the wrong code is entered when the power is restored, the radio may lock up and
become inoperable, even if the correct code is used in a later attempt.
m
a
com
tion in
•= If you are going to work under a vehicle on the ground, make sure that the ground is level. Block the wheels to
r
te o
thi
keep the vehicle from rolling. Disconnect the battery negative terminal (ground strap) to prevent others from
s
iva
do
starting the vehicle while you are under it.

r
rp
cum
fo
en
ng
t.
yi
•= Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to yourself and
Co
Cop py
others if you are tired, upset or have taken medicine or any other substances that may impair you or keep you from
t. rig
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being fully alert. cop
by
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Prote AG.
•= Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.
•= Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid. Wear
goggles, gloves and other protective clothing whenever the job requires working with harmful substances.
•= Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near
machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery, severe
injury could result.
•= Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used
only once and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts,
washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners with
new parts where indicated, and any other time it is deemed necessary by inspection.
Page 1 of 3
© 2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0
Cautions & Warnings
•= Illuminate the work area adequately but safely. Use a portable safety light for working inside or under the vehicle.
Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled
fuel or oil.
•= Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not create dust by
grinding, sanding, or by cleaning with compressed air. Avoid breathing asbestos fibers and asbestos dust.
Breathing asbestos can cause serious diseases such as asbestosis or cancer, and may result in death.
•= Finger rings should be removed so that they cannot cause electrical shorts, get caught in running machinery, or be
crushed by heavy parts. G. Volkswage
A n AG d
agen oes
olksw not
V
•= Before starting a job, make d bcertain that you have all the necessary
y gu
ara tools and parts on hand. Read all the
instructions thoroughly; rise not attempt shortcuts. Use tools that are
do nte
appropriate to the work and use only
tho eo
au
replacement parts meeting Volkswagen specifications. Makeshift tools,r a parts and procedures will not make good
ss c
repairs.
ce
e
nl
pt
du
an
itte
y li
•= Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or beverage containers that
erm
ab
might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills at
ility
ot p
once, but do not store the oily rags, which can ignite and burn spontaneously.
wit
, is n
h re
hole
spec
•= Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten
es, in part or in w
fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque
t to the co
listed.
•=
rrectness of i
Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping hydrogen gas is
ignited, it will ignite gas trapped in the cells and cause the battery to explode.
l purpos
•= Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of nform
ercia
the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local ordinances that
govern the disposal of wastes.
m
at
om
ion
c
•=
in t
The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C system should be
or
his
e
serviced only by trained automotive service technicians using approved refrigerant recovery/recycling equipment,
at
do
riv
trained in related safety precautions, and familiar with regulations governing the discharging and disposal of
p
cum
or
automotive chemical refrigerants.

f
en
ng
t.
yi Co
Cop py
•=
t.
Before doing any electrical welding on vehicles equipped with anti-lock brakes (ABS), disconnect the battery
rig
gh ht
yri by
negative terminal (ground strap) and the ABS control module connector. cop Vo
by lksw
cted agen
Prote AG.
•= Do not expose any part of the A/C system to high temperatures such as open flame. Excessive heat will increase
system pressure and may cause the system to burst.
•= When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the Transmission
Control Module (TCM), the ABS control module, and the trip computer. In cases where one or more of these
components is not separately fused, disconnect the control module connector(s).
•= Some of the vehicles covered by this manual are equipped with a supplemental restraint system (SRS), that
automatically deploys an airbag in the event of a frontal impact. The airbag is operated by an explosive device.
Handled improperly or without adequate safeguards, it can be accidentally activated and cause serious personal
injury. To guard against personal injury or airbag system failure, only trained Volkswagen Service technicians
should test, disassemble or service the airbag system.
Page 2 of 3
Version 1.0
Cautions & Warnings
•= Do not quick-charge the battery (for boost starting) for longer than one minute, and do not exceed 16.5 volts at the
battery with the boosting cables attached. Wait at least one minute before boosting the battery a second time.
•= Never use a test light to conduct electrical tests of the airbag system. The system must only be tested by trained
Volkswagen Service technicians using the VAG 1551 Scan Tool (ST) or an approved equivalent. The airbag unit
must never be electrically tested while it is not installed in the vehicle.
•= Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that may have been
inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of ignition away from the tire repair
area. Inflate and deflate the tire at least four times before breaking the bead from the rim. Completely remove the
tire from the rim before attempting any repair.
•= When driving or riding in an airbag-equipped vehicle, never hold test equipment in your hands or lap while the
vehicle is in motion. Objects between
agen
you
AG. Voland
kswagthe
en Aairbag
G do can increase the risk of injury in an accident.
w es n
olks ot g
byV ua
ed ran
ris tee
ho
I have
au
t
read and I understand these Cautions or
ac and Warnings.
ss
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le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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thi
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Page 3 of 3
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Repair Manual olkswagen AG

Golf 2009 ➤ , Golf 2013 ➤ ,

Golf Plus 2005 ➤ , Golf Plus 2009 ➤ ,

Passat (NMS - US) 2012 ➤ ,

Passat Variant 1997 ➤ ,

Passat Variant 2011 ➤ ,

Passat Variant 2015 ➤ , Phaeton 2003 ➤ ,

Polo 1995 ➤ , Polo 2002 ➤ ,

Polo 2010 ➤ , Polo 2014 ➤ ,

Polo KH IN 2010 ➤ , Polo KH IN 2015 ➤ ,

Service Department. Technical Information

Touareg 2003 ➤ , Touareg 2010 ➤ ,

Service Department. Technical Information

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

because their careful and constant adherence to the instructions is essential to

precautions for working on motor vehicles must, as a matter of course, be

Copyright © 2015 Volkswagen AG, Wolfsburg D3E800230E1

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Copyright © 2015 Volkswagen AG, Wolfsburg D3E800230E1

2.2 Batteries, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.4 Visual Display in Battery Cover, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.1 Battery Charger VAS5095A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

94 - Exterior Lights, Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

96 - Interior Lights, Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

1 Vehicle Diagnosis, Testing and Information Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

27 – Battery, Starter, Generator, Cruise Control

acts as a power reserve for the entire vehicle electrical system.

1.2 Types of Batteries

teries. Do not remove any of the labels on the battery and do

1.2.1 Battery with Visual Indicator, Standard

Do not check or charge batteries that have a visual indicator

distilled water. Only perform a visual inspection. Note the chap‐

⇒ “2 Battery, Checking”, page 6 .

that is bright yellow. Jump starting must not be used!

There is a risk of explosion during testing, charging or jump

These batteries must be replaced.

The battery is installed in certain Stop/Start vehicles due to spe‐

cial requirements. “EFB” is written on the battery cover to identify

An “EFB” battery has a visual indicator for checking the battery

“EFB” batteries are being installed in smaller gasoline engines

2 Rep. Gr.27 - Battery, Starter, Generator, Cruise Control

1.2.3 AGM Battery

Always replace an AGM battery with another AGM battery.

1.3 Warnings and Safety Precautions

1.3.1 Battery Safety Precautions

♦ Personnel instructed in protection, such as a trainee or

1. - When working in the area of batteries, fire, sparks, open flame

bles and electrical devices, and from electrostatic discharge.

2. - Wear protective eyewear when working on the battery.

3. - Always keep acid and batteries out of the reach of children.

4. - Disposal: old batteries require special disposal. They may

consideration of legal regulations.

5. - Do not dispose of old batteries in household waste.

charging produces a highly explosive gas mixture.

7. - Always observe notes on battery in ELSA "Electrical Equip‐

ment - General Information" and in the Owner's Manual.

8. - Danger of burns: battery acid is severely corrosive, therefore

protective gloves and eyewear must be worn when working on

4 Rep. Gr.27 - Battery, Starter, Generator, Cruise Control

1.3.3 Working on Airbag System

When working on the airbag system (pyrotechnic components,

♦ There must be no one inside the vehicle when connecting

deployment and belt tensioner zones.