Service: Service Department. Technical Information

Service
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Service Department. Technical Information

Service
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Electrical system - general information

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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
27 - Starter, current supply, CCS
90 - Gauges, instruments
92 - Windscreen wash/wipe system
94 - Lights, bulbs, switches - exterior
96 - Lights, bulbs, switches - interior
97 - Wiring
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Technical information should always be available to the foremen and mechanics,

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Copyright © 2019 Volkswagen AG, Wolfsburg K0059101320

Service
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All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2019 Volkswagen AG, Wolfsburg K0059101320

Ameo 2017 ➤ , Arteon 2018 ➤ , Atlas 2017 ➤ , Bora 1999 ➤ , Bora Varian ...
Electrical system - general information - Edition 08.2019
Contents
27 - Starter, current supply, CCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Fundamentals for batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Types of batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Warning notices and safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Battery terminal connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Checking battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Checking the various types of batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Information about battery replacement and battery gas venting . . . . . . . . . . . . . . . . . . . . 8
2.4 Checking colour indicator in battery cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5 Battery tester with printer VAS 6161 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.6 Midtronics MCR340V battery. tester only for USA/Canada vehicles . . . . . . . . . . . . . . . . . . 16
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2.7 Current draw test ol.ks.w.a.ge. . . . . . . . . . . . . . d.o.es. n.o. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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3 Charging theisebattery
db . . . . . . . . . . . . . . . . . . . . . . .ar.an.t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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3.1 Battery charger
ho VAS 5095 A . . . . . . . . . . . . . . . . . . . e. o.r a. . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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3.2 Batterysscharger VAS 5900 . . . . . . . . . . . . . . . . . . . . . . . .c . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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3.3 Battery charger VAS 5900 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
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3.4 Battery charger VAS 5903 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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3.7 Midtronics INC 940 battery charger only for USA/Canada . . . . . . . . . . . . . . . . . . . . . . . . . . 72
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3.8 Solar charger module VAS 6102B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
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3.9 Totally discharged batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

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4 Cruise control system (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.1 Activating and deactivating cruise control system (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . . 79
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90 - Gauges, instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
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92 - Windscreen wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

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1 Washer fluid line hose couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

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1.1 Windscreen and rear window washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

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1.2 Headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

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2 Hose repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
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2.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

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2.2 Repairing smooth pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

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2.3 Repairing corrugated pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
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3 Distinguishing features of jointless wiper blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
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94 - Lights, bulbs, switches - exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1 Operation and safety notes for gas discharge lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
96 - Lights, bulbs, switches - interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

1 12 V socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.1 Removing and installing 12 V socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.2 Removing and installing socket illumination bulb L42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2 Cigarette lighter U1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.2 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2.3 Removing and installing cigarette lighter socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.4 Removing and installing cigarette lighter illumination bulb L28 . . . . . . . . . . . . . . . . . . . . . . 94
Contents i
97 - Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1 Vehicle diagnosis, testing and information systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.1 Connecting vehicle diagnostic tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.2 Connecting vehicle diagnostic tester Golf Model Year 1998 - 2003 . . . . . . . . . . . . . . . . . . 98
2 Repairs to wiring harnesses and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2.1 General notes concerning repairs to vehicle electrical system . . . . . . . . . . . . . . . . . . . . . . 99
2.2 Wiring harness repair set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
2.3 Tool descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
2.4 Repairs to wiring harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
2.5 Repairs to fibre optic cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
2.6 Repair of aerial wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
2.7 Repairs to contact housings and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
2.8 Releasing and dismantling contact housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
3 Contact surface cleaning set VAS 6410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
3.1 Using contact surface cleaning set VAS 6410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
4 Renewing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
4.1 Renewing LSF Lambda probe (4-pin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
4.2 Renewing LSU Lambda probe (6-pin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
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4.3 Types of protective tube on uniform Lambda probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
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ii Contents
27 – Starter, current supply, CCS AG. Volkswagen AG d

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Danger of injury! Observe warning notices and safety regula‐
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Caution
To prevent damage to the battery or vehicle, read the informa‐
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tion about the types of battery ⇒ page 1 .
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On vehicles with high-voltage battery, a voltage test of the 12 V
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electrical system must be performed after the 12 V battery is dis‐
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connected. If voltage is detected, the high-voltage system must
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1.1 Fundamentals for batteries
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To ensure long use of the battery, the battery must be checked,
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serviced and maintained according to the specifications in this
AG.
manual.
Apart from supplying energy for starting the engine, the battery
has other tasks: it acts as a buffer and supplies electrical energy
to the complete electrical on-board supply of the vehicle.
1.2 Types of batteries

General information
Caution
The description for the following batteries is for maintenance-

free batteries. No stickers may be removed and do not replen‐
ish with distilled water. Only perform a visual check. Refer to
chapter, Checking battery ⇒ page 6 .
1. Battery 1
1.2.1 Battery with »standard« colour indicator

This is a maintenance-free battery with liquid electrolyte (wet bat‐
tery).
WARNING
It is not permissible to test or charge batteries whose colour

indicator is light yellow. Do not slave/jump start the vehicle!
Danger of explosion when checking and charging or slave/
jump starting.
These batteries must be renewed.
AG. Volkswagen A
This battery is equipped with aolkcolour
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⇒ page 9 au
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1.2.2 Battery with »enhanced« colour indica‐
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This is a maintenance-free battery with liquid electrolyte (wet bat‐
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Caution
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No stickers may be removed and do not replenish with distilled
water. Only perform a visual check. Refer to chapter, Checking
rrectness of i
battery ⇒ page 6 .
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WARNING
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The battery is used for particular requirements in certain vehicles
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equipped with a start/stop system. The battery can be identified
AG.
by the lettering “EFB” on the battery cover. “EFB” stands for »en‐
hanced flooded battery«.
An “EFB” battery may only be replaced with another “EFB” bat‐
tery.
The “EFB” battery has a colour indicator to enable the electrolyte
level to be checked.
Checking the colour indicator ⇒ page 9
Note
“EFB” batteries are used in the smaller petrol engines with start/
stop system and manual gearbox as of 05.2011.
2 Rep. gr.27 - Starter, current supply, CCS

1.2.3 Absorbent glass mat battery

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

absorbent glass mat battery.
♦ If the battery is renewed, the battery monitor control unit -
J367- must be adapted.
satelettronica
– Connect vehicle diagnostic tester .
– Adapt battery monitor control unit - J367- ⇒ Vehicle diagnostic
tester.
1.3 Warning notices and safety regulations

⇒ “1.3.1 Dangers when handling vehicle batteries”, page 3
⇒ “1.3.2 Safety markings on battery”, page 4
⇒ “1.3.3 Working on airbag system”, page 5
1.3.1 Dangers when handling vehicle batter‐

ies
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Batteries can be dangerous. These dangers can be avoided horiswhen nte
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1. Battery
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♦ Untrained personnel aue.g. apprentices and trainees, may
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only work on batteries when supervised by a trained spe‐
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♦ Acid is highly corrosive. There is a considerable danger of
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acid burns if personnel do not handle batteries correctly.
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burns. A suitable solution is: e.g. a soap solution.
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♦ If electrolyte leaks from a battery it may cause skin burns
or acid corrosion and rusting on the vehicle. This may
damage safety relevant components on the vehicle.
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♦ The gas which forms when charging and the gas which
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may escape through vent valves is explosive. In extreme

cases a battery may explode if the battery is not handled
correctly.
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♦ Batteries whose magic eye shows light yellow must be re‐

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placed. They must not be checked or charged and do not
io
satelettronica
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slave/jump start. Danger of explosion when checking and
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te o
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charging or slave/jump starting.
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♦ It is prohibited to cause sparks through grinding, welding,
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cutting operations and use naked lights in the vicinity of

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batteries. Smoking is also prohibited. Sparks generated Cop py
by electrostatic charging must also be avoided. Always
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touch the vehicle body before touching the battery.
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♦ Only work on batteries in well ventilated and suitable
Prote AG.
rooms.
1.3.2 Safety markings on battery

Safety markings on battery
1. - Fires, sparks, naked flames and smoking are prohibited when
handling batteries. Avoid sparks as well as electrostatic discharge
when working with cables and electrical units. Avoid short circuits.
Therefore never lay a tool on a battery.
2. - Wear eye protection before commencing work on battery.
3. - Keep children away from acid and batteries.
4. - Disposal: old batteries are classed as hazardous waste. They
may only be disposed of through a suitable collection centre and
only in accordance with respective legislation.
5. - Never dispose of old batteries in household waste system!
6. - There is a danger of an explosion when working with batteries.
A highly explosive gas is produced when batteries are charged.
7. - Always follow instructions on battery, in ELSA "Electrical Sys‐
tem, General Information" and in owner's manual.
8. - Battery acid is very caustic; therefore wear eye protection and
gloves when working with batteries. Do not tilt battery. Acid can
leak out of the gas vents of some batteries.

1.3.3 Working on airbag system
WARNING
When work is performed on the airbag system (pyrotechnical

components, airbag control unit - J234- , wiring) the battery
earth strap must be disconnected with the ignition switched on.
Exception: in vehicles with a battery in the vehicle interior, the
ignition must be switched off.
♦ Then, cover the negative terminal.
♦ A waiting time of 10 seconds is necessary after discon‐
necting the battery. . Volkswage AG n AG d
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♦ Battery must be connected with ignition
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switched
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♦ No persons may be in the interior rwhen
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connected. s au ra
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Ensure, in this case, that you are not within the effective range
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of the airbag and the belt tensioner.
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If when reconnecting the battery and the ignition was not in the
satelettronica
ility
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on position - warning lights in dash panel will not light up - the
wit
ignition may only be switched on (key/button) from the driver's
, is n
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seat with the seat set in the rearmost position.
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spec
es, in part or in w
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Note
rrectness of i
On vehicles with high-voltage battery, a voltage test of the 12 V
l purpos
electrical system must be performed after the 12 V battery is dis‐

connected. If voltage is detected, the high-voltage system must
nform
be de-energised.
mercia
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1.4 Battery terminal connection ion

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WARNING
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tions ⇒ page 3 ! t. C rig
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Caution
To prevent damage to the battery terminal clamps and battery

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

tions ⇒ page 3 !
Caution

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

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

tions ⇒ page 3 ! agen
AG. Volkswagen AG d
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Carry out procedure in sequence as follows: tho or
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1. Visual check ⇒ page 7 ss
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2. Check the colour indicator, “3-colour”, ⇒ page 9 or “2-

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colour”, ⇒ page 10
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WARNING
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3. Battery test with battery tester with printer - VAS 6161-

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

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draw test” ⇒ page 20 .

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2.1.2 Absorbent glass mat battery

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Carry out procedure in sequence as follows: Cop
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1. Visual check ⇒ page 7 opyri
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2. Battery check using battery tester with printer - VAS 6161- Prote
cted agen
⇒ page 11
AG.

Ameo 2017 ➤ , Arteon 2018 ➤ , Atlas 2017 ➤ , Bora. V1999 ➤ , Bora Varian ...
n AG olkswagen AG do
Electrical system - general
olkswageinformation - Editiones08.2019
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3. Depending on the result of the battery test, “performhocurrent
ris nte
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draw test” ⇒ page 20 . au
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2.2 Visual check
le
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tions ⇒ page 3 !
spec
es, in part or in w
t to the co
It is essential first to visually check the external condition, the ter‐
minals of the battery, the plugs of the gas vent openings and that
rrectness of i
the battery is seated securely before performing more extensive
tests.
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Note
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Observe the chapter "Battery" for the respective vehicle ⇒ Main‐
ion in
tenance ; Booklet .
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♦ The battery will be damaged if the battery is not secured
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correctly.
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♦ Vibrations shorten the life of the battery, there is a danger
Prote AG.
of an explosion, the cell plates may be damaged and the

clamping bracket may damage the battery housing.
♦ Check battery is securely seated, if necessary tighten se‐
curing bolt to specified torque.
Performing this test establishes:

♦ If battery housing is damaged Electrolyte can leak out if the
housing is damaged. If battery acid leaks out, serious damage
to the vehicle could be caused. Treat components affected by
leaked battery acid immediately with acid neutraliser or a soap
solution.
♦ Check whether the battery terminals (battery wire connec‐
tions) are damaged. The necessary contact on the battery
terminal clamps cannot be guaranteed if the battery terminals
are damaged. When connecting the battery clamps, tighten
the battery clamps to torque specified in this workshop manual
“Electrical system” for the respective vehicle. If the battery ter‐
minal clamps are not correctly seated and tightened, the wiring
may burn. Which will cause malfunctions in the electrical sys‐
tem. Therefore it can no longer be guaranteed that the vehicle
will function correctly.
♦ Whether the gas vent hose and the plug are fitted correctly.
On vehicles with batteries in the passenger compartment or
luggage compartment, it is essential to ensure that the gas
vent hose is fitted correctly. Make sure that there are no ex‐
posed gas vent openings in the area of the positive battery
terminal. If a gas vent opening is exposed in this area, it must
be sealed with a plug. The gas vent hose must be connected
in the area of the negative battery terminal to the exposed gas
vent opening. Observe chapter
⇒ “2.3 Information about battery replacement and battery gas
venting”, page 8
2. Checking battery 7
2.3 Information about battery replacement

and battery gas venting
♦ For safety reasons, it is important to determine which side of
the battery gas is vented from.
♦ For areas of application in which a gas vent hose is used, en‐
sure that the gas vent hose is seated securely and that the gas
vent opening on the opposite side is sealed.
♦ When renewing the vehicle battery, make absolutely sure that
the gas vent opening in the area of the positive battery terminal
is not exposed. Should a vent opening be exposed in this area,
it must be sealed with a plug and the vent in the area of the
negative battery terminal must be opened.
♦ If the vehicle is installed with an AGM battery outside the en‐
gine compartment, ensure that the battery is replaced with a
different AGM battery.
♦ If the AGM battery is renewed, the battery monitor control unit
- J367- must be adapted.
♦ Connect vehicle diagnostic tester .
satelettronica
♦ Adapt battery monitor control unit - J367- ⇒ Vehicle diagnostic
tester.
♦ For launch of the Passat 3C (2006), the gas vent opening is
always on the negative battery terminal side.
♦ If there is a protective cap with sprayed on plug on the battery
positive terminal of the replacement AGpart
. Volksbattery
wagen AG
agen does
000.915.105.DX, with theVoexception
lksw of 000.915.105.DN not and
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all Economy batteriesedwith by single index, this must also be uaran
changed on the negative
ho
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battery terminal or positive battery tee o
aut
terminal side according to the situation. A list of batteries can r ac
ss
be found here ⇒ page 8 .
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♦ All AGM, EFB+, EFB batteries and the 36AH battery with orig‐
an
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inal part no.: 000.915.105.DN, installed e.g. in the up! and

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ab
Polo, have a protective cap without sprayed on plug on the

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positive battery terminal. The gas vent on the positive battery

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terminal side is already sealed here.

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spec
If a genuine replacement part battery is discovered with the fol‐

es, in part or in w
lowing part numbers, a red sealing plug must be fitted either on

t to the co
the positive or negative battery terminal side. If this is not installed,

it must be retrofitted - genuine part no.: 000.915.506
rrectness of i
List of batteries with protective cap and sprayed on plug

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OES wet:
♦ “36 Ah” 000.915.105.DA
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♦ “44 Ah” 000.915.105.DB

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♦ “51 Ah” 000.915.105.DC

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♦ “60 Ah” 000.915.105.DD

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♦ “61 Ah” 000.915.105.DE

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♦ “72 Ah” 000.915.105.DG
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♦ “80 Ah” 000.915.105.DH
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♦ “85 Ah” 000.915.105.DJ cted agen
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♦ “95 Ah” 000.915.105.DK

♦ “110 Ah” 000.915.105.DL
♦ “36 Ah” 000.915.105.DN

Economy batteries:
♦ “61 Ah” JZW.915.105.
♦ “72 Ah” JZW.915.105.A
♦ “85 Ah” JZW.915.105.B
♦ “44 Ah” JZW.915.105.C
♦ “36 Ah” JZW.915.105.D
♦ “95 Ah” JZW.915.105.E
♦ “80 Ah” JZW.915.105.F
2.4 Checking colour indicator in battery cov‐

er
2.4.1 Checking colour indicator, “3-colour”
WARNING
satelettronica
tions ⇒ page 3 !
General information about colour indicator:

Applies for all batteries with “1J0”, “7N0” and “3B0” indexes in
original equipment and gefor all
n AG. Vreplacement
olkswagen AG
dobatteries 191 915 105
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AB and from “000y Volk915 105 AX” index. ot g
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The colour ho indicator provides you with information about
ris nte
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ut
trolytes alevel and charge state of the battery. ra
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Before carrying out a visual check, tap the inspection window

un
pt
lightly and carefully using the handle of a screwdriver. The air

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bubbles, which can influence the display, will dissipate when do‐
erm
ab
ing this. This will make the colour indicator reading more accurate.
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Note
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♦ Air bubbles can form under the sight glass, particularly when
a battery has been recharged, i.e. also when the battery has
been charged during normal vehicle operation. These falsify
rrectne
the reading of the colour indicator.

♦ Since the colour indicator is only located in one battery cell,
ss
the indicator also only applies to this battery cell. Determining

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the exact condition of the battery is possible only by means of

inform
a battery test ⇒ page 11 .

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♦ The colour indicator can be located at various positions on the

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battery.
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Three different colour displays are possible:

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♦ »Green«, battery is charged sufficiently.

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♦ »Black«, battery partly discharged, charge state < 65 % or
ht. rig
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♦ »Colourless or light yellow«, battery must be renewed.
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WARNING

jump starting.
2.4.2 Checking colour indicator, “2-colour”

WARNINGolkswage es n
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ise
Danger of injury!
tho
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or
tions ⇒ page
s au 3 ! ac
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General information about colour indicator:
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The general introduction of the “2-colour” display took place grad‐
ot p
satelettronica
ually in 2009. The “2-colour” indicator does not include the colour
wit
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»green« for indicating the charge level.
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The colour indicator provides you with information on the elec‐ spec
es, in part or in w
t to the co
trolyte level of the battery.
The battery's charge state can no longer be read off via the colour
indicator. The battery test has to be used for this purpose,
rrectness of i
⇒ page 11
l purpos
Before carrying out a visual check, tap the magic eye lightly and
carefully using the handle of a screwdriver. The air bubbles, which
can influence the display, will dissipate when doing this. The col‐
nf
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our display of the magic eye will therefore be more accurate.

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♦ Air bubbles can form under the sight glass, particularly when
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a battery has been recharged, i.e. also when the battery has
t.
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been charged during normal vehicle operation. These falsify
Cop py
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the reading of the colour indicator.
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♦ Since the colour indicator is only located in one battery cell,
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the indicator also only applies to this battery cell. Determining
AG.
the exact condition of the battery is only possible by means of

a battery test ⇒ page 11 .
♦ The colour indicator can be located at various positions on the
battery.
Three different colour displays are possible:

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

WARNING

jump starting.
2.5 Battery tester with printer - VAS 6161-

General description:
WARNING

tions ⇒ page 3 !
It is not necessary to remove or disconnect battery when using
satelettronica
battery tester with printer - VAS 6161- .
The battery tester with printer - VAS 6161- does not load the bat‐
tery any more. It works on the principle of dynamic conductance
acquisition.
Every battery type is stored in the tester.
Data can be stored on an SD card.
The battery tester with printer - VAS 6161- can be updated via an
interface or an SD card, so that batteryagdata
en AGfrom
. VolksVolkswagen
wagen AG
does are
always up to date. yV
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The integrated temperature rissensor improves measurement qual‐ tee
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A 2D scanner is available as an option to read data directly from
ce
le
un
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the battery's 2D code.

an
d
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Note
wit
is n
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Observe the ⇒ operating manual of the battery tester with printer

spec
- VAS 6161- .
t to the co
rrectness o
cial p
f inform
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Cop py
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2.5.1 Description of battery tester with printer

- VAS 6161-
1 - Integrated printer
2 - Operating lever for paper compartment
3 - Paper slot
4 - LCD screen with main menu
5 - Control panel with ON/OFF button
6 - Connection for battery test cable
7 - Memory card slot
8 - Infrared temperature sensor
9 - Data transmitter for PC
2.5.2 Perform battery test with battery tester

with printer - VAS 6161- . n AG. Volkswagen AG do
satelettronica
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WARNING tho eo
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tions ⇒ page 3 !
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Special tools and workshop equipment required
wit
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hole
♦ Battery tester with printer - VAS 6161-
spec
es, in part or in w
t to the co
rrectness of i
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Performing battery test:

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WARNING C py
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Prote AG.

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

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

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

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

tested with this, both during and after warranty.
♦ “Non”-VW battery test: batteries from all other manufacturers
are to be tested with this.
♦ Stock maintenance: for batteries in showroom and storage
vehicles requiring maintenance. swage
es n
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♦ Genuine Volkswagen battery oris tee
⇒ “2.5.3 Genuine Volkswagen
auth
battery test”, page 13 . or
ac
ss
♦ “Non”-VW battery ⇒ “2.5.4 Non-VW battery test”, page 14 .
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♦ Stock maintenance
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⇒ “2.5.5 Carrying out stock maintenance”, page 14 .
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♦ The test is completed after about 10 seconds.
t to the co
♦ The result of the test is printed out by the printer.
rrectness of i
♦ The tester requires no cooling phase before it is ready for the
next measurement.
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2.5.3 Genuine Volkswagen battery test

nform
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WARNING
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These batteries must be renewed. p by
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Prote AG.
– Select “Genuine Volkswagen battery test” in the menu.

– Select “In vehicle” or “Outside vehicle”.
– Select “On battery terminal” or “On jump-start point”.
– Scan in 2D code of battery or manually select battery type and
amperage.
– Measure temperature. Hold temperature sensor about 5 cm
above one battery terminal until temperature stabilises.
– Start test.
– Print out test log if necessary.
2.5.4 “Non”-VW battery test
Note
♦ The print-out may vary depending on the software version.

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

jump starting.
– Select “Non-Volkswagen battery test” in the menu.
satelettronica
olkswagen AG
en AG. V
– Select battery type “Normal”, “AGM”, “2*6V”olkor
sw“Gel”.
ag does
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– Select “CCA”, “JIS”, “DIN”, “SAE”, “IEC”
ris or “EN”
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– Select battery value. s au ra
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an
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above one battery terminal until temperature stabilises.

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– Start test.
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2.5.5 Carrying out stock maintenance spec

es, in part or in w
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WARNING
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nform
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tion in
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– Select “Stock maintenance” in the menu.

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

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


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

♦ The test printout is required for warranty claims.
1- Check type.
2- Battery test result
3- Measured voltage
4- Measured cold start value of battery.
5- Nominal cold start value of battery selected on tester.
satelettronica
6- Measured temperature of battery.
7- Fitting location of battery agen
AG. Volkswagen AG d
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8- Position of battery terminal clamp selected on tester. ed by ara
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9- Selected battery technology. aut
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2.5.7 Assessing test results
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Evaluating battery test results for guarantee and service tests
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Battery test results Measure
h re
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Battery OK No measures on battery
spec
es, in part or in w
Battery OK - recharge. Charge battery ⇒ page 22 . In
t to the co
case of discharging, look for
fault
rrectness of i
Perform current draw test Perform current draw test
⇒ page 20 . Fully charge bat‐
l purpos
tery ⇒ page 22 and repeat

test.
nform
ercia
Renew battery Disconnect battery and repeat

test. The result “Renew battery”
m
at
may be caused by a weak cable

om
ion
contact.
c
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Battery cell defective - renew. Renew battery

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Check connection. Connect cable directly to bat‐

um
for
tery and not to jump start termi‐

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nal.
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Battery dead Renew battery
gh ht
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Evaluating battery test results for maintenance test
agen
Prote AG.

Battery OK No measure
Charge battery immediately. Charge battery fully
⇒ page 22 .
Mark as defective. Mark as defective.

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

only for USA/Canada vehicles
General description ⇒ page 16
Performing battery test with Midtronics - MCR340V- battery tester
⇒ page 17
Dealing with problems with Midtronics - MCR340V- battery tester
AG. Volkswagen AG d
⇒ page 19 agen
satelettronica
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2.6.1 General description ris
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tee
tho or
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WARNING ce
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Danger of injury. y li
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Before working on the battery, read through the warning and wit
, is n
safety regulations carefully, and comply with them ⇒ page 3 .

h re
hole
Dispose of electrolyte (mixture of sulphuric acid and water)

spec
es, in part or in w
safely! Waste electrolyte is only allowed to be disposed of at

t to the co
appropriately indicated collecting points. Comply with the lo‐

cally applicable disposal guidelines.
Do not test batteries that are liberating gas. Otherwise, there
rrectness of i
is a danger of explosion.
l purpos
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ercia
WARNING
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atio
om
It is not permissible to test or charge batteries whose magic

n in
or c
eye shows light yellow. Do not slave/jump start the vehicle!

thi
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jump starting.
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These batteries must be renewed. C py
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Prote AG.
Note
To prevent damage to the battery and vehicle, note the types of

battery and the remarks given ⇒ page 1 .
Batteries in VW vehicles are only allowed to be tested with battery

testers approved by VW. In the USA/Canada, it is permitted for
the Midtronics - MCR340V- battery tester to be used.
Read all the information about safety, set-up and operation in the
operating instructions for the Midtronics - MCR340V- battery test‐
er and follow the instructions to the letter.

Refer to ⇒ Self-study programme No. ; Vehicle batteries for more

information.
The following charging and analysis procedures apply to all bat‐
teries, all battery installation locations (engine compartment or
luggage compartment) and battery application purposes (starter
battery or second/convenience battery).
Always comply with the safety regulations, the regulations for
setting up the battery tester, the display menu/display buttons,
LEDs and the operating procedures described in the ⇒ operating
manual MCR340V .
Note
Observe and comply with all subsections, remarks and referen‐

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

MCR340V- battery tester
Prerequisites:
satelettronica
WARNING AG. Volkswagen AG d
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Before working on the battery, read through ed by the warning and
V gu
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safety regulations carefully, and comply horiwith
s them ⇒ page 3 . nte
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It is not permissible to test or charge
ss batteries whose magic c
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– Read general description ⇒ page 16 .
t to the co
– Perform visual check ⇒ page 7 .
– Open bonnet or cover for other installation location of battery.
rrectne
– Determine whether battery type is “Standard” or “AGM”.

ss
– Remove covers from battery positive and negative terminals.

o
cial p
f inform
– Use wing covers or other kinds of cover before you use equip‐
mer
ment in engine compartment or interior.

atio
om
– Close all doors.

c
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or
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Note
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♦ Battery temperature must be at least 10 °C.
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♦ For additional information, refer to the ⇒ operating manual
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Perform test: ss c
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WARNING itte
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jump starting.
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– Check magic eye on batteries with magic eye ⇒ page 6 .
nf
ercia
– Switch tester on.
orm
m
atio
– Connect red terminal “+” of tester to positive terminal.
om
n in
or c
– Connect black terminal “-” of tester to negative terminal.
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Note
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Ensure test clamps have a good contact!
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– Select “In vehicle” or “Outside vehicle”. Prote AG.
– Select “Warranty test”.
Note
Use the print function of the Midtronics - MCR340- tester if the

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

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

Results of battery test:
Battery OK None
Good - charge Charge battery ⇒ page 72 .
Use Incharge Charge battery ⇒ page 72 .
Renew battery Renew battery ⇒ Electrical sys‐
tem; Rep. gr. 27 ; Removing
and installing battery


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

MCR340V- battery tester
Under certain circumstances, the display may show errors or
messages according to status.
The most frequent display messages areaglisted below,
en AG. V
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does
with suggested solutions. Volksw not
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For messages not listed here, please refer to ⇒ operating manual
an
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MCR340V .
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Display message Measure
is n
h re
ole,
satelettronica
No display – Check whether terminals of
spec
battery tester are firmly con‐
t to the co
nected to battery terminals.
– Check battery terminals are
rrectne
tightened according to reg‐
ulations and do not have
corrosion.
ss o
cial p
f
– Charge battery
inform
⇒ page 72 .
mer
System noise – Switch off all electrical con‐ atio

om
n
sumers.
c
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– Wait until all electrical loads

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monitored by on-board sup‐

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ply control unit have switch‐

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ed off.
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– Pull out ignition key.
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– Disconnect any suspect
electrical equipment not
connected to on-board sup‐
ply as standard.
Wait a few minutes and test again ⇒ page 17 .
Note
If you have performed test at jump-start point and message does

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

Danger of explosion when checking and charging
olks
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These batteries must be renewed. autho or
ac
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Note
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♦ Ensure that the correct charging mode is set on the charger
h re
so that the current draw test is not falsified.
ole,
spec
♦ VAS 5095A ⇒ page 23
t to the co
♦ VAS 5900 ⇒ page 28
satelettronica
♦ VAS 5900 A ⇒ page 40
rrectne
♦ VAS 5903 ⇒ page 48
ss
♦ VAS 5908 ⇒ page 63
o
cial p
f inform
mer
To quickly ascertain the state of discharged batteries, the battery
atio
current draw test whilst charging helps to determine whether the
om
n
battery must be replaced or fully recharged.
c
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Note
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For battery tester with printer - VAS 6161- , the current draw test C py
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must always be performed when the test result “Perform current
gh ht
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draw test” appears on the display.
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The current draw test should always be carried out if

♦ The result of the test with battery tester with printer - VAS
6161- gave the following result:
1 - Perform current draw test
Performing a current draw test whilst charging the battery will
quickly establish whether a partly or fully discharged battery
⇒ page 77 can be recharged to return it to a serviceable condi‐
tion.
Test requirements:
♦ When charging the battery, its temperature must be at least ≥
+10 °C.
♦ The charger must be capable of outputting a charge current of
at least 30 A, as for example with VAS 5095A, VAS 5900, VAS
5903
♦ The battery's current draw must be measured with a current
pick-up clamp, e.g. VAS 5051B/7, when charging with battery
charger - VAS 5095A- . Battery charger - VAS 5900- and bat‐
tery charger - VAS 5903- display the current draw on the unit.
Battery charger - VAS 5900- performs the current draw test
automatically with menu guidance.
– Connect battery to battery charger and start charging se‐
quence.

– Measure charge current of battery after 5 minutes.

Test result:
If the current draw A is higher than 10% of the nominal capacity
(e.g. > 6.1 A for a 61 Ah battery), fully charge battery and test
again.
Note
For Eos with two 6 V absorbent glass mat batteries, the charge
current must only be 5 % higher than the nominal capacity of the
battery. Example for Eos: the 50 Ah battery must have a charge
current higher than 2.5 A after 5 minutes of starting the charging
sequence. swa
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– Fully charge the battery
orise
when the charge current is higher than
nte
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10% of the nominal
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capacity (observe exception for Eos in or a
above note).ss c
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– Perform battery test after allowing battery to rest for two hours
du
an
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⇒ page 12 .
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ility
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If the charge current, in amperes, lies below 10 % of the nominal
ot p
wit
capacity after 5 minutes of starting the charging sequence (5 %
, is n
h re
for the 2 x 6 volt batteries in Eos) (example for 50 Ah battery <
hole
spec
5 A), renew battery. For warranty and goodwill cases, please
es, in part or in w
complete the battery test sheet.
t to the co
rrectness of i
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nf
ercia
orm
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atio
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3 Charging the battery
Note
♦ A charger with a charge current of at least 70A is required if

the software is updated or flashed in a vehicle to prevent prob‐
lems during updating and flashing.
♦ “VAS 5900 A”
⇒ “3.3 Battery charger VAS 5900 A ”, page 40
♦ “VAS 5903” ⇒ “3.4 Battery charger VAS 5903 ”, page 48
WARNING

tions ⇒ page 3 !
satelettronica
Caution

AG. Volkswagen AG d
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erm
ab
jump starting.
ility
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3.1 Battery charger - VAS 5095 A-

rrectness of i
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This chapter describes the basic functions of the battery charger

um
for
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- VAS 5095 A- . For additional information refer to ⇒ operating

n
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instructions for battery charger - VAS 5095 A- . Cop py
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e ran
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ss
Note
ce
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itte
♦ The effective charge current can not be read on these units.
y li
erm
ab
The charge current must be read externally using a pick-up
ility
ot p
clamp.
wit
, is n
h re
♦ Observe ⇒ operating instructions for battery charger - VAS
hole
spec
5095 A- .
es, in part or in w
t to the co
3.1.1 Description of battery charger - VAS
5095 A-
rrectness of i
l purpos
Note
nf
ercia
o
rm
m
atio
m

o
n in
or c
thi
e

t
sd
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Charge current of charger: 12 A.
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The battery charger - VAS 5095- is suitable for charging all 12V cop Vo
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batteries supplied by Volkswagen.
cted agen
Prote AG.
The battery charger charges without peaks in amperage or volt‐

age. This will not adversely effect the on-board electronics. The
battery can remain in the vehicle while it is being charged and
need not be disconnected.
Battery charger - VAS 5095 A-
1 - ON / OFF switch (0 = charger OFF)
2 - Charge current indicator (I > 12 A)
3 - Charge current indicator, battery partially charged > 90 %
4 - Trickle charge mode; lights up green when battery is fully
charged
5 - Malfunction indicator
6 - Support mode indicator
7 - Support mode/normal mode changer-over switch
8 - Charger cable, red terminal “+”, black terminal “-”
9 - Battery type change-over switch (on base of charger unit)
3.1.2 Charging battery with battery charger -

VAS 5095 A-
Note

3. Charging the battery 23

WARNING

tions ⇒ page 3 !

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

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jump starting.
, is n
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spec
es, in part or in w
t to the co

– Check setting for battery type on type of battery switch
rrectness of i
⇒ page 23 . Must be set to 2.4 V/C (volts/battery cell).

l purpos
– Connect red terminal clamp “+” of charger unit to positive ter‐

minal on battery.
nform
mercia
at
om
Note
ion
c
in t
or
his
e
In vehicles with start/stop function and battery monitor control unit

at
do
riv
- J367- fitted, black terminal clamp “–” must be connected to body

p
cum
or
earth. Connecting it to battery negative terminal will cause start/

f
en
ng
stop system to malfunction.

t.
yi Co
Cop py
t. rig
gh ht
yri
– Connect black terminal clamp “–” of battery charger to nega‐ p by
co Vo
by lksw
tive terminal. Prote
cted AG.
agen

– Switch on battery charger ⇒ page 23 .

The charge current indicators ⇒ page 23 -2- and -3- light up yel‐
low. If only the yellow light emitting diode (LED) -3- lights up,
battery is partially discharged (approx. 90 %).
If the green LED also lights up ⇒ page 23 -4-, the charger has
switched to trickle charge mode. The battery is fully charged.
– Switch off charging unit ⇒ page 23 .
– Remove charger unit terminals from battery terminals.
3.1.3 Charging totally discharged battery with

battery charger - VAS 5095 A-
Note

satelettronica
AG. Volkswagen AG d
agen oes
lksw not
WARNING d byV
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ise nte
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h
Danger of injury!
s aut Observe warning notices and safety regula‐ or a
c
tions ⇒ pages3 !
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nl
pt
du
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itte
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erm
The charger unit automatically recognises totally discharged bat‐

ab
ility
teries and initiates a gentle charging procedure with a low charg‐

ot p
wit
ing current. The charge current is automatically adapted to suit

, is n
h re
the charge condition of the battery.

hole
spec
es, in part or in w
t to the co
Note
♦ Observe notes in chapter ⇒ page 77 .

rrectness of i
♦ Totally discharged batteries in unregistered vehicles must be

l purpos
exchanged prior to delivery. Preliminary damage cannot be

excluded.
nform
ercia
♦ The battery voltage must be at least 0.6 V.

m
at
om
ion
c
in t
or
WARNING
his
ate
do
priv

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for
en
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n
t.
yi Co
Cop py
Danger of explosion when checking and charging or slave/ ht. rig
rig ht
jump starting. py by
co Vo
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– Charge battery ⇒ page 23 .

3.1.4 Charging battery in support mode with

battery charger - VAS 5095A-
Note agen
AG. Volkswagen AG d
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♦ A charger with a charge current of at leastoris70A is required if
ed
nte
the software is updated or flashed in a vehicle
ut
h to prevent prob‐ eo
ra
lems during updating and flashing. s s a c
ce
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nl
pt
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erm
ab
ility
ot p
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, is n
General notes:
h re
hole
The support mode provides the on-board supply with power when
spec
es, in part or in w
the battery is removed or disconnected.
t to the co
For further information, refer to the ⇒ operating manual VAS
5095A .
rrectness of i
The support mode is suitable in the following situations:
l purpos
satelettronica
♦ Support mode of on-board supplies without installed battery
♦ Power conservation when renewing the battery
nf
ercia
orm
♦ Ancillaries test without battery
m
atio
om
n in
or c
WARNING
thi
te
sd
iva
o
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f
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tions ⇒ page 3 !
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted
WARNING
agen
Prote AG.

jump starting.
Caution
♦ The terminal polarity protection in operating mode “charg‐

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

Caution
When battery is removed, ensure there is no contact between

terminal clamp connected to positive clamp of battery and body
earth. Also ensure there is no contact between battery clamps.
AG. Volkswagen AG d
agen oes
olksw not
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– Connect red terminal clamp d by “+” to positive terminal of vehicle.guar
e an
ris tee
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au ac
ss
Note
ce
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un
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an
d
itte
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rm
ab
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ility
ot
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, is n
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hole
spec
– Connect black terminal clamp “-” to negative terminal of vehi‐
es, in part or in w
t to the co
cle.
– Check setting for battery type on normal/support mode switch
⇒ page 23 . It must be switched on support mode.
rrectness of i
satelettronica
– Check polarity of charger unit cables.
l purpos
– Switch on battery charger.
nform
ercia
The battery charger starts with support mode.

m
a
End battery support mode:
com
tion in
r
– Switch off battery charger.

te o
thi
s
iva
do
– Disconnect black terminal clamp “–” of charger unit from neg‐
r
rp
cum
ative terminal of vehicle.

fo
en
ng
t.
yi Co
– Disconnect red terminal clamp “+” of charger unit from positive Cop py
t. rig
terminal of vehicle. opyri
gh by
Vo
ht
by c lksw
– Pull charger plug out of battery charger. Prote
cted AG.
agen
3.1.5 Charging battery in trickle charge mode

with battery charger - VAS 5095 A-
Note

WARNING

tions ⇒ page 3 !

WARNING

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

that the battery is charged correctly and is maintained in fully
charged condition.
– Proceed as for charging battery ⇒ page 23 .
Note
♦ When a battery is being charged in trickle charge mode and

an electrical consumer sdraws wage current from thedobattery,
n AG. Volkswagen AG
es n the
battery charger - VAS o5095
lk A- automatically compensates
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satelettronica
V
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charge. ris
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♦ The trickles acharge can be continued for an unlimited period.r ac
u o
s
ce
♦ The battery is always ready for use.

e
nl
pt
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itte
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erm
3.2 Battery charger - VAS 5900-

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

rrectness of i

l purpos

nf
ercia
orm
WARNING
m
atio
om
n in
or c

thi
te
tions ⇒ page 3 !
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rig ht
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cted agen
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jump starting.

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

Note
♦ The effective charge current can be read directly on this bat‐

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

5900-
Note

satelettronica
The battery charger - VAS 5900- is suitable for charging all 12V
batteries supplied by Volkswagen.
Battery charger - VAS 5900-
1 - Display
2 - Adjustment button “Up” ↑ AG. Volkswagen AG d
agen oes
ksw
3 - Adjustment button “Down” ↓ by
Vol not
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4 - START / STOP ut
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5 - INFO s
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3.2.2 Charging battery with battery charger - ab

ility
ot p
VAS 5900- wit

, is n
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hole
spec
es, in part or in w
Note
t to the co

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orm
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WARNING
or
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tions ⇒ page 3 !
f
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yV gu
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n r tee
ho
aut or
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ss
WARNING
ce
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nl
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du
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itte
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It is not permissible to test or charge batteries whose magic erm
ab
ility
ot p
wit
, is n
h re
jump starting.
hole
spec
es, in part or in w
t to the co
rrectness of i
♦ Battery charger - VAS 5900-
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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f
en
ng
t.
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Cop py
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pyri by
Vo
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cted agen
Prote AG.
Note
The battery must have a temperature of at least 10 °C.

– Connect charger plug to battery charger. The last selected
type of battery will appear on display.
– Set battery to respective operating mode with INFO .
In the display the symbol -1- for “standard charge for wet batter‐
ies” or symbol -2- for “standard charge for gel/absorbent glass
mat batteries” will appear.
– Set battery capacity (Ah) of battery to be charged using re‐
spective button (“Up” ↑ or “Down” ↓ ).
– Connect red terminal clamp “+” to positive terminal on battery.
Note

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

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

At a charge condition of approx. 80 - 85 % the battery charger

. Volkswagen AG
switches to the “final
w agen AG mode. The
charge” fourth
does bar appears in
ks not
display -1-. TheVol
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is n
h re
ole,
spec
t to the co
At a charge level of 100 %, all bars appear on the display.
rrectne
Note
ss
♦ In the case of battery type “standard charge”, the parallel op‐
o
cial p
f
eration of electrical consumers while charging is possible. The
inform
charging period will be longer.
mer
satelettronica
atio
m
♦ The battery charger will switch to trickle charge mode after

o
n
c
about 1-7 hours, depending on type of battery. To achieve a

i
or
100% charge the battery should remain connected for this pe‐ n thi
te
sd
va
riod.
i
o
pr
cum
r
fo
en
ng
t.
yi
Possible faults and fault rectification:
Co
Cop py
ht. rig
1- Displayed battery voltage is not as per nominal voltage:
rig ht
py by
co Vo
by lksw
– Press and hold respective button (“Up” ↑ or “Down” ↓ ) until
cted agen
Prote AG.
charging process starts.
2- Displayed battery voltage is not as per nominal voltage –
charging process has already started:
– Press START / STOP twice.
charging process starts again.
3- Battery charger does not detect a battery when battery volt‐
age is less than 2 V:
Display remains unchanged.
The battery type and ampere hours (Ah) as set is displayed.
Ending battery charging sequence:
– Press START / STOP .
– Disconnect black terminal clamp “-” of charger from negative
terminal.
– Disconnect red terminal clamp “+” of charger from positive
terminal on battery.
– Pull charger plug out of battery charger.

3.2.3 Charging battery in service mode with

battery charger - VAS 5900-
Note

WARNING

tions ⇒ page 3 !
satelettronica
Caution
The operating mode “service charge” is not permitted on VW

vehicles as the voltage peaks will damage the on-board elec‐
tronics.
If you nevertheless use “service charge” the battery must be
disconnected from the on-board supply.
WARNING
AG. Volkswagen AG d
agen oes
olksw not
It is not permissible to test or charge batteries whose magic ed by V gu
ara
eye shows light yellow. Do not slave/jump start the vehicle! ho ris nte
eo
ut ra
Danger of explosion when checking and charging or slave/ s a c
s
jump starting.
ce
le
un
pt
an
d

itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
Caution
spec
When charging always set the battery charger to the correct

t to the co
type of battery ⇒ operating instructions for battery charger -

VAS 5900- !
rrectne
The “service mode” is suitable for:

♦ Wet batteries where the magic eye allows charging (magic
ss
eye black or green)

o
cial p
f inform
mer
atio
The operating mode “service charge (SERV)” is only used on

om
sulphated batteries. The battery is charged at a voltage of

c
i
or
> 14.4 V. This can result in a partial reduction of the sulphated

thi
te
sd
a
layer. After charging, always check the colour of the magic eye
iv
o
pr
before using the battery ⇒ page 9 .

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

Note

AG. Volkswagen AG d
agen oes
lksw not
– Switch off ignition and all electrical
d by
V consumers.
o gu
ara
ise nte
r
– Connect charger plug to ubattery charger. The last selected
satelettronica
tho eo
ra
operating mode will appear
ss a on display ⇒ page 29 . c
ce
e
nl
– Set battery to respective battery type with INFO .
pt
du
an
itte
y li
In the display, the symbol -1- for “Service charge for wet batteries”
erm
ab
or symbol -2- for “Service charge for gel/absorbent glass mat bat‐
ility
ot p
teries” will appear.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Note rrectness of i
l purpos

nf
ercia

orm

m
atio
om
n in
or c

thi
te
sd
iva
o
r
rp
cu

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

At a charge condition of approx. 80 - 85 % of the battery voltage,

the battery charger switches to the “final charge” mode. The fourth
bar appears in display -1-. The battery is ready for use.
Note
The success of the “service charge” depends on the severity of

the sulphation of the battery.

satelettronica
swage es n
3 - Battery charger does not detect a battery whenby V battery volt‐
olk ot g
ua
age is less than 2 V: ir se
d ran
t ee
ho
Display remains unchanged. aut or
ac
ss
ce
le
The operating mode and ampere hours (Ah) as set are displayed.
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
terminal.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
3.2.4 Charging totally discharged batteries

with battery charger - VAS 5900-
nform
mercia
a
com
tio
Note
n in
r
te o
thi
s

iva
do
r

rp
cum
fo

en
ng
t.
yi Co
op
C py
t. rig
gh ht
yri by
♦ “VAS 5908” ⇒ “3.6 Battery charger VAS 5908 ”, page 63 cop Vo
by lksw
cted agen
Prote AG.
WARNING

tions ⇒ page 3 !

AG. Volkswagen
Ameo 2017 ➤ , Arteon
ksw 2018 ➤ , Atlas 2017 ➤
agen AG do
es n, Bora 1999 ➤ , Bora Varian ...
Vol o g
db
y Electrical system - generalt information
ua
ra - Edition 08.2019
e nte
ris
tho eo
au ra
c
WARNING ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
jump starting. hole
spec
es, in part or in w
t to the co
rrectness of i
Caution
l purpos

nform
ercia
battery terminals.
m
a
com
ti
♦ When charging always set the battery charger to the cor‐
on in
rect type of battery ⇒ operating instructions for battery
r
te o
thi
charger - VAS 5900- !
s
iva
do
r
rp
c
♦ Totally discharged batteries are not recognised by the
satelettronica
um
fo
en
g
battery charger ⇒ page 77 .

n
t.
yi Co
Cop py
t. rig
gh ht
yri
p by
o Vo
by c lksw
damaged. Prote
cted AG.
agen
Batteries with a voltage of less than 2 volts will not be recognised

automatically by battery charger - VAS 5900- .
Note

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

operating mode will appear on display ⇒ page 29 .

– Set battery to respective battery type with INFO .

Note

AG. Volkswagen AG d
agen oes
olksw not
V
ed by gu
ara
ris nte
o eo
– Press START / STOP for approx. 5 seconds. aut The menu
h
ra
“charging totally discharged batteries/support
ss
mode” will be c
ce
le
activated.
un
pt
satelettronica
an
d
itte
– Press respective button (“Up” ↑ or “Down” ↓ ) to set required
y li
erm
ab
battery voltage (6 V, 12 V or 24 V).
ility
ot p
wit
is n
h re
ole,
Note
spec
t to the co
If a button is not pressed within 5 seconds the charger will return
to the main menu (select operating mode).
rrectne
– Confirm the selected battery voltage with START / STOP .
Then follows the enquiry for "is charger cable terminal polarity
ss o
correct".
cial p
f inform
mer
atio
m
– Confirm polarity of charger unit cables with START / STOP .

o
n
c
i
or
n thi
Charger will start charging sequence for totally discharged bat‐

te
sd
a
tery.
iv
o
pr
cum
r
fo

en
ng
t.
yi Co
op
C py
t. rig
gh ht
yri by
op Vo
by c lksw
cted
terminal.
agen
Prote AG.



Note

General notes:
olkswagen AG
en AG. V
For further information, refer oto the
ksw
ag ⇒ operating manual
does
VAS
not
V l
5900 . ed by gu
ara
ris nte
The support modeaisho
ut suitable in the following situations:
eo
ra
satelettronica
ss c
ce
le
un
pt
an
d

itte
y li
erm
ab
ility
ot p
wit
is n
h re
WARNING
ole,
spec

t to the co
tions ⇒ page 3 ! rrectne
WARNING
ss o
cial p
f i

nform

mer
atio
m

o
n
c
jump starting.
i
or
n thi
te
sd
a

iv
o
pr
cum
r
fo
en
ng
t.
yi Co
op
– Switch off ignition and all electrical consumers. C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
Caution cted agen
Prote AG.

battery terminals.
♦ It can cause sparks through a short-circuit.
damaged.
– Remove battery.


wage
Caution olks es n
ot g
byV ua
d ran
ir se tee
When battery is removed, ensure there is no contact between utho
or
ss
a ac
ce
le
un
pt
an
d
itte
y li
erm
ab
– Connect red terminal clamp “+” to positive terminal of vehicle.
ility
ot p
wit
is n
h re
ole,
Note
spec
t to the co
rrectne
s
s o
cle.
cial p
satelettronica
inform
– Press START / STOP for approx. 5 seconds. The menu
mer
atio
“charging totally discharged batteries/support mode” will be
om
activated.
n
c
i
or
n thi
e

t
sd
iva
o
r

p
cum
r
fo
en
ng
t.
yi Co
op py
Note
t. C rig
gh ht
pyri by
Vo
co lksw
by
If a button is not pressed within 5 seconds the charger will return cted agen
Prote AG.

correct".
– Disconnect red terminal clamp “+” of charger unit from positive
terminal of vehicle.


Note

Note
♦ When a battery is being charged in the trickle charge mode

and an electrical consumer draws current from the battery, the
battery charger - VAS 5900- automatically compensates the
charge.
satelettronica
♦ The trickle charge can be continued for an unlimited period.
♦ Observe battery manufactures maintenance instructions!
WARNING

tions ⇒ page 3 !
AG. Volkswagen AG d
WARNING olksw
agen oes
not
V gu
d by ara
e
It is not permissible to test or charge batterieshoris
whose magic nte
eo
eye shows light yellow. Do not slave/jump start
s aut the vehicle! ra
c
s
ce
le
un
pt
jump starting.
an
d
itte
y li
erm
ab

ility
ot p
wit
is n
h re
ole,
When the battery is fully charged the battery charger - VAS 5900-
spec
switches to trickle charge mode.

t to the co

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

3.3 Battery charger - VAS 5900 A-

⇒ “3.3.1 General description - battery charger VAS 5900 A ”, page
40
⇒ “3.3.2 Charging battery with battery charger VAS 5900 A ”, page
41
⇒ “3.3.3 Charging totally discharged battery with battery charger
VAS 5900 A ”, page 42
⇒ “3.3.4 Charging battery in support mode with battery charger
VAS 5900 A ”, page 45
⇒ “3.3.5 Mains supply mode with battery charger VAS 5900 A ”,
page 46
3.3.1 General description - battery charger -

VAS 5900 A-
WARNING
Danger of injury! Observe warning instructions and safety reg‐
satelettronica
ulations ⇒ page 3 .

- VAS 5900 A- . For additional information refer to ⇒ operating
instructions for battery charger - VAS 5900 A- .
Product characteristics agen
AG. Volkswagen AG d
oes
olksw not
♦ Fully automatic charging using the Plug & ed bCharge
yV feature. gu
ara
ris nte
o
♦ Simple user guidance and maximumauoperational
th safety thanks eo
ra
to the animated graphical display.sAll functions and charging
s c
data can be configured, read and are clearly presented on the
ce
le
un
pt
display.
an
d
itte
y li
erm
ab
♦ Automatic pre-selection of battery voltage (6 V, 12 V and 24 V).

ility
ot p
♦ Robust and compact housing for flexible use in the workshop.

wit
is n
h re
ole,
♦ Pluggable charging and power supply cables (in different

spec
lengths).
t to the co
♦ Edge protection for high stability and protection against paint‐

work damage.
rrectne
♦ For charging or trickle-charging conventional lead-acid, lead-

calcium/silver, or absorbent glass mat batteries (AGM, MF) as
well as of maintenance-free lead-gel batteries without having
ss
to disconnect the batteries from the vehicle’s electrical system.

o
cial p
f inform
♦ Can be used on batteries with capacities of 3 to 350 Ah.

mer
atio
m
♦ Optional USB interface for software updates of the battery

o
n
c
charging system ensures a long-term and future-proof use.

i
or
n thi
te
sd
a
♦ Based on the active inverter technology.

iv
o
pr
cum
r
fo
♦ Full protection of the vehicle, the onboard electronics and bat‐

en
ng
t.
tery thanks to electronics protection, short-circuit protection,
yi Co
op
electronic inverse polarity protection, safety shut-off and ther‐
C py
t. rig
gh
mal overload protection.
ht
pyri by
Vo
o
by c lksw
cted
Applications
agen
Prote AG.
♦ Charging: automatic charging and buffering of parallel con‐

sumers during the restricted service time.

♦ Diagnosis and software update: in buffer mode, the parallel

consumers are supplied with power during the diagnosis or
during software updates.
♦ Battery change: in support mode, the user settings in the ve‐
hicle are retained, when the battery is renewed.
♦ In power supply mode, an external power supply without any
support from the battery is provided.
♦ In refresh mode, totally discharged batteries are regenerated.
Operating unit on battery charger - VAS 5900 A-
1 - Graphic display
2 - Menu button
3 - Up/Down buttons AG. Volkswagen AG d
agen oes
4 - Stop/start button olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
satelettronica
y li
erm
ab
ility
ot p
wit
, is n
h re
VAS 5900 A-
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
Procedure
t. rig
gh ht
pyri by
Vo
co
– Connect battery charger - VAS 5900 A- to mains supply.
by lksw
cted agen
Prote AG.
Charging mode is available as standard once charging unit has
been connected to mains supply.
– Select Ah setting or battery type using Menu button.
– Use Up/Down buttons to enter value (e.g. 100 Ah or wet bat‐
tery type).
– Connect red charging cable from battery charger - VAS 5900
A- to positive terminal of battery.
Battery removed
– Connect black charging cable from battery charger - VAS 5900
A- to negative terminal of battery.
Battery installed in vehicle
A- to dedicated negative jump-start connection with battery in
situ.

Battery charger automatically detects that battery is connected

and starts the charging process after 5 seconds.
If battery voltage was not detected correctly, e.g. in event of ex‐
haustively discharged battery, select battery voltage within 5
seconds as follows:
– Set correct battery voltage using Up/Down buttons.
Note
To prevent damage to the components, always ensure that the

battery voltage is set correctly.
– Confirm selection with Stop/Start button.

If selection window for battery voltage does not appear, battery is
exhaustively discharged. In this case, perform action on exhaus‐
tively discharged battery using battery charger - VAS 5900 A-
⇒ page 42 .
Note
satelettronica
Do not disconnect charging cable during charging. Danger of
damage to plug sockets and connectors.
Ascending bars -1- indicate the charge level of the battery, e.g. 3
bars denote a charge level of 80%.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
Once all 4 bars -1- are displayed permanently, the charge level
itte
y li
is 100%.
erm
ab
ility
ot p
Battery can remain connected to battery charger - VAS 5900 A-

wit
, is n
for as long as necessary.

h re
hole
spec
If required, interrupt/continue charging process

es, in part or in w
t to the co
– Press Stop/Start button to interrupt charging process.

– Press Stop/Start button to continue charging process.
rrectness of i
Ending charging process

l purpos
– Press Stop/Start button to end charging process.

– Disconnect red charging cable from positive terminal of bat‐
nf
ercia
tery.
rm
m
atio
m
– Disconnect black charging cable from negative terminal of

o
n in
c
battery and/or jump-start connection.

or
thi
te
sd
iva
o
r
rp

cu
o
m
f
en
ng

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

Refresh mode serves as a means of charging the battery if ex‐

haustive discharge is likely to have extended over a longer period
of time (e.g.: battery sulphated).
WARNING
Danger of injury! Observe warning instructions and safety reg‐

satelettronica
WARNING
AG. Volkswagen AG d
agen oes
olksw not
It is not permissible to d btest
y V or charge batteries whose magic gu
ara
eye shows light yellow.
horise
Do not slave/jump start the vehicle! nte
eo
ut ra
s a c
s
jump starting.
ce
e
nl
pt
du
an

itte
y li
erm
ab
ility
ot p
wit
, is n
h re
Caution
hole
spec
es, in part or in w

t to the co

battery terminals.
rrectness of i

l purpos

charger - VAS 5900 A- !
nform
ercia

m

at
om
ion
c
in t
♦ Do not press START / STOP button if charger unit cables

or
his
e
are connected incorrectly. The charger unit may be dam‐

at
do
riv
aged.
p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
Caution py by
co Vo
by lksw
cted agen
Prote AG.
The refresh charge mode is not permitted on VW vehicles as
the voltage peaks will damage the onboard electronics.
If refresh charge mode is used nevertheless, the battery must
be disconnected from the onboard supply.


Procedure
Note
♦ Follow instructions in chapter ⇒ page 77 .

– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Battery;

Removing and installing battery .
– Connect battery charger - VASen5900
AG. VoA-
lksto
wagmains
en AG supply.
ag does
lksw not
– Select refresh mode using
by
Vo Up/Down buttons. gu
ara
ed nte
ris
– Select Ah setting
ut or battery type using
ho Menu button. eo
ra
a c
ss
– Use Up/Down buttons to enter value (e.g. 100 Ah or wet bat‐
ce
e
nl
pt
tery type).
du
an
itte
y li
erm
ab
satelettronica
ility
ot p
wit
, is n
h re
hole
A- to negative terminal of battery.
spec
es, in part or in w

and starts the charging process after 5 seconds. t to the co
rrectness of i

seconds as follows:
l purpos

nform
mercia
Note
at
om
ion
c
in t
or

his
ate

do
priv
cum
for
en
g

n
t.
yi Co
Cop py
t. rig
If selection window for battery voltage does not appear, battery is yri
gh by
ht
exhaustively discharged with a voltage of under 2 volts. A corre‐ cop Vo
by lksw
sponding warning appears. cted agen
Prote AG.
If battery charging is still desired despite the battery being ex‐

haustively discharged:
– Press OK in warning message using Stop/Start button.
– In next selection window that appears, set correct battery volt‐
age using Up/Down buttons.
Note


Note
Do not disconnect charging cable during charging. Danger of

damage to plug sockets and connectors.
Ascending bars -1- indicate the charge level of the battery, e.g. 3
bars denote a charge level of 80%. gen AG
. Volkswagen AG
d wa oes
olks not
byV gu
ara
ed nte
ris
tho eo
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Once all 4 bars -1- are displayed permanently, the charge level
is 100%.
satelettronica
Battery can remain connected to battery charger - VAS 5900 A-
rrectne
for as long as necessary.
s
If required, interrupt/continue refresh charging process
s o
cial p
f i
– Press Stop/Start button to interrupt charging process.
nform
mer
– Press Stop/Start button to continue charging process.
atio
om
n
c
Ending refresh charging process
i
or
n thi
te
sd
a
– Press Stop/Start button to end charging process.

iv
o
pr
cum
r
fo
en
ng
t.
yi
tery.
Co
Cop py
t. rig
gh
– Disconnect black charging cable from negative terminal on
ht
pyri by
Vo
battery.
co lksw
by
cted agen
Prote AG.

Backup power supply mode serves exclusively as a means of re‐

lieving the load on the battery during diagnosis or a software
update on the vehicle. Over a longer period of time, the consumed
current must be lower than the maximum output current of the
charging unit as otherwise the battery will discharge. Backup
power supply mode is not suitable for fully charging the battery.

agen
information - nEdition
AG. Volkswage AG do 08.2019
w es n
olks ot g
yV ua
Procedure ris
ed
b ran
tee
tho or
– Connect battery aucharger - VAS 5900 A- to mains supply. ac
ss
ce
e
– Select backup power supply mode using Up/Down buttons.
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
A- to dedicated negative jump-start connection.
hole
spec
es, in part or in w
t to the co
and starts the charging process after 5 seconds.
rrectness of i
seconds as follows:
l purpos
nf
ercia
orm
Note
m
atio
om
n in
c

or
thi
e
satelettronica
t
sd
iva
o
r
rp
cu
o
m
f
– Confirm selection with Stop/Start button. en

ng
t.
yi Co
op py
If selection window for battery voltage does not appear, battery is
. C rig
ht ht
rig
exhaustively discharged with a voltage of under 2 volts. In this py by
co Vo
case, backup power supply mode is not permissible. Replace‐
by lksw
cted agen
Prote
ment of the battery is recommended.
AG.
Note
Do not disconnect charging cable during backup power supply.

Danger of damage to plug sockets and connectors.
If required, interrupt/continue backup power supply

– Press Stop/Start button to interrupt backup power supply.
– Press Stop/Start button to continue backup power supply.
Ending backup power supply
– Press Stop/Start button to end backup power supply.
tery.
– Disconnect black charging cable from negative jump-start con‐
nection.
3.3.5 Mains supply mode with battery charger

- VAS 5900 A-

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
Mains supply mode serves as a means of supplying power to the
h re
ole,
electronics in the vehicle when the battery is removed. Since only
spec
the battery cables of the vehicle are connected to the battery
charger - VAS 5900 A- , the battery voltage detection function is
t to the co
not available.
Procedure
rrectne
– Connect battery charger - VAS 5900 A- to mains supply.
satelettronica
s
– Select mains supply mode using Up/Down buttons.
s o
cial p
f in
– Set vehicle electrical system voltage with Menu button.
form
mer
atio
om
n
c
Note
i
or
n thi
te
sd
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vehicle electrical system voltage is set correctly.

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A- to positive battery cable of vehicle. p by
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– Connect black charging cable from battery charger - VAS 5900 Prote AG.
A- to negative battery cable of vehicle.
Caution
When the battery is removed, ensure there is no contact be‐

tween the positive terminal clamp of charger and the body
earth.
Also ensure there is no contact between individual battery ter‐
minal clamps.
– Start mains supply mode with Stop/Start button.

A security question appears on the display to determine whether
the charging cables are connected correctly.
– Confirm security question with Stop/Start button and start
external power supply of vehicle electronics.
Ending mains supply mode
– Press Stop/Start button to end mains supply mode.
– Disconnect red charging cable from positive battery cable of
vehicle.
– Disconnect black charging cable from negative battery cable
of vehicle.

Note

WARNING

tions ⇒ page 3 !
WARNING
satelettronica
jump starting.

- VAS 5903- . For additional information refer to ⇒ operating in‐
structions for battery charger - VAS 5903- . AG. Volkswagen A n G do
wage es n
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Note oris tee
th or
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ss
Observe ⇒ operating instructions for battery charger - VAS
ce
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un
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Note
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♦ A charger with a charge current of at least 70 A is required if

rrectne

s

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form
mer
atio
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o
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or
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ks wage es n
The battery charger - VAS 5903- is suitable for chargingVol all 12 V ot g
by ua
batteries supplied by Volkswagen. ris
ed ran
tee
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Battery charger - VAS 5903- s au ac
s
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e
1 - Display
nl
pt
du
an
itte
2 - Adjustment button “Up” ↑
y li
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ility
ot p
3 - Adjustment button “Down” ↓
wit
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4 - START / STOP
hole
spec
5 - INFO es, in part or in w
t to the co
rrectness of i
VAS 5903-
l purpos
nf
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Note
orm
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atio
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or
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WARNING cted agen
Prote AG.

tions ⇒ page 3 !
WARNING

jump starting.


Note

Volkswagen AG
– Set battery to respective operating mode with
swa INFO .
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.
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In the display the symbol -1- for “standard
ised charge for wet batter‐
b ara
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ies” or symbol -2- for “standard charge
ut
hor
for gel/absorbent glass eo
mat batteries” will appear. ss a ra
c
ce
le

un
pt
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itte
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ility
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Note
spec
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t to the co
rrectne
s
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form
mer
atio
automatically.
om
n
c
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or
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At a charge condition of approx. 80 - 85 % the battery charger

t
sd
va
switches to the “final charge” mode. The fourth bar appears in

i
o
pr
cum
r
display -1-. The battery is ready for use.

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

Note
♦ In the case of battery type “standard charge”, the parallel op‐

eration of electrical consumers while charging is possible. The
charging period will be longer.
♦ The battery charger will switch to trickle charge modeswafter
agen
AG. Volkswagen AG d
oes
about 1-7 hours, depending on type of battery. To y Vachieve a
olk not
gu
100% charge the battery should remain connected
ris
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nte
riod. ut
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ility
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es, in part or in w
t to the co
satelettronica
rrectness of i
charging process starts again.
l purpos

nf
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o
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atio
m
The battery type and ampere hours (Ah) as set is displayed.

o
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or c
thi
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op
terminal.
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Prote AG.
3.4.3 Charging battery in refresh charge

mode with battery charger - VAS 5903-
WARNING

tions ⇒ page 3 !
WARNING

jump starting.

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

vehicles as the voltage peaks will damage the on-board elec‐
tronics.
If you nevertheless use “refresh charge” mode the battery must
be disconnected from the on-board supply.
Caution
When charging always set the battery charger to the correct

type of battery ⇒ operating instructions for battery charger -
VAS 5903- !
The “refresh charge” mode is suitable for: swage
es n
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♦ Wet batteries, where distilled water can be replenished.d b ua
ran
ir se tee
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Do not use operating mode “refresh charge” with maintenance-
auth or
ac
free wet batteries. ss
ce
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satelettronica
un
pt
an
d
itte
y li
The “refresh charge (refr)” operating mode is only used on sus‐
erm
ab
ility
pect defective batteries (e.g. sulphation). The battery will be
ot p
charged to maximum specific gravity and the plates will be reac‐
wit
is n
h re
tivated (dissipation of sulphur layer).
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
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fo
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ng
t.
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Cop py
t. rig
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Note
p by
co Vo
by lksw
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Prote AG.



In the display the symbol -1- for “refresh charge for wet batteries”
or symbol -2- for “refresh charge for gel/absorbent glass mat bat‐
Note
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In vehicles with start/stop
ir se
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function and battery monitor controlran unit
t e
- J367- fitted, ublack
tho terminal clamp “–” must be connected toebody or
earth. Connecting
ss
a it to battery negative terminal will cause start/ ac
ce
le
un
pt
an
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itte
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ab
pe
ility
ot
wit
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automatically.
hole
spec
satelettronica
es, in part or in w
t to the co
At a charge condition of approx. 80 - 85 % of the battery voltage,
the battery charger switches to the “final charge” mode. The fourth
bar appears in display -1-. The battery is ready for use.
rrectness of i
l purpos
Note nform
ercia
The success of the “refresh charge” depends on the severity of

the sulphation of the battery.
m
a
com
tion in

r
te o
thi
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iva

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Co
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ht
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Prote AG.
The operating mode and ampere hours (Ah) as set are displayed.
terminal.


Note

WARNING agen
AG. Volkswagen AG d
oes
olksw not
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b ara
Danger of injury! Observe warning noticesorise and safety regula‐
d
nte
tions ⇒ page 3 ! auth eo
ra
ss c
ce
le
un
pt
an
d
itte
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satelettronica
WARNING
rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
jump starting.
rrectness of i
l purpos
Caution
nform
ercia

m

a
com
tio

n in
r
battery terminals.
te o
thi
s
iva
do

r
rp
cum

fo
en
g
charger - VAS 5903- !

n
t.
yi Co
Cop py
t. rig
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p by
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by lksw
cted agen
Prote AG.

damaged.


AG. Volkswagen AG d
agen oes
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Note aut ra
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ab
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ot
excluded.
wit
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satelettronica
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
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tion in
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te o
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fo
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ng
t.
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Cop py
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rig ht
py by
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Prote AG.


Note


activated.
satelettronica
Note


correct".
– Check polarity of charger unit cables. agen
AG. Volkswagen AG d
oes
olksw not
– Confirm polarity of charger unit cables with ed b
V
ySTART / STOP . gu
ara
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Charger will start charging sequence forauttotally discharged bat‐
h
ra
tery. ss c
ce
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un
pt

an
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itte
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rm

ab
pe
ility
ot

wit
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terminal.
hole
spec

es, in part or in w
t to the co

rrectness of i
l purpos
nform
mercia
a
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tion in
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te o
thi
s
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fo
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t.
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Cop py
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rig ht
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56
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Rep. gr.27 - Starter, current supply, CCS Prote AG.

Note

General notes:
5903 .
satelettronica
Volkswagen AG
♦ Power conservation when renewing the
swabattery
gen AG
.
does
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♦ Ancillaries test without batteryised b ara
nte
r
ho eo
aut ra
c
WARNING ss
ce
e
nl
pt
du
an
itte
y li
tions ⇒ page 3 !
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
WARNING
es, in part or in w
t to the co

rrectness of i

jump starting.
l purpos

nf
ercia
orm
m
atio

om
n in
or c
thi
e
Caution
t
sd
iva
o
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rp
cu
o

f
en
ng
t.
yi
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op py
. C rig
ht ht
rig
battery terminals. py by
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by lksw
cted agen
♦ It can cause sparks through a short-circuit. Prote AG.
damaged.
– Remove battery.


lkswage es n
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Caution ir se
d b ran
tee
tho
u or
a ac
When battery is removed, ensure there is no contact between
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
– Connect red terminal clamp “+” to positive terminal of vehicle.
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
cle.
satelettronica
m
a
com
tion in
r
te o
thi
activated.
s
iva
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rp
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fo
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ng
t.
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Cop py
t. rig
gh ht
yri by
Note cop Vo
by lksw
cted agen
Prote AG.

correct".
– Disconnect red terminal clamp “+” of charger unit from positive
terminal of vehicle.


Note

Note
♦ When a battery is being charged in the trickle charge mode

and an electrical consumer draws current from the battery, the
battery charger - VAS 5903- automatically compensates the
charge.
satelettronica
♦ The trickle charge can be continued for an unlimited period.
♦ Observe battery manufactures maintenance instructions!
WARNING
AG. Volkswagen AG d
agen oes
Danger of injury! Observe warning notices and Volsafety regula‐
ksw not
gu
tions ⇒ page 3 ! d by ara
ise r nte
ho eo
aut ra
ss c
ce
e
nl
WARNING pt
du
an
itte
y li
erm
ab
ility
ot p

wit
, is n
h re

hole
spec
jump starting.
es, in part or in w
t to the co

rrectness of i
When the battery is fully charged the battery charger - VAS 5903-
switches to trickle charge mode.
l purpos

nf
ercia

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

Ameo 2017 ➤ , Arteon 2018 ➤ , Atlas 2017 ➤ , Boraolk1999 ➤ , Bora Varian ...
AG. V swagen AG d
Electrical system - general information - lEdition
kswagen 08.2019 oes
n o ot g
yV ua
edb ran
3.5 Battery charger - VAS 5906- tho
ris tee
or
au ac
ss
3.5.1 General description
ce
le
un
pt
an
d
itte
Battery charger - VAS 5906-
y li
erm
ab
ility
ot p
wit
Note is n
h re
ole,
spec
t to the co
rrectne
ss o
cial p
f in
WARNING
form
mer
atio
m

o
n
c
tions ⇒ page 3 !
i
or
n thi
te
sd
a
satelettronica
iv
o
pr
cum
r
fo
en
ng
t.
WARNING
yi Co
Cop py
t. rig
gh ht
yri
It is not permissible to test or charge batteries whose magic p by
o Vo
by c
lksw
cted agen
Prote AG.
jump starting.

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


VAS 5906-
Note

WARNING

tions ⇒ page 3 !
AG. Volkswagen AG d
agen oes
olksw not
V gu
by
satelettronica
ara
WARNING rised
nte
ho eo
aut ra
It is not permissible to test or charge batteries whose magic ss c
ce
e

nl
pt
du
an
itte
y li
erm
ab
jump starting.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Overview of operating panel:

1- Charge condition display 25 %.
5- Display ready
6- Start/Stop and Setup buttons for interrupting and resum‐
ing charging process. Entry to Letup menu and selection of
characteristic type (press for 10 sec.).
7- Malfunction display.
– Place charger in engine compartment or under vehicle.
– Connect mains cable to charger and plug it into mains.
Charger is in no-load operation - ready light is on.
WARNING
satelettronica
tions ⇒ page 3 !
– Switch off ignition.

en AG. Volkswagen AG d
– Connect red charging cable to positive terminal “+”
olks
wagon battery. oes
not
yV gu
db ara
rise nte
tho eo
Note au ra
c
ss
ce
e
nl
In vehicles with start/stop function and battery monitor control unit pt

du
an
itte
y li
erm

ab
ility
ot p
wit
, is n
h re
– Connect black charging cable to negative terminal “-” on bat‐

hole
spec
tery.
es, in part or in w
t to the co
Charging starts after about 2 seconds.

Number of LEDs lit indicates charge condition of battery. Battery
rrectness of i
has been charged up once all lights are lit.

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

matically switches over to trickle charging.
nform
ercia
Caution
m
at
om
ion
c
Danger of sparking if charging terminals are removed too soon.

in t
or
Terminate charging by pressing START/STOP button.

his
ate
do
priv
cum
for
en
ng
t.
– Press start/stop button to terminate charging.
yi Co
Cop py
ht. rig
– Disconnect black charging cable from negative terminal “-” on rig ht
py by
battery.
co Vo
by lksw
cted agen
Prote AG.
– Disconnect red charging cable from positive terminal “+” on
battery.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
Ameo 2017 ➤ , Arteon 2018 ut
h ➤ , Atlas 2017 ➤ , Bora 1999 ➤ , Bora Varian
o e o ...
ra
a
Electrical
ss system - general information - Edition 08.2019 c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
⇒ “3.6.1 General description - battery charger VAS 5908 ”,
ility
ot
page 63
wit
, is n
h re
hole
⇒ “3.6.2 Auto mode on battery charger VAS 5908 ”, page 64
spec
es, in part or in w
⇒ “3.6.3 Charging battery with battery charger VAS 5908 ”, page
t to the co
66
⇒ “3.6.4 Charging battery in support mode with battery charger
rrectness of i
VAS 5908 ”, page 68
l purpos
⇒ “3.6.5 VAS I-CHECK current draw test with battery charger VAS
5908 ”, page 70
nform
ercia
3.6.1 General description - battery charger -
m
VAS 5908-
a
com
tion in
r
te o
thi
s
iva
do
Note
r
rp
cum
fo
en
ng

t.
yi Co
op
C py
satelettronica
ht. rig
lems during updating and flashing. rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Battery charger - VAS 5908- has the following operating modes:

♦ AUTO MODE , trickle charge with automatic load detection (bat‐
tery or electrical consumer) ⇒ page 64
♦ CHARGE MODE , battery charging with adjustable parameters
⇒ page 66
♦ EPS MODE , external power supply (support mode)
⇒ page 68
♦ I-CHECK , current draw test with short circuit test between cells
⇒ page 70
Technical data
♦ Input voltage: 100-240 VAC
♦ Output voltage: 14.4 VDC (13.2 VDC with trickle charge)
♦ Charge current: 90 A (max. 105 A)
♦ Weight: 8.2 kg
Replacement parts
♦ Charger cable 5m - VAS 5908/1-
♦ Charger coupling - VAS 5908/2-
For additional information, refer to ⇒ Operating instructions for
battery charger - VAS 5908- .

Equipment overview of battery charger - VAS 5908-

1 - “ON/OFF” mains switch
2 - Mains cable connection
3 - UP ▲ button for menu selection
4 - ENTER button for menu selection or start
5 - DOWN ▼ button for menu selection
6 - Battery charger clamp connection + (red clamp)
7 - Battery charger clamp connection - (black clamp)
8 - RS232 communication interface, 9-pin
9 - Signal interface, 25-pin
10 - Display for menu selection
11 - LED display for displaying operating and equipment status
LED display -11-
The LED display on the front of the equipment serves to indicate
satelettronica
the operating and equipment statuses. The relevance of the flash‐
ing or lit green, amber or red LEDs in the various operating
statuses is listed in a table ⇒ Operating instructions battery
charger - VAS 5908- , 8) Attachment for LED and remote indicator
signals .
Equipment menu
In the equipment menu, various parameters and basic settings
can be predefined to safeguard measured
agen
AG. Volkswavalues
gen AG and determine
does
the activation and deactivation
Volksw behaviour of the battery not charger -
gu
VAS 5908- . sedb
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ni tee
or
– Switch on battery
au
th charger - VAS 5908- . or
ac
ss
– Using buttons ▲▼ , choose menu line »MENU« and confirm
ce
le
un
pt
with ENTER button.

an
d
itte
y li
rm
ab
– Using buttons ▲▼ , choose sub-menu »EQUIPMENT MENU«

pe
ility
and confirm with ENTER button.

ot
wit
, is n
h re
For further information about the equipment menu, see ⇒ Oper‐

hole
spec
ating instructions for battery charger - VAS 5908- .

es, in part or in w
t to the co
3.6.2 Auto mode on battery charger - VAS

5908-
rrectness of i
l purpos
Note
nform
ercia

m

com
tio

n in
r
te o
thi

s
iva
do
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rp

um
fo
en
ng
t.
yi Co
op
»AUTO MODE« serves to maintain the voltage in the vehicle
C py
t. rig
gh
electrical system (trickle charge) during flashing or diagnostic
ht
pyri by
Vo
o
work. In »AUTO MODE«, the battery charger - VAS 5908- auto‐ by c lksw
cted agen
matically detects whether a battery or an electrical consumer with
Prote AG.
resistive load is connected by means of integrated load detection.

Starting supply process
Note
If the charger clamps are connected to an electrical consumer or

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

agen oes
ksw not
– Using buttons ▲▼ , choose AUTO MODE and confirm by V with EN-
ol
gu
ara
d
TER button. orise nte
h eo
ut ra
– Connect red terminal clamp “+” to positive
s terminal of vehicle
s a c
battery.
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
♦ On vehicles installed with a start/stop system and battery
h re
hole
monitor control unit - J367- , the black charger terminal clamp
spec
“-” must be connected to the body earth.
es, in part or in w
t to the co
♦ If it is connected to the negative terminal of the battery, the
battery monitor control unit - J367- will be bridged. This could
result in malfunctions in the start/stop system.
rrectness of i
l purpos
– On vehicles with start/stop system, fit the black charger clamp

“-” to body earth.
nform
ercia
– On vehicles without start/stop system, fit the black charger

clamp “-” to the negative terminal of the vehicle battery.
m
at
om
ion
OR
c
in t
or
his
te
– Fit the charger clamps with correct polarity to an electric con‐

a
do
riv
sumer with resistive load.

p
cum
for
en
ng
– Using buttons ▲▼ , choose menu START and confirm with EN-

t.
yi Co
op
TER button to start the supply.
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote
Note
AG.
The battery charger - VAS 5908- adapts the current and voltage
thresholds automatically for auto mode.
Ending supply process

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

lkswage es n
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– Switch off battery charger - VAS 5908- .
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– Disconnect black charger clamp “-” of battery charger from
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negative terminal of vehicle battery or electrical consumer.
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– Disconnect red charger clamp “+” of battery charger from pos‐
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itive terminal of vehicle battery or electrical consumer.
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– Pull out mains plug of charger.
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Danger of injury! Observe warning instructions and safety reg‐ Prote
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WARNING
Do not test or charge batteries - A- whose magic eye is »col‐

ourless/light yellow«. Do not slave/jump start the vehicle!
jump starting.
Note
♦ Follow instructions in chapter »Exhaustively discharged bat‐

teries« ⇒ page 77 .
excluded.
♦ The minimum voltage “Uesp” of the battery to be charged must
be at least 5 V.

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Charging battery
– Switch off ignition and all electrical equipment and then re‐
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– Switch on battery charger - VAS 5908- .
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– Connect red terminal clamp “+” to positive terminal of vehicle
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♦ If it is connected to the negative terminal of the battery, the
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clamp “-” to the negative terminal of the vehicle battery.
– Using buttons ▲▼ , choose CHARGE MODE and confirm with
ENTER button.
Note
♦ The battery charger - VAS 5908- adapts the current and volt‐
age thresholds automatically for charge mode.
♦ Predefine different current and voltage thresholds in the
charging menu if necessary ⇒ page 68 .
Ending battery charging process

negative terminal of vehicle battery.
itive terminal of vehicle battery.

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

matically changes to trickle charging once the battery is fully
charged.
Charging menu
The battery charger adapts the current and voltage thresholds
automatically for charge mode. The parameters for charging
mode can also be set manually.
with ENTER button.
– Using buttons ▲▼ , choose sub-menu »CHARGING MENU«
and confirm with ENTER button.
For further information about the charging menu, see ⇒ Operating
instructions for battery charger - VAS 5908- .
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the software is updated or flashed in a vehicle to prevent prob‐ en AG. Volkswagen AG
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♦ “VAS 5903” ⇒ “3.4 Battery charger VAS 5903 ”, page
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♦ “VAS 5908” ⇒ “3.6 Battery charger VAS 5908
ss ”, page 63
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Support or backup mode (»EPS MODE«) serves to supply the
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vehicle electrical system with power if the battery is disconnected
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In »EPS MODE«, only a resistive load (electrical consumer)

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Performing support mode

– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Removing
and installing battery .
– Switch on battery charger - VAS 5908- .
satelettronica
Caution
Make absolutely sure that the red charger clamp does not
come into contact with the body earth.
Make absolutely sure that the battery terminal clamps do not
come into contact with each other.
– Connect red terminal clamp “+” of charger to positive terminal

clamp of vehicle battery.
Note
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♦ On vehicles
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clamp “-” to the negative terminal clamp of the vehicle battery.

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♦ The battery charger - VAS 5908- adapts the current and volt‐
l purpos
age thresholds automatically for support mode.

♦ Predefine different current and voltage thresholds in the EPS
nform
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menu if necessary ⇒ page 70 .

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– Using buttons ▲▼ , choose EPS MODE and confirm with EN-

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with ENTER button.
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– Using buttons ▲▼ , choose sub-menu »EPS MENU« and con‐
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firm with ENTER button.
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For further information about the EPS menu, see ⇒ Operating
hole
instructions for battery charger - VAS 5908- .
spec
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3.6.5 VAS I-CHECK current draw test with
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The current draw test serves as a means of quickly appraising the
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Note
For the battery current draw test, take measures to ensure that
the battery is testing without electrical consumers attached in
parallel.

Perform current draw test

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

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

battery .
– Switch on battery charger - VAS 5908- and connect to battery
with correct polarity using charger clamps.
– Using buttons ▲▼ , choose menu line »AUTO MODE« and
confirm with ENTER button (display flashes).
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– Using buttons ▲▼V,ochoose
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– Activate abattery
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capacity input »Qbat:« by pressing ENTER
or
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button (flashes).
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– Using buttons ▲▼ , set capacity (Ah) of battery to be tested and
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confirm with ENTER button.
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– Using buttons ▲▼ , choose menu line »TEST START« and
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confirm with ENTER button to start the current draw test. Note
h re
hole
possible connection error messages ⇒ page 72 .
spec
es, in part or in w
While current draw test is running, »TEST« flashes in display.
t to the co
Button lock is activated, active test can only be interrupted by re‐
moving charger clamps. Note possible abort error messages
satelettronica
⇒ page 72 .
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End of test with result 'Current draw I less than 100 %' (battery
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If the current draw »I« is <100 % at the end of the test, the current
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supply to the battery is interrupted and »FILL IN WARRANTY rm
APPLICATION« appears in the display.
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– Using buttons ▲▼ , choose »OK« and confirm with ENTER but‐

or
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ton to display the test results.

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The current draw percentage is displayed in the results windows

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test sheet. t. Cop py
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– Using buttons ▲▼ , choose »TEST END« and confirm with yri
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ENTER button to stop the current draw test.
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End of test with result 'Current draw I greater than 100 %' (battery
in order but insufficiently charged)
If the current draw »I« is >100 % at the end of the test, the current
supply to charge the battery is continued.
– Using buttons ▲▼ , choose »RESULT« and confirm with EN-
TER button to display the test results.
The current draw percentage is displayed in the results windows

under »I«.
– Using buttons ▲▼ , choose »OK« or »TEST END« and confirm
with ENTER button to change to “I-Check charge mode” and
continue charging the battery.
In I-Check charging mode, »CHARGING« flashes in the display
until the battery is fully charged. Once the charging process is
complete, the equipment switches automatically to trickle charge.
»TRICKLE« flashes in the display.

Note
♦ While the battery is being charged in “I-Check charging mode”,

the short circuit between cells test is automatically active.
♦ When the short circuit between cells test is active, the battery
charge is interrupted twice for approx. 30 seconds in order to
perform a voltage measurement.
♦ If the short circuit between cells test is positive, the charging
process is interrupted and »CELL SHORT CIRCUIT« is dis‐
played.
Connection error messages

♦ »APPLICATION ERROR - CONTACT« = no battery detected
and no battery connected.
♦ »APPLICATION ERROR - POLARITY REVERSAL« = battery
was connected with polarity reversal.
♦ »APPLICATION ERROR - EXHAUSTIVE DISCHARGE« =
voltage level of connected battery is below the activation volt‐
satelettronica
age limit (Uesp) as defined in the charging menu.
Abort error messages
♦ »APPLICATION ABORT - CONTACT« = battery was discon‐
nected during the test.
♦ »APPLICATION ABORT - SHORT CIRCUIT« = short circuit
determined in battery cables.
3.7 Midtronics - INC 940- battery charger

only for USA/Canada
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Warning and safety regulations
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General description ⇒ page
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Charge battery ⇒ page 73 .

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Dealing with problems with Midtronics - INC 940- battery tester

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⇒ page 75
ility
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3.7.1 General description of Midtronics - INC

h re
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940- battery tester

spec
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Batteries in VW vehicles are only allowed to be charged with bat‐

tery chargers approved by VW. In the USA/Canada, it is permitted
for the Midtronics - INC 940- battery charger to be used.
rrectness of i
Midtronics - INC 940- battery charger combines battery charging

l purpos
with a charge condition checks and a battery test.

The following charging and analysis procedures apply to all bat‐
nform
ercia
teries, all battery installation locations (engine compartment or

luggage compartment) and battery application purposes (starter
m
at
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battery or second/convenience battery).

ion
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Always comply with the safety regulations, the regulations for

his
ate
setting up the battery charger, the display menu/display buttons,

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LEDs and the operating procedures described in the ⇒ operating

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manual INC 940 .

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Read through ⇒ operating manual INC 940 carefully.
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Refer to ⇒ Self-study programme No. ; Vehicle batteries for more
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WARNING

tions ⇒ page 3 !
No naked flames, sparking or smoking in the vicinity of batter‐
ies.
Battery charger must be switched off before cables are con‐
nected or disconnected.
Do not remove cell plugs during charging.
Overcharging sulphated batteries can lead to explosions.
Do not store precision tools in rooms where batteries are
charged, because corrosion can ensue due to chemical reac‐
tions.
WARNING
satelettronica
jump starting.
These batteries must be renewed. AG. Volkswagen AG d
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3.7.2 Charging battery or eo
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To avoid problems when updating or flashing the vehicle soft‐
ot p
ware, a charger capable of outputting a charge current of at least
wit
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70 A (such as e.g. the “VAS 5903”) should be used. ⇒ page 48
hole
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Prerequisites:
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WARNING
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nform
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jump starting.
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INC 940 initial set-up performed (dealership number, date/time)

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⇒ Operating manual INC 940 .

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– Check general information ⇒ page 72 . C py
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– Open bonnet or cover for other installation location of battery. op Vo
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– Perform visual check of battery ⇒ page 7 .
AG.
– Determine whether battery type is “Standard” (wet battery) or

“AGM” (absorbent glass mat battery).
– Close all vehicle doors.

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

INC 940 .
Perform charging procedure:

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

- J367- fitted, black terminal clamp “–” must be connected to body AG. Volkswagen A
earth. Connecting it to battery negative terminal will cause start/ wage
n G do
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stop system to malfunction. ot g
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– Connect black terminal clamp “–” of battery charger
au to nega‐ ac
ss
tive terminal.
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un
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– Connect Midtronics - INC 940- battery charger to an earthed
an
d
itte
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socket.
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ab
pe
ility
– Set “ON/OFF” switch of Midtronics - INC 940- battery charger
ot
wit
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to “ON”.
h re
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spec
– Select “Automatic” or “Manual” charging mode.
es, in part or in w
t to the co
– Select test “In vehicle” or “Outside vehicle”.
– Select battery type “Standard” or “AGM” (absorbent glass
mat).
rrectness of i
– Select test type “Warranty” or “Miscellaneous”. Note additional
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details (depending on type of test).
nform
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Note
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INC 940 .
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♦ If necessary, make a note of menu items required for “War‐

um
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ranty” test type ⇒ Warranty service circular .

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Midtronics - INC 940- battery charger tests battery and starts rig ht
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charging procedure. Display then shows one of three results, as
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well as approximate charging time.
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Result: Measures:
Battery OK Battery can be returned to op‐
eration.

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

procedure is interrupted. Re‐
new battery.
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In case ut
h Midtronics - INC 940- shows fault messagese oor text
or
dis‐
plays
ss
a other than those listed above, please refer to r ac
⇒ page 75 . ce
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WARNING ility
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Stop charging if battery is liberating a lot of gas. Press “Stop”

h re
ole,
button on front.
spec
t to the co
When charging and testing procedure has finished, Midtronics -

INC 940- battery charger displays “Battery good” or “Renew
rrectne
battery” and total charging time.

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

o
cial p
f in
♦ Generate test code (only possible after automatic charging

form
mer
and test).
atio
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♦ Print last test result (for warranty).

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♦ Display last test results.

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For additional information, refer to the ⇒ operating manual INC
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3.7.3 Dealing with problems with Midtronics -

INC 940- battery tester
Under certain circumstances, the display may show errors or
messages according to status.
The most frequent display messages are listed below, together
with suggested solutions.
Note
For messages not listed here, please refer to ⇒ operating manual

INC 940 .

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Electrical system - general information - Edition 08.2019 Volksw not
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Display message Measure tho or
s au ac
s
Check connection. – Check whether terminals of
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battery charger are firmly
pt
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connected to battery termi‐
itte
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erm
nals.
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ility
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– Check battery terminals are
, is n
h re
tightened according to reg‐
hole
spec
ulations and do not have
es, in part or in w
corrosion.
t to the co
Terminals connected? Safety function of tester.
– Connect terminals to battery
before starting charging pro‐
rrectness of i
cedure.
l purpos
System noise – Switch off all electrical con‐
sumers.
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– Wait until all electrical loads
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atio
monitored by on-board sup‐
om
ply control unit have switch‐
n in
or c
ed off.
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– Pull out ignition key.

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– Disconnect any suspect
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electrical equipment not
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connected to on-board sup‐ p by
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ply as standard.
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Wait a few minutes and repeat charging procedure ⇒ page 73 .
3.8 Solar charger module - VAS 6102B-

with solar panel - VAS 6102B-
Solar charger module VAS 6102B
Solar panel - VAS 6102B- supports onboard supply and prevents
spontaneous discharging of battery.
Solar charger module - VAS 6102B- achieves max. voltage of
14.3 V and a charge current of max. 255 mA.
Solar charger module - VAS 6102B- is allowed to be used for
charging all rechargeable lead or lead gel batteries.
Solar charger module - VAS 6102B- is connected to diagnostic
connection in vehicle.
A green LED is integrated in the frame to indicate its function. The
brighter the LED, the higher the charging current.
Integrated electronics prevent battery overcharging.

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

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– Place underside on dash panel -2-. olksw not
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Note ss a c
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Solar charger module - VAS 6102B- is not allowed to lie fully on
an
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dash panel. It is only allowed to be positioned with the bottom
rm
ab
edge for support. Placing it fully on the surface can result in dis‐
pe
ility
colouration of the dash panel.
ot
wit
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h re
hole
– Pull attachment string tight so that solar charger module - VAS
spec
es, in part or in w
6102B- is positioned close to windscreen.
t to the co
– Connect solar panel - VAS 6102B- to diagnostic connection of
vehicle. Connection procedure is as for vehicle diagnostic
tester ⇒ page 96
rrectness of i
– Check function of solar panel - VAS 6102B- . Green LED in‐
l purpos
dicates function of solar panel - VAS 6102B- .
nform
ercia
3.9 Totally discharged batteries

m
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tion in
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WARNING
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A battery is designated “totally discharged” when the no-load volt‐ co Vo
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WARNING

jump starting.
Caution
♦ Totally discharged batteries freeze prematurely.

♦ Frozen batteries should no longer be used.

Note

excluded.
♦ Batteries that have not been used for a long period of time
discharge themselves, e.g. those fitted in stored vehicles.
♦ In totally discharged batteries, the electrolyte is comprised al‐
most entirely of water because the acid content is so low.
♦ Totally discharged batteries sulphate, that means, the entire
plate surfaces of the battery harden.
♦ If a battery is recharged shortly after it has totally lost its
charge, the sulphation will mostly dissipate.
♦ If these batteries are not recharged, the plates continue to
harden and the ability to recharge is reduced. The result of
which is a reduction in the battery output.
– Check battery no-load voltage ⇒ page 22 .
satelettronica
AG. Volkswagen AG d
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Electrical
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4 Cruise control system (CCS)
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The functions of the cruise control system are controlled by the
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engine control unit.
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spec
– The cruise control system can be activated/deactivated
⇒ page 79 .
t to the co
Fault detection and fault display:
Faults on the CCS are output via the engine control unit.
rrectne
For fault finding, use vehicle diagnosis, testing and information
s
system in “Guided fault finding” mode.
s o
cial p
f in
4.1 Activating and deactivating cruise con‐
form
mer
trol system (CCS)
atio
om
n
c
i
– Connect vehicle diagnostic tester ⇒ page 96 .
or
n thi
te
sd
iva
o
pr
c
– Select “Guided fault finding” mode in vehicle diagnostic tester .
um
r
fo
en
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t.
– Using the “GoTo” button, select “Function/component selec‐
yi Co
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tion” and the following menu items in succession:
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♦ Engine code
♦ 01 - Systems capable of self-diagnosis
♦ Engine management/diesel direct injection and glow plug sys‐
tem
♦ Functions
♦ Activating and deactivating cruise control system (CCS)
4. Cruise control system (CCS) 79

90 – Gauges, instruments
satelettronica
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80
Prote AG.
Rep. gr.90 - Gauges, instruments
92 – Windscreen wash/wipe system

1 Washer fluid line hose couplings
The following hose coupling types are used to connect the hose
connection to pumps and washer jets and/or as points of sepa‐
ration:
1.1 Windscreen and rear window washer

system
– Pull the two coupling sections apart (no securing device) to
loosen the connection.
– To secure the connection, push the two coupling sections to‐
gether, until you hear and feel them engage.
satelettronica
– To loosen the connection, rotate the lock ring -1- 90° -arrow-
and pull off the hose connection.
wage es n
– To secure the connection, push on the hose connection yV
o and
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rotate the lock ring -1- -arrow- until it engages. rised b ran
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– To loosen the connection, pull up the lock ring -1- by approx.

t to the co
1 mm -arrow-, and pull off the hose connection.
– To secure connection, attach hose connection and press in
rrectness of i
clip -1- until it engages.

l purpos
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ate
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1. Washer fluid line hose couplings 81

– To loosen the connection, pull up the lock ring -1- -arrow- and
pull off the hose connection.
– To secure connection, attach hose connection and press in
clip -1- until it engages.
1.2 Headlight washer system

– To loosen the connection, push the lock ring -1- -arrow- and
pull off the hose connection.
– To secure the connection, push and hold the lock ring
-arrow- and push on the hose connection. Check that the se‐
curing clip has correctly engaged by depressing and trying to
pull off without the clip.
satelettronica
AG. Volkswagen AG d
agen oes
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ate
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Prote AG.
82 Rep. gr.92 - Windscreen wash/wipe system

2 Hose repair
A new repair concept has been developed for repair work on wash
system hoses. Various connectors, special EPDM hoses (ethyl‐
ene-propylene-diene monomer) and heat-shrink hose are avail‐
able as spare parts.
2.1 General description

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

Smooth pipes with a diameter of 5x1 mm or 6x1 mm can be re‐
paired with EPDM hose.
– Cut damaged section at right angles out of smooth pipe which
is to be repaired.
– Select the appropriate EPDM hose -2- and cable ties accord‐
satelettronica
ing to the electronic parts catalogue (ETKA).
– Cut EPDM hose -2- so that ends -1- and -3- of smooth pipe
can each be pushed about 10 mm into the EPDM hose -2-.
– Secure the repair joints with cable ties -1-.
AG. Volkswagen AG d
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2.3 Repairing corrugated pipe
ility
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hole
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♦ Hot air blower - VAS 5179- or

es, in part or in w
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♦ Hot air blower - V.A.G 1416/- or

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♦ Hot air blower - VAS 1978/14- C py
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Prote AG.
2. Hose repair 83
Note
♦ Repair points must not be subjected to pulling or bending

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

which is to be repaired.
– Select suitable end pieces -2- and -3- and correct sized shrink-
fit piping from the electronic parts catalogue (ETKA).
– Heat end of corrugated tube -1-.
– Push connector -2- into corrugated tube -2- -arrow A-.
– Heat end of corrugated tube -4-.
– Push connector -3- into corrugated tube -4- -arrow B-.
satelettronica
– Cut heat-shrink hose so that ends of corrugated tube are each
covered by about 20 mm -dimension x- of heat-shrink hose.
– Push heat-shrink hose over corrugated tube, join connectors
and secure repair joints with heat-shrink hose. swa
gen AG
. Volkswagen AG
does
k not
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cial p
f inform
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Prote AG.
84 Rep. gr.92 - Windscreen wash/wipe system

3 Distinguishing features of jointless

wiper blades
Distinguishing features of Bosch and Federal Mogul products.
When renewing wiper rubbers, note the make. When renewing
wiper blades, the same make must be used.
Wiper blades can be identified according to wiper arm fastening.
Bosch wiper blades -1 and 2-:
satelettronica
Federal Mogul wiper blades -1-:
AG. Volkswagen AG d
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cial p
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3. Distinguishing features of jointless wiper blades 85

94 – Lights, bulbs, switches - exterior

1 Operation and safety notes for gas
discharge lamps
– If repairs are to be made to the headlight with gas discharge
bulbs, observe the following:
♦ Notes on dangerous high voltage/currents ⇒ page 86
♦ Notes on pressure, temperature, radiation/arcs ⇒ page 87
♦ Assembly notes for gas discharge bulbs ⇒ page 88
♦ Disposal regulations for gas discharge bulbs ⇒ page 88
Special tools and workshop equipment required AG. Volkswagen AG d
agen oes
olksw not
♦ Safety goggles d by V gu
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♦ Gloves utho eo
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satelettronica
WARNING
un
pt
an
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It is absolutely necessary to disconnect the battery earth strap
ility
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before working on parts of the gas discharge headlights
wit
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marked with yellow high voltage symbols.
h re
ole,
Then switch dipped beam on and off again. This will eliminate
spec
any possible residual voltage.
t to the co
The gas discharge lamp control unit must never be operated
without a gas discharge lamp.
rrectne
Due to the high voltage (above 28000 V when igniting the gas
discharge bulb) and high temperatures, the gas discharge bulb
s
must only be operated in the headlight housing.
s o
cial p
f inform
mer
atio
m
WARNING
o
n
c
i
or
n thi
e
♦ Never change bulbs if you are not familiar with the appro‐
t
sd
iva
priate procedures, safety precautions and tools.

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Notes on dangerous high voltage and current
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WARNING Prote AG.
Control units for light systems, connectors and components

pertaining to bulb holders conduct lethally high voltage.
Operating the control unit and the starter unit is permitted only
with the bulb fitted.
86 Rep. gr.94 - Lights, bulbs, switches - exterior

WARNING
• Switch off ignition and all electrical consumers and re‐

move ignition key.
• When working on the headlight system, ensure that there
is no voltage in any component, including dissipation of
residual voltage after the headlights are switched off.
• Residual voltage can be dissipated by turning the dipped
beams on and then off again after withdrawing the ignition
key.
• When working on the headlight system, ensure that the
lights cannot be switched on.
Notes on pressure, temperature, radiation/arcs
WARNING
• The bulbs may be operated in the headlight housing only

(protection against contact due to very hot bulbs, absorp‐
satelettronica
tion of UV radiation, avoidance of dazzling light, protection
against explosion).
• The glass of the bulbs can become very hot - danger of
burns! agen
AG. Volkswagen AG d
o
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olks o
• Avoid dlooking
by
V directly into the beam, as the
t gu
arUV rays from
theorgas discharge bulb are about 2.5 times greater
ise an
tee than
normal
au
th halogen bulbs. or
a
ss c
• Avoid looking into the light beam (danger of glare); vision
ce
le
un
pt
may be impaired for a substantial time.

an
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WARNING
h re
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spec
• Avoid contact with burst glass part of the bulbs.

es, in part or in w
t to the co
• H7 bulbs and gas discharge bulbs (xenon and bi-xenon)

are under pressure and can explode while being changed
– danger of injury.
rrectness of i
• Always wear eye protection and gloves when removing

l purpos
and installing gas discharge lamps!

nform
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te o
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Prote AG.
1. Operation and safety notes for gas discharge lamps 87

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

ing a bulb.
G. Volkswagen AG d
♦ Switch off ignition and all electrical consumers and
lkswre‐
agen
A
oes
not
move ignition key. db
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♦ Do not touch the glass part of the bulb uwith
thor
bare fingers; eo
use clean cloth gloves. When the lightssbulb is switched on,
a ra
c
the heat would vaporise the oil of the finger prints which
ce
le
un
would then settle on the reflector, impairing the brightness
pt
an
d
itte
of the headlight.
y li
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ab
♦ A light bulb must always be renewed with a bulb of the
ility
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same sort. The designation appears on the base of the
wit
is n
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bulb or on the bulb glass.
ole,
spec
♦ Properly engage connectors during installation and the

connection is seated tightly.
t to the co
satelettronica
rrectne
Disposal regulations for gas discharge bulbs
s
WARNING
s o
cial p
f inform
• Gas discharge bulbs must be disposed of as hazardous
mer
waste; never dispose of gas discharge bulbs as consumer
atio
m
waste.
o
n
c
i
or
n thi
• Gas discharge bulbs contain metallic mercury (Hg) and
te
sd
a
traces of thallium; never destroy these bulbs.

iv
o
pr
cum
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fo
• These components must be recycled in the correct man‐

en
ng
t.
yi
ner according to national law.
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• Only dispose of in containers intended for this purpose at
ht
pyri by
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an authorised collection point.
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Prote AG.
88 Rep. gr.94 - Lights, bulbs, switches - exterior

96 – Lights, bulbs, switches - interior

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

the retaining sleeve may be damaged.
Only illuminated sockets (cigarette lighter) can be removed
with the puller T 40148.
The puller does not manage to release the locking lugs of
sockets without illuminated
wage
retaining
n AG. Volkssleeve.
wagen AG
doe
olks s no
Usually sockets ewithout illumination cannot be removed
ara with‐
yV gu t
db
out being damaged.
horis nte
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satelettronica
t or
au ac
ss
ce
e
nl
Refer to removing and installing cigarette lighter - U1-

pt
du
⇒ page 90 . an
itte
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ab
1.2 Removing and installing socket illumi‐ ility
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nation bulb - L42-

h re
hole
spec
The removal of the socket illumination bulb - L42- is performed in

es, in part or in w
the same way as the removal of the cigarette lighter illumination

t to the co
bulb - L28- ⇒ page 94 .

rrectness of i
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Prote AG.
1. 12 V socket 89
2 Cigarette lighter - U1-

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

sockets without illuminated retaining sleeve.
Usually sockets without illumination cannot be removed with‐
out being damaged.
satelettronica
2.1 General description
Caution

The puller does not manage togerelease
AG. Volksthe
wagelocking
n AG d lugs of
a n
sockets without illuminatedVoretaining
lksw sleeve. oes
not
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Usually sockets without
ris illumination cannot be removed with‐ ntee
e ra
out being damaged.tho or
au a c
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an
On some vehicles, the illumination is not provided by a light bulb,

itte
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but by an LED (light-emitting diode), depending on the equipment

erm
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level. This LED is permanently attached to the retaining sleeve

ility
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and cannot be renewed separately.

wit
, is n
h re
Retaining sleeves with a light bulb are available in different ver‐

hole
spec
sions. On the one version, the light bulb can be replaced sepa‐
es, in part or in w
rately; on the other version, the light bulb cannot be replaced

t to the co
separately. In this case, the bulb carrier has to be replaced to‐

gether with the light bulb.
rrectness of i
Depending on the space requirement, the vehicles are equipped

with various electric sockets and cigarette lighter sockets. They
l purpos
differ in length and have different electrical connections. In the

case of electric sockets or cigarette lighter sockets with a wiring
nform
ercia
tail, it may be necessary to perform additional work in order to

gain access to the connector.
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om
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ate
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Prote AG.
90 Rep. gr.96 - Lights, bulbs, switches - interior

2.2 Assembly overview
Caution

out being damaged.
1 - Cigarette lighter socket with

wiring tail
2 - Cigarette lighter
3 - Electric socket
satelettronica
4 - Cigarette lighter socket
5 - Clamping sleeve
6 - Light bulb W 5 12 V 1.2 watt
7 - Bulb carrier olkswage es n
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cial p
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2. Cigarette lighter U1 91
2.3 Removing and installing cigarette lighter

socket
Note
The removal and installation procedure is the same for all sockets
and is therefore described here only for the cigarette lighter sock‐
et.
Caution
AG. Volkswagen A
If excessive force is exerted oon
lkswsockets without illumination,
agen G do
es n
the retaining sleeve may dbe Vdamaged. ot g
by ua
r e an
ris tee
Only illuminated socketstho (cigarette lighter) can be removed or
s au
with the puller T 40148. ac
s
ce
le

un
pt
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ab
ility
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ot p
out being damaged.
wit
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spec
t to the co
♦ Puller - T 40148-
rrectness o
cial p
f inform
mer
atio
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Removing:
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– Remove cigarette lighter, dummy cigarette lighter etc. from by c lksw
cted agen
socket if necessary. Prote AG.
Note
For reasons of clarity, the socket is removed in the illustration.
Caution
The socket or the retaining sleeve can be damaged.

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

– Push puller -arrow- into socket so that locking lugs -1- engage
in recesses -2-.
– Pull grip -3- in direction of -arrow- to release locking lugs of

retaining sleeve.
– Pull socket out of retaining sleeve using puller.
Caution
The socket wiring can be damaged.
satelettronica
Take care not to stretch the wiring when pulling out the socket.
Depending on the fitting location, it is recommended to use the

thrust piece 40148/1 -2- with the knurled nut -1-.
Caution
When using the thrust piece, ensure that no surrounding com‐

ponents are damaged. G. Volkswage nA n AG d
wage oes
Volks not
gu
by ara
ed
– Pull off socket connector.
oris nte
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th
au ra
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ss
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e
Note
nl
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an
itte
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erm
Depending on the space requirement, the vehicles are equipped

ab
ility
with various electric sockets and cigarette lighter sockets. They

ot p
wit
differ in length and have different electrical connections. In the

, is n
h re
case of electric sockets or cigarette lighter sockets with a wiring

hole
spec
tail, it may be necessary to perform additional work in order to

es, in part or in w
gain access to the connector.

t to the co
rrectness of i
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nf
ercia
orm
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Prote AG.
– Release puller locking lugs by pressing spindle -1- in direction

of -arrow B-. Then release puller -2- by turning it briefly to left
-arrow A-. Remove puller from socket.
Note
Ensure that the puller locking lugs are not spread.

AG. Volkswagen AG d
agen oes
olksw not
Caution byV gu
ara
ed
ris nte
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ut
The cigarette lighter might be ejected out
ss a of the socket after ra
c
the heating phase.
ce
e
nl
pt
du
an
When the puller is mounted, the socket retaining springs are
itte
y li
pressed apart and the retaining force is reduced.
erm
ab
ility
ot p
After removing the socket, carefully press the retaining springs
wit
, is n
together and check if the cigarette lighter remains in the re‐
h re
moval position after the heating phase.
hole
spec
es, in part or in w
t to the co
satelettronica
– Carefully press socket retaining springs together -arrows-.
rrectness of i
– Check if cigarette lighter remains in removal position after
heating phase and ensure it is not ejected in vehicle interior.
l purpos
Installing:
nf
ercia
Installation is carried out in the reverse sequence of removal.
orm
m
atio
om
n in
or c
thi
te
sd
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t.
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2.4 Removing and installing cigarette lighter rig ht
py by
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illumination bulb - L28-
by c lksw
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Prote AG.
Note
♦ On some vehicles, the illumination is not provided by a light

bulb, but by an LED (light-emitting diode), depending on the
equipment level. This LED is permanently attached to the re‐
taining sleeve and cannot be renewed separately.
♦ Retaining sleeves with a light bulb are available in different
versions. On the one version, the light bulb can be replaced
separately; on the other version, the light bulb cannot be re‐
placed separately. In this case, the bulb carrier has to be
replaced together with the light bulb.
Removing:
– Remove socket ⇒ page 92 .

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

gether with bulb carrier.
– Unclip bulb carrier from retaining sleeve.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
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ce
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un
pt
– Separate bulb carrier in areas -A- and -B-.
an
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itte
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rm
ab
– Open part -B- of bulb carrier.
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
satelettronica
rrectness of i
l purpos
nform
ercia
– Remove light bulb in direction of -arrow-.

m
a
com
Installing:
tion in
r
te o
Installation is carried out in the reverse sequence of removal.
thi
s
iva
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Prote AG.
97 – Wiring
1 Vehicle diagnosis, testing and infor‐
mation systems
WARNING
♦ During testing or measuring operations using a vehicle di‐

agnostic information system there is a risk of serious or
even fatal injury!
♦ If the vehicle diagnostic information system is situated in
the activation area of an airbag during testing or measur‐
ing operations, serious or even fatal injury may result if an
airbag is triggered! olks
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♦ During testing and measuring operations,
ris
ed work with a per‐ ara
nte
son who can operate the vehicleutdiagnostic
ho and informa‐ eo
ra
tion system from one of the back
ss seats.
a c
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♦ All the operations described, e.g. adaptation, coding, etc. can
ole,
spec
be performed using the vehicle diagnostic tester .
t to the co
♦ All work procedures can be found in “guided fault finding” and
“guided functions” modes.
♦ Additional information:
rrectne
⇒ Self-study programme No. 202 ; Vehicle diagnostic, testing
ss o
and information system VAS 5051
cial p
f inform
⇒ Self-study programme No. 256 ; VAS 5052
mer
atio
m
⇒ Self-study programme No. 294 ; Online connection of VAS

o
n
c
5051
i
or
n thi
te
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– Connect vehicle diagnostic tester ⇒ page 96 .

iv
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1.1 Connecting vehicle diagnostic tester

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Observe the latest operating instructions for vehicle diagnostic
tester , which are displayed after selecting the “Administration”
and “Operating Manual” keys.
96 Rep. gr.97 - Wiring

♦ Vehicle diagnostic tester
♦ Diagnostic cable - VAS 5051/6A- (5 m)
satelettronica
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♦ Diagnostic cable - VAS 5051/5A- (3 m)

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

rrectness of i
Connecting vehicle diagnostic tester :

l purpos
– Apply handbrake.
– Vehicles with automatic gearbox, move selector lever to posi‐
nf
ercia
tion “P” or “N”.

orm
m
– Vehicles with manual gearbox, move gear lever to neutral po‐

atio
m
sition.
o
n in
or c
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– With ignition switched off, connect vehicle diagnostic tester

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

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-arrow- in vehicle.
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– Switch on ignition. t. Cop py
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– Switch off all electrical consumers. pyri by
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Note
All other and the following vehicle diagnosis, testing and informa‐
tion systems or vehicle diagnostic and service information sys‐
tems are connected accordingly in the sequence described
above.
1. Vehicle diagnosis, testing and information systems 97

1.2 Connecting vehicle diagnostic tester

Golf Model Year 1998 - 2003
– Apply handbrake.
– Vehicles with automatic gearbox, move selector lever to posi‐
tion “P” or “N”.
– Vehicles with manual gearbox, move gear lever to neutral po‐
sition.
– Pull out trim -1- in direction of arrow.
– With ignition switched off, connect vehicle diagnostic tester
using diagnostic cable to diagnostic interface -arrow- in vehi‐
cle.
– Switch on ignition.
– Switch off all electrical consumers.
Note
All other and the following vehicle diagnosis, testing and informa‐
satelettronica
tion systems or vehicle diagnostic and service information sys‐
tems are connected accordingly in the sequence described
above.
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es, in part or in w
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98
cop Vo
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Rep. gr.97 - Wiring Prote
cted AG.
agen
2 Repairs to wiring harnesses and con‐

nectors
2.1 General notes concerning repairs to ve‐

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

dure described in the workshop manual must be strictly ob‐
served.
WARNING
Some tools are equipped with a tool safety device. This must
be pushed over the tip of the tool after use in order to protect
satelettronica
the tip and prevent personal injury.
AG. Volkswagen AG d
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2. Repairs to wiring harnesses and connectors 99

satelettronica
AG. Volkswagen AG d
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es, in part or in w
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♦ Observe the latest notes in the respective workshop manual

when carrying out repairs.
♦ Observe country-specific regulations.
♦ Always disconnect the battery earth strap before working on
the electrical system. Disconnecting the battery earth strap
(open circuit) provides a safe working environment for repairs
to the electrical system. The battery positive wire need only be
disconnected for removal of the battery.
♦ Before starting a repair, it is important tonidentify
AG. Volksand
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the cause of damage (e.g. sharp oedges
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oes
not
fective electrical components,d bcorrosion,
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♦ For additional information,
ut e.g. removal and installation of in‐
ho or
dividual components, splease
sa refer to the relevant workshop ac
manual.
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♦ Soldering is not permitted for repairs to vehicle wiring.

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

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

m
regarding repairs to wiring harnesses in airbag and belt ten‐
a
com
tio
sioner systems, fibre optic cables, CAN bus lines, aerial cables
n in
r
and wiring with cross sections up to 0.35 mm2 ⇒ page 110 .

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

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

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

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

Wiring harness repair set - VAS 1978- allows optimal repair qual‐
ity to be achieved in the area of vehicle electrics. Using the tools,
repairs to connectors and wiring open circuits can be carried out.
To do this, complete repair wire sections with contacts already
crimped on are used and joined to the vehicle's own wiring har‐
ness with the aid of crimp connectors. A special set of pliers with
three different crimp recesses and a hot air blower for shrinking
the crimp connectors make a perfect electrical connection.
Note
Additional information:
⇒ Operating instructions Wiring harness repair set - VAS 1978-
2.2.2 Upgrade kit - VAS 1978/50-
satelettronica
Upgrade kit - VAS 1978/50- is required to bring the “old” wiring
harness repair set - VAS 1978- up to the latest standard of wiring
harness repair set - VAS 1978A- . The upgrade kit comprises of
4 assembly and 10 release tools, a new set of crimping pliers for
crimp connectors with head adapter 0.35 - 2.5 mm2 -VAS
1978/1-1- , 4.0 - 6.0 mm2 -VAS 1978/2 A- and head adapter for
JPT contacts - VAS 1978/9-1- . Also included are newagstickers,
en AG. V a agen AG doe
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new set of operating instructions, crimp connectorsol for
ksw 0.35 s no
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2 yV
mm cable cross-section and a roll of blackisefelt adhesive tape.
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2.2.3 Wiring harness repair set - VAS 1978A-

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The new wiring harness repair set - VAS 1978A- allows optimal
ole,
repair quality to be achieved in the area of vehicle electrics. Using

spec
the new pliers, repairs to connectors and wiring open circuits can
t to the co
be carried out. To do this, complete repair wire sections with con‐

tacts already crimped on are used and joined to the vehicle's own
wiring harness with the aid of four different types of crimp con‐
rrectne
nectors. A new set of crimping pliers with head adapters and a

hot air blower for shrinking the crimp connectors make a perfect
electrical connection.
ss o
cial p
f inform
Note
mer
atio
om
Additional information:
c
i
or
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sd
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⇒ Operating instructions Wiring harness repair set - VAS 1978A-

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2.2.4 Release tool set - VAS 1978/35-

Release tool set - VAS 1978/35- serves as a means of releasing
various primary and secondary locking devices in Group vehicles.
The set comprises of 26 different tools with which, for example,
round connector systems, flat contacts with one or two fasteners
and also single wire seals can be released or fitted.
Allocation of the correct release tool to the respective locking de‐
vices can be gleaned from the table in the ⇒ operating instruc‐
tions of -VAS 1978/35- . n AG. Volkswagen AG do
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2.3 Tool descriptions
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2.3.1 Special pliers with insert
hole
spec
es, in part or in w
t to the co
The special pliers without insert - VAS 1978/1- with insert for spe‐
satelettronica
cial pliers - VAS 1978/2- is part of the wiring harness repair set -
VAS 1978- and is used to crimp connectors during wiring harness
repairs.
rrectness of i
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Colour of crimp Colour of crimp re‐ Wiring cross section

connector cess
nf
ercia
Yellow Yellow 0.35 mm2
orm
Red Red
m
0.5 mm2 - 1.0 mm2
atio
om
n in
blue blue 1.5 mm2 - 2.5 mm2
or c
thi
e
Yellow Yellow 4.0 mm2 - 6.0 mm2

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♦ As an alternative, the connectors can also be crimped with
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crimping pliers (base tool) - VAS 1978/1-2- in conjunction with
agen
Prote AG.
head adapters -VAS 1978/1-1- or -VAS 1978/2A-
⇒ page 105 .
♦ Ensure without fail that the correct crimp recess is chosen for
the crimp connectors being used.
♦ The insulation on the wires must not be crimped.

2.3.2 Release tools for contacts

The various release tools serve as a means of detaching the dif‐
ferent contacts from the contact housings without damage.
A selection of release tools is included in wiring harness repair
set - VAS 1978- and wiring harness repair set - VAS 1978A- . The
complete set of release tools is included in release tool set - VAS
1978/35- ⇒ page 103 .
WARNING
Some tools are equipped with a tool safety device. This must
be pushed over the tip of the tool after use in order to protect
the tip and prevent personal injury.
Releasing and dismantling contact housings ⇒ page 147 .
2.3.3 Assembly tools for single wire seals

The assembly tools serve as a means of sliding the single wire
satelettronica
seals fully into the contact housing without damage and thereby
assure complete sealing between single wire and contact hous‐
ing.
Four assembly tools for single wire seals are included in each
wiring harness repair set - VAS 1978 B- and previous versions.
Assembling single wire seals ⇒ page 144 . wage
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2.3.4 Wire stripper - VAS 1978/3-
ab
ility
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Wire strippers - VAS 1978/3- serve as a means of stripping insu‐
h re
lation off wires and cutting wires in the correct manner.
ole,
spec
Wire strippers - VAS 1978/3- are included in wiring harness repair
t to the co
set - VAS 1978 B- and previous versions.
The wire strippers have an adjustable limit stop within the pliers
jaws, with which the desired length of insulation to be removed
rrectne
can be adjusted.
s
Stripping:
s o
cial p
f i
– Adjust the sliding limit stop in the pliers jaws to the desired
nform
length of insulation to be removed.

mer
atio
om
n
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i
or
– Insert the end of the wire from the front fully into the pliers jaws
thi
te
sd
a
and squeeze the pliers together completely.

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– Open the pliers and removed the stripped wire end.

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ng
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– Cut the wire if necessary with the cutting part on the upper side
of the wire strippers.
2.3.5 Hot air blowerolk220 V/50 Hz - VAS

AG. V swagen AG d
1978/14-
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When shrink-fitting, take care not to damage any other wiring,

un
pt
plastic parts or insulating material with the hot air blower.
an
d
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rm
ab
Observe the operating instructions of the hot air blower without
pe
ility
fail!
ot
wit
, is n
h re
hole
spec
The hot air blower, 220 V / 50 Hz - VAS 1978/14- is used in con‐
es, in part or in w
t to the co
junction with shrink element for hot air blower - VAS 1978/15- to
shrink fit the crimp connectors. After crimping, the crimp connec‐
tor has to be shrink fitted using the hot air blower in order to
rrectness of i
prevent any ingress of moisture.

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

harness repair set - VAS 1978 B- and previous versions.
nform
ercia
Shrink fitting crimp connectors using hot air blower, 220 V / 50 Hz

m
- VAS 1978/14- ⇒ page 123 , or ⇒ page 124 .

a
com
tion in
r
te o
2.3.6 Crimping pliers - VAS 1978/1A-

thi
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Crimping pliers - VAS 1978/1A- or crimping pliers (base tool) -

um
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VAS 1978/1-2- together with head adapter 0.35 - 2.5 mm² - VAS
n
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1978/1-1- or head adapter 4.0 - 6.0 mm² - VAS 1978/2A- are used
Cop py
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to squeeze together crimp connectors from the wiring harness
yri
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repair sets.
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Crimping connectors using crimping pliers - VAS 1978/1A-
AG.
⇒ page 124 .
The following heads adapters are available for crimping pliers
(base tool) - VAS 1978/1-2- :
♦ Head adapter 0.35 mm2 - 2.5 mm2 - VAS 1978/1-1-
♦ Head adapter 4.0 mm2 - 6.0 mm2 - VAS 1978/2A-
♦ Head adapter for JPT contacts - VAS 1978/9-1-
In conjunction with head adapter for JPT contacts - VAS
1978/9-1- , the crimping pliers are used to crimp contacts to single
wires during repairs to wiring with cross sections up to 0.35
mm2 ⇒ page 110 .
Interchanging head adapter:
– Open up the crimping pliers fully.

– Unclip both locking pins -arrows- from the body of the crimping
pliers.
– Insert the required head adapter from above -arrow- in the

body of the crimping pliers.
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– Lock the head adapter by engaging the pins -arrows- in the
h re
body of the crimping pliers.
hole
spec
es, in part or in w
t to the co
rrectness of i
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ercia
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or c
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2.4 Repairs to wiring harnesses

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Note
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Cop py
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Observe the general notes on repairs to the vehicle electrical cop Vo
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system cted agen
Prote AG.
⇒ “2.1 General notes concerning repairs to vehicle electrical sys‐
tem”, page 99 .
⇒ “2.4.1 Notes on repairs to airbag and belt tensioner wiring”,

page 107
⇒ “2.5 Repairs to fibre optic cables”, page 126
⇒ “2.4.2 Repairing CAN bus wiring”, page 109
⇒ “2.6 Repair of aerial wires”, page 132
⇒ “2.4.3 Renewal of aerial wiring”, page 109
⇒ “2.4.4 Repairing 0.13 mm2/0.35 mm2/0.5 mm2 wire”,
page 110
⇒ “2.4.7 Wiring open circuit with one repair position”, page 123

⇒ “2.4.8 Wiring open circuit with two repair positions”, page 124
2.4.1 Notes on repairs to airbag and belt ten‐

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

♦ Faulty repairs to the airbag and seat belt tensioning sys‐
tem can cause malfunctions in the passenger protection
system.
♦ For repairs to airbag and belt tensioner wiring harnesses,
only contacts, connectors and wiring designed specifically
for this purpose may be used ⇒ Electronic Parts Cata‐
logue (ETKA) .
satelettronica
AG. Volkswagen AG d
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ility
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wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
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or
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te
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Cop py
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Prote AG.

AG. Volkswagen
Ameo 2017 ➤ , Arteon 2018 ➤ , Atlas ksw 2017 ➤ , Bora 1999 ➤
agen AG do
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Vol ot g
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Note
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♦ Wires from airbag and belt tensioner wiring harness are only
erm
ab
allowed to be repaired using the wiring harness repair set -
ility
VAS 1978 B- and previous versions. ot p
wit
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♦ Observe the general notes on repairs to the vehicle electrical
hole
spec
system ⇒ page 99 .
es, in part or in w
t to the co
♦ Observe vehicle stickers indicating high voltage components.
Before carrying out repairs, discharge residual voltage ⇒
General body repairs, interior; Rep. gr. 69 ; Occupant safety .
rrectness of i
♦ For repairs to wiring in the airbag and belt tensioner system,
l purpos
a maximum of two positions may be repaired. The more the

repairs there are in the wiring, the greater the resistance and
this can trigger faults in the self-diagnosis of the system.
nform
ercia
♦ To avoid corrosion, the crimp connectors are always to be

m
at
om
shrink-fitted when performing airbag or belt tensioner wiring
ion
c
harness repairs.
in t
or
his
ate
♦ Do not incorporate the repaired wiring back in the vehicle's
do
riv
own wiring harness and mark the area of repair clearly with
p
satelettronica
um
for
yellow insulating tape.
en
ng
t.
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op
♦ Repairs in the area of the airbag or belt tensioner should not
C py
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gh
be more than 30 cm from the next contact housing. Together
ht
pyri by
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with the yellow insulating tape, this gives a clear indication of by c lksw
cted agen
repairs that have already been carried out. Prote AG.
♦ In series production, the wires leading to the triggering units

(airbags) are twisted with a length of lay of 20 mm ± 5 mm.
This lay length is ensured in production by means of standard-
part numbers for pairs of wires and must be adhered to under
all circumstances when sections of twisted wires are repaired.
♦ During repairs, the wiring to the triggering units (airbags) must
have the same length. When wires -1- and -2- are entwined,
the twine spacing of A = 20 mm ± 5 must be adhered to without
fail.
♦ There must not be any section of wiring, for example in the
vicinity of crimp connectors -arrow-, longer than B = 100 mm
with the wires not twisted.

2.4.2 Repairing CAN bus wiring

♦ Adhere to general instructions concerning repairs to vehicle
electrical system ⇒ page 99 .
♦ An unshielded, twisted two-wire line -1- and -2- is used as a
CAN bus wire.
♦ When repairs are performed, both CAN bus wires must have
the same length.
♦ It is not permitted to repair the individual cores.
♦ Repairs to CAN bus wires must be carried out observing the
correct cross section.
♦ For allocation, refer to ⇒ Electronic parts catalogue (ETKA) .
♦ The repair must not result in excess lengths.
♦ There must not be any section of wiring, for example in the
vicinity of crimp connectors -arrow-, longer than -A- = 50 mm
where the wires are not twisted.
♦ Mark the area of repair with yellow insulation tape to make it
easy to identify.
satelettronica
♦ The crimping of cable ends with connectors is to be carried out
. Volkswagen AG
according to the same procedure.
sw agen AG does
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♦ The repair areas -arrows-
se
d bmay be above one another. ara
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♦ The colour codes ofauthe
t CAN bus wiring can be gleaned from ra
c
the following table:
ss ce
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pt
du
Powertrain CAN, high wire Orange/black

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ab
Convenience CAN, high wire Orange/green

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Infotainment CAN, high wire Orange/violet

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CAN low wire, (all) orange/brown

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spec
es, in part or in w
t to the co
2.4.3 Renewal of aerial wiring

A new approach to repair work on aerial wires has been devel‐
rrectness of i
oped ⇒ page 132 .

l purpos
Now connecting wires in different lengths and various adapter

cables are available as replacement parts instead of a complete
nf
ercia
aerial wire.
orm
m
atio
om
n in
c
♦ Replacement parts can be found in the ⇒ Parts catalogue

or
thi
e
(ETKA): Special catalogue; Electrical connections; Genuine

t
sd
iva
accessories; Subgroup 35 from illustration No. 035-20 .

o
r
rp
cu
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f
en
♦ These genuine parts are suitable for all aerial wires and wire
ng
t.
yi Co
diameters which may need to be replaced. t. Cop py
rig
gh ht
♦ The connector housings for aerial wires are only available as pyri by
Vo
co
genuine parts in one colour. However, they can be used for all
by lksw
cted agen
Prote
colours of aerial connector.
AG.
♦ No provision has been made for replacement of individual

aerial connectors in the event of repair.
♦ The wires can be used retroactively for all VW models, with all
installed aerial wire diameters.
♦ All adapter and connection wires are suitable for all transmitter
and receiver signals.
♦ This repair method can also be used for testing or retrofitting.

Assembly overview of aerial cable:

Example: aerial wire between radio and aerial is defective. The
following wires are required for the
genrepair:
AG. Volkswagen AG d
wa oes
olks no
1- Adapter cable, to radio
db
y V connection. Length approx. 30
t gucm.
ar
e an
ris tee
2- Connecting wire,
ut
ho available in different lengths. or
a ac
ss
3- Adapter cable, to aerial connection. Length approx. 30 cm.
ce
le
un
pt
an
Installing a new aerial cable:
d
itte
y li
rm
ab
pe
ility
ot
Note
wit
, is n
h re
hole
spec
Note that the total length of an aerial wire, depending on vehicle
es, in part or in w
equipment level, can be divided into sections by aerial diversity
t to the co
control unit, traffic information control unit or aerial amplifier. Only
the defective section of aerial wire must be replaced.
rrectness of i
– Pull defective aerial wire connections off units.
l purpos
– Determine the routing of the defective aerial wire in vehicle

and measure the total length of the aerial connecting wire to
satelettronica
nform
ercia
be replaced.
m
a
com
ti
The total length of aerial connecting wire is the sum of the length
on in
of adapter cables required -1- and -3- and the connecting wire
r
te o
-2-. thi
s
iva
do
r
rp
– To determine the length of connecting wire required, subtract

um
fo
en
g
60 cm from the measured total length of aerial connecting wire

n
t.
yi Co
-2-. t. Cop py
rig
gh ht
yri
– Procure the required adapter cables -1- and -3- and connect‐ p by
co Vo
ing wire -2- at length calculated as genuine part from the
by lksw
cted agen
Prote
Electronic parts catalogue (ETKA).
AG.
– Cut off connectors of defective aerial wire.

The remainder of the defective aerial wire remains in the vehicle.
– Connect adapter cables -1- and -3- to equipment in vehicle.
– Route and attach the connection line -2- in the immediate vi‐
cinity of the factory routing.
Note
Do not kink or excessively bend aerial wires! The bending radius

must not be below 50 mm.
– Connect connecting wire to adapter cables.

– Perform functional test.
2.4.4 Repairing 0.13 mm2/0.35 mm2/0.5 mm2

wire

♦ Hot air blower - VAS 1978/14A- from wiring harness repair set
- VAS 1978 B-
♦ Crimping pliers (body) - VAS 1978/1-2- from wiring harness

repair set - VAS 1978 B-
♦ Adapter head 0.13 - 0.5 mm² - VAS 1978/1-3- AG. Volkswagen AG d
agen oes
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d by ara
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Note horis nte
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satelettronica
Repair wires with a cross section of 0.35 mm2 and 0.5 mm2 are
ce
le
un
pt
available for the repair.
an
d
itte
y li
rm
ab
Procedure
pe
ility
ot
wit
, is n
– Fit adapter head 0.13 - 0.5 mm² - VAS 1978/1-3- -1- on crimp‐
h re
ing pliers (body) - VAS 1978/1-2- as follows:
hole
spec
es, in part or in w
– Open crimping pliers -VAS 1978/1-2- .
t to the co
– Pull out locking pins -2- in direction of -arrow A- as far as stop.
– Fit adapter head -VAS 1978/1-3- -1- centrally on crimping pli‐
rrectness of i
ers -VAS 1978/1-2- in direction of -arrow B-.
l purpos
– Insert locking pins -2- again as far as stop.

– Clear the wire to be repaired about 20 cm either side of the
nform
ercia
repair position.
m
a
com
tion in
Caution
r
te o
thi
s
iva
do
Risk of damage to electrical wiring.

r
rp
cum
fo
en
g
♦ Carefully lay wrapped wiring harnesses aside.

n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
– If necessary, remove wrapping of wiring harness.
o
by c lksw
cted agen
Prote AG.
– Cut out the damaged piece of wiring using side cutters.
Note
♦ If, after the damaged wire has been cut out, both ends of the
vehicle's own wiring are too short for a repair using single butt
connectors, use a piece of yellow repair wire of the appropriate
length with two crimp connectors.
♦ When repairing a single wire with crimped/attached contact,
lay the yellow repair wire next to the damaged single wire of
the vehicle and cut to the required length.

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

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

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

Correct crimping result

– After crimping, the crimp connector has to be shrink fitted us‐
ing the hot air blower in order to prevent any ingress of
moisture.
• For 0.13 mm2 wires, it is then necessary to shrink-fit the ad‐
ditional heat-shrink hose to ensure complete sealing.
– Fit shrink element for hot air blower - VAS 1978/15A- onto hot
air blower - VAS 1978/14A.-
Caution
Risk of damage to electrical wiring.

♦ When shrink-fitting the hose, take care not to damage any
satelettronica
other wiring, plastic parts or insulating material with the hot
nozzle of the hot air blower.
♦ Observe the operating instructions of the hot air blower
without fail!
– For 0.13 mm2 wires, position heat-shrink hose -1- centrally

over crimp connector -2- by feeling contours.
• Dimension -a- must be approximately even on both sides.
– Heat up heat-shrink hose/crimp connector using hot air blower
along a straight line, working from centre outwards, until it is
sealed completely and adhesive escapes from the ends.
• This is how the finished repair point should look -3-. AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
♦ Ensure that, where several wires have to be repaired, the

h re
crimp connectors are not directly adjacent to each other. To

hole
spec
prevent the circumference of the wiring harness from becom‐

es, in part or in w
ing to great, position the crimp connectors so they are offset

t to the co
slightly.
♦ If the repair position was already wrapped, this section has to
rrectness of i
be wrapped again with yellow adhesive tape once the repair

has been carried out.
l purpos
♦ Attach the repaired wiring harness with a cable tie, if neces‐

sary, to prevent it from generating noise when the vehicle is in
nform
ercia
motion.
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
by
113
copy Vo
by lksw
cted 2. Repairs to wiring harnesses and connectors
agen
Prote AG.
Premature release
– Push release lever -1- upwards in direction of -arrow A-.
– At same time, press together crimping pliers slightly and then
open.
Caution
♦ Do not use the crimp connector after premature release.
. Volkswagen AG
gen AG does
kswa
2.4.5 Repair of 10 mm2 or 16 mm wire with 2 ol not
byV gu
ara
ed
single butt connector ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
- VAS 1978 B-
erm
ab
ility
ot p
satelettronica
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
♦ Shrink element for hot air blower - VAS 1978/15A- from wiring
atio
harness repair set - VAS 1978 B-
om
n
c
i
or
n
♦ Wiring harness repair set - VAS 631 003-
thi
te
sd
iva
o
pr
cum
r
fo
Note
en
ng
t.
yi Co
Cop py
♦ Repair wires (by the metre) with a cross section of 10 mm2 or
ht. rig
rig ht
py by
16 mm2 are available for the repair.
co Vo
by lksw
cted agen
Prote AG.
♦ Furthermore, single repair wires with a crimped/attached con‐
tact are available for repair work.
Procedure
– Attach the crimping anvil and crimping stamp relevant to the
wire thickness to the crimping pliers as follows:
– Open crimping pliers from wiring harness repair set - VAS 631
003- .
go.
– Open adapter -2- in direction of arrow -B-.

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

-2- on adapter -arrow A-.
– Insert crimping anvil -3- until it is heard to engage in mounting
-4- of crimping pliers -arrow B-.
AG. Volkswagen AG d
agen oes
olksw not
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ed
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ut
– Close adapter
s a -1- in direction of arrow -A-. ra
c
satelettronica
s
ce
e
– Insert locking pin -2- onto stop in direction of arrow -B-.

nl
pt
du
an
itte
y li
erm
ab
repair position.
ility
ot p
wit
, is n
h re
Caution
hole
spec
es, in part or in w
Risk of damage to electrical wiring. t to the co
♦ Carefully lay wrapped wiring harnesses aside.

rrectness of i
– If necessary, cut through wrapping of wiring harness with a

l purpos
knife.
nform
– Cut out damaged section of wire with wire stripper from wiring
ercia
harness repair set - VAS 631 003- .

m
at
om
ion
c
in t
or
Note
his
ate
do
priv
♦ If, after the damaged wire has been cut out, both ends of the
um
for
en
g
vehicle's own wiring are too short for a repair using single butt
n
t.
yi Co
connectors, use a piece of yellow repair wire of the appropriate Cop py
. rig
length with two crimp connectors.
ht ht
rig by
copy Vo
♦ When repairing a single wire with crimped/attached contact,
by lksw
cted agen
Prote
lay the yellow repair wire next to the damaged single wire of
AG.
the vehicle and cut to the required length.

– Set the adjustable stop in the wire stripper from wiring harness
repair set - VAS 631 003- to the length that needs to be strip‐
ped.
♦ 10 mm2 wires: 14 mm
♦ 16 mm2 wires: 16.5 mm
– Insert the end of the wire from the front fully into the pliers jaws
and squeeze the pliers together completely.
• Insulation must be cut cleanly and removed from the wire
• Do not leave any insulation on the stripped
swa
genwires
AG. Volkswagen AG d
oes
k not
Vol gu
ed
by ara
nte
is
or eo
– Use a suitable butt connector
au and heat-shrink hose from wiring
th ra
harness repair set - VASs 631 003- to perform repair.
s c
ce
e
nl
pt
– Push heat-shrink hose onto one of the wires.
du
an
itte
y li
erm
ab
– Position butt connector -1- with first crimping point centrally on
ility
ot p
crimping anvil -2-.
wit
, is n
satelettronica
h re
• Dimension -a- must be even on both sides
hole
spec
es, in part or in w
– Turn quick-action lever -3- in anti-clockwise direction -arrow-
t to the co
until butt connector -1- is secure.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
– Insert wire -2- with stripped end into butt connector -1- as far
op Vo
by c lksw
as stop -arrow-. cted agen
Prote AG.
• All single wires must be pushed into the butt connector

– Close and open the crimping pliers several times until the
crimping anvil moves downwards automatically to the start
position.
Note
The insulation on the wires must not be crimped.
– Crimping the wire with butt connector on the other side as de‐
scribed.

– Pull out locking pin in direction of arrow -A- as far as it will go.
– Open adapter in direction of arrow -B-.
– Remove crimped butt connector.

A - 10 mm2, star crimp
B - 16 mm2, B crimp
satelettronica
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
After crimping, the heat-shrink hose over the butt connector has
pt
an
d
itte
to be shrink fitted using the hot air blower in order to prevent any
y li
erm
ab
ingress of moisture.
ility
ot p
– Fit shrink element for hot air blower - VAS 1978/15A- onto hot
wit
is n
h re
air blower - VAS 1978/14A- .

ole,
spec
Caution
t to the co
Risk of damaging adjacent components.

rrectne

s

s o
cial p
f in

form
mer
without fail!
atio
om
n
c
i
or
n thi
te
sd
a
– Position heat-shrink hose -1- centrally over butt connector

iv
o
r
-2- by feeling contours.

p
cum
r
fo
en
ng
t.
• Dimension -a- must be roughly even on both sides
yi Co
Cop py
t. rig
– Heat up heat-shrink hose using hot air blower along a straight gh ht
yri by
line, working from centre outwards, until it is sealed completely
op Vo
by c lksw
and adhesive escapes from the ends.
cted agen
Prote AG.
• This is how the finished repair point should look -3-.

Electrical system - general information - .Edition 08.2019
Volkswage AG n AG d
agen oes
olksw not
yV gu
db ara
ise nte
Note tho
r eo
s au ra
c
s
♦ Ensure that, where several wires have to be repaired, the butt
ce
e
nl
pt
connectors are not directly adjacent to each other. To prevent
du
an
itte
the circumference of the wiring harness from becoming too
y li
erm
ab
great, position the butt connectors so they are offset slightly.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
motion.
rrectness of i
l purpos
Premature release
– Push lever -1- downwards -arrow A-.
nform
ercia
– Turn quick-action lever -2- in clockwise direction -arrow B- until

m
at
crimping anvil is in the start position.
om
ion
c
in t
r
If premature release is not possible by hand:

o
satelettronica
his
ate
do
riv
– Push lever -1- downwards -arrow A-.

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

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

Note
♦ Copper repair wires (by the metre) with a cross section of 2.5
mm2, 4 mm2 or 6 mm2 are available for repair.
♦ Furthermore, single copper repair wires with crimped contacts
are available for repair work.
Procedure
– Choose the crimping anvil, crimping stamp and contact posi‐
tioner with contact locking mechanism relevant to the wire
thickness and attach to the hand pliers as follows:
– Open hand pliers from wiring harness repair set - VAS 631
001- .
go.
– Open support -2- in direction of arrow -B-.
satelettronica
– Place crimping anvil -1- in hand pliers in such a way that
crimping anvil -1- is flush with front of pliers.
– Secure crimping anvil with pins -2- -arrow A- and tighten
knurled screw by hand.
– Insert crimping stamp -3- that corresponds with crimping anvil
into support.
– Secure crimping stamp with pins -4- -arrow B- and tighten
knurled screw by hand.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
– Close adapter -1- in direction of arrow -A-.

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

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

– Insert contact locking mechanism -1- in contact positioner

-2-.
– Locate contact positioner with contact locking mechanism on
hand pliers -5- and push hole in contact positioner -2- over
knurled screw -4-.
– Screw in knurled screw -3- and tighten by hand.
repair position.
Caution
AG. Volkswagen AG d
Risk of damage to electrical wiring. agen oes
olksw not
byV gu
ara
♦ Carefully lay wrapped wiringris harnesses aside.
ed
nte
ho eo
aut ra
ss c
ce
e
– If necessary, cut through wrapping of wiring harness with a

nl
pt
du
knife.
an
itte
y li
erm
ab
ility
– Cut out damaged section of wire using wire stripper from wiring
ot p
wit
harness repair set - VAS 631 001- .
satelettronica
, is n
h re
hole
spec
es, in part or in w
Note
t to the co
If, after the damaged wire has been cut out, both ends of the ve‐
hicle's own wiring are too short for a repair using single butt
rrectness of i
connectors, use a piece of yellow copper repair wire of the ap‐
propriate length with two crimp connectors.
l purpos
nf
ercia
orm
m
atio
m
– Insert end of wire from front into matching adapter (relevant to

o
n in
or c
wire thickness) in jaws of pliers as far as it will go.

thi
te
sd
iva
– Squeeze pliers together completely.

o
r
rp
cu
o
m
f
en

ng
t.
yi Co
op py
• Insulation must be cut cleanly and removed from the wire
. C rig
ht ht
rig by
py
• Do not leave any insulation on the stripped wires
co Vo
by lksw
cted agen
Prote AG.
– Use a suitable butt connector and heat-shrink hose from wiring
harness repair set - VAS 631 001- to perform repair.
– Push heat-shrink hose onto one of the wires.

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

• Butt connector -1- must be flush with contact positioner -2-
-arrow A-
– Push contact locking mechanism -3- as far as stop in direction
of arrow -B- and, in doing so, secure butt connector -1-.
• Lugs -4- on butt connector -1- must engage in groove -5- on
contact locking mechanism -3- gen AG. Volkswagen AG
wa does
olks not
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ara
ed nte
ris
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Insert wire -2- with stripped end into butt connector -1- as far
satelettronica
as stop -arrow-.
rrectness of i
• All single wires must be pushed into the butt connector
l purpos
• End of insulation should be no further than front edge of insu‐

lation crimp
nf
ercia
– Close hand pliers until hand pliers open again automatically.
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
– Turn contact locking mechanism -2- onto stop in direction of Cop py
t. rig
-arrow-. gh ht
pyri by
Vo
co lksw
by
– Remove butt connector -1- from contact positioner -3-. Prote
cted AG.
agen
– Rotate hand pliers for 2nd crimping.

– Crimping the wire with butt connector on the other side as de‐
scribed.
go.
– Open support -2- in direction of arrow -B-.
– Remove crimped butt connector.


• End of wire must protrude 0.1 mm … 1.0 mm at front edge of
wire crimp, dimension -a-
• End of insulation must not be crimped with wire crimp
• Insulation should end no further than front edge of insulation
crimp -arrows-
After crimping, the heat-shrink hose over the butt connector has
to be shrink fitted using the hot air blower in order to prevent any
ingress of moisture.
– Fit shrink element for hot nair
AGblower
. Volkswa- gVAS
en AG1978/15A- onto hot
air blower - VAS 1978/14A-
olkswage . does
no
yV t gu
db ara
rise nte
Caution
tho eo
au ra
satelettronica
ss c
Risk of damaging adjacent components.
ce
le
un
pt
an
d
itte

y li
erm
ab

ility
ot p

wit
is n
h re

ole,
without fail!
spec
t to the co
– Position heat-shrink hose -1- centrally over butt connector

rrectne
-2-.
• Dimension -a- must be roughly even on both sides
ss o
– Heat up heat-shrink hose using hot air blower along a straight

cial p
f in
line, working from centre outwards, until it is sealed completely

form
mer
and adhesive escapes from the ends.

atio
om
• This is how the finished repair point should look -3-.

n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
Note cted agen
Prote AG.
♦ Ensure that, where several wires have to be repaired, the butt

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

2.4.7 Wiring open circuit with one repair posi‐

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

side of the repair position).
– If necessary, unbind the wiring harness using the folding knife.
– Cut out the damaged piece of wiring using the wire strippers -
VAS 1978/3- .
Note
satelettronica
If, after the damaged wire has been cut out, both ends of the ve‐
hicle's own wiring are too short for a repair using single crimp
connectors, use a piece of repair wire of the appropriate length
with two crimp connectors ⇒ page 124 .
AG. Volkswagen AG d
agen oes
o lksw not
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ara
ed
– Strip the wire ends of insulation by 6 - 7 mm tusing
horis
the wire nte
eo
strippers. s au ra
c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Push the crimp connector on both stripped wire ends of the

l purpos
vehicle's own single wire and crimp it on using the crimping

pliers.
nform
mercia
Note
at
om
ion
c
in t
or
his
ate
the crimp connectors being used ⇒ page 103 .

do
priv
cum
or

f
en
ng
t.
yi Co
Cop py
After crimping, the crimp connector has to be shrink fitted using ht. rig
rig ht
by
the hot air blower in order to prevent any ingress of moisture. copy Vo
by lksw
cted agen
Prote
– Place shrink element for hot air blower - VAS 1978/15- on hot
AG.
air blower, 220 V / 50 Hz - VAS 1978/14- .

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

fail!
Note

slightly.
satelettronica
be wrapped again with yellow insulation tape once the repair
♦ Attach the repaired wiring harness with a cable tie, if neces‐ gen AG
. Volkswagen AG
does
swa
sary, to prevent it from generating noise when the vehicle is biny Volk not
gu
motion. rised ara
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2.4.8 Wiring open circuit with two repair posi‐
ce
le
un
pt
an
d
tions
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rm
ab
pe
ility
Repair position with interlinked wire.
ot
wit
, is n
– Place the wire to be repaired to the side at two points (about
h re
hole
20 cm to both sides of the relevant repair position).
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tio
– Place the yellow repair wire next to the damage wiring harness
n in
r
and, using wire strippers - VAS 1978/3- , cut the repair wire to
te o
thi
the required length.

s
iva
do
r
rp
cum
– Cut the damaged section of wire out of the vehicle's own single
fo
en
g
wire.
n
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

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byV Electrical
ua system - general information - Edition 08.2019
d ran
ir se tee
tho
o
– au the wire ends of insulation by 6 - 7 mm using rthe
Strip ac wire
ss
strippers.
ce
e
nl
pt
du
an
– Push the crimp connector onto one side of the vehicle's own
itte
y li
single wire and on the other side onto the repair wire.
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
– Crimp the connector using the crimping pliers to both wire

ends.
nf
ercia
o
– Repeat this procedure on the other end of the repair wire.
rm
m
atio
om
n in
or c
Note
thi
te
sd
iva
o
r
rp
cu
satelettronica
o
the crimp connectors being used ⇒ page 103 . m

f
en
ng
t.
yi Co
op
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
After crimping, the crimp connector has to be shrink fitted using
Prote
cted AG.
agen
the hot air blower in order to prevent any ingress of moisture.
– Place shrink element for hot air blower - VAS 1978/15- on hot
air blower, 220 V / 50 Hz - VAS 1978/14- .
– Heat up the crimp connector using the hot air blower along a
straight line, working from the middle outwards, until it is
sealed completely and the adhesive escapes from the ends.
Caution

fail!
Note

slightly.
motion.

2.5 Repairs to fibre optic cables

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

Fault Finding” or “Guided Functions”, it is possible to ascertain
the components between which the fibre optic cable has been
damaged. AG. Volkswagen AG d
agen oes
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♦ The colour “yellow” indicates a fibre optic cable that has al‐ by V ol not
gu
ready been repaired. rised ara
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Procedure: s
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e
nl
pt
du
– Select “Guided functions” or “Guided fault finding” in the vehi‐
an
itte
y li
cle diagnostic tester ⇒ Vehicle diagnostic tester.
erm
ab
ility
ot p
– Prepare fibre optic cable ⇒ page 126
wit
, is n
satelettronica
h re
hole
Caution
spec
es, in part or in w
t to the co
Do not over-bend fibre optic cables. Minimum radius for bends
is 25 mm.
rrectness of i
Do not route fibre optic cables over sharp edges.
l purpos
Make sure that the ends of the fibre optic cables are not dirty
and do not touch them with your bare hands.
nf
ercia
Do not expose fibre optic cables to heat.
orm
m
It is not permissible to twist 2 fibre optic cables together or one
atio
m
fibre optic cable with a copper wire.

o
n in
or c
thi
e
Protect connectors and connecting cables against dust. Use

t
sd
iva
protective caps from the case.
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op py
2.5.1 Preparing fibre optic cable
. C rig
ht ht
rig by
copy Vo
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cted agen
Prote AG.
♦ Fibre optic cable repair kit - VAS 6223A-

♦ Cutting pliers - VAS 6228-
AG. Volkswagen AG d
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un
pt
an
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itte
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♦ Vehicle diagnostic tester
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
satelettronica
rrectness of i
l purpos
nform
mercia
a
com
tion in
Caution
r
te o
thi
s
iva
do
Do not over-bend fibre optic cables. Minimum radius for bends

r
rp
is 25 mm.
um
fo
en
ng
t.
yi
Do not route fibre optic cables over sharp edges.
Co
Cop py
ht. rig
Make sure that the ends of fibre optic cables are not dirty and
rig ht
py by
o Vo
do not touch them with your bare hands. by c lksw
cted agen
Prote AG.
Do not expose fibre optic cables to heat.
It is not permissible to twist 2 fibre optic cables together or one
fibre optic cable with a copper wire.
Protect connectors and connecting cables against dust. Use
protective caps from the case.
Fit tool adapter for fibre optic cable pliers - VAS 6223/1- .

– Press locking pins -arrows- out.

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

– Determine required length of fibre optic cable.
– Open fibre optic cable pliers and insert length of fibre optic
cable -1- to be cut.
– To cut the fibre optic cable to size, close fibre optic cable pli‐
ers .
satelettronica
Stripping off insulation
– Open fibre optic cable pliers - VAS 6223/1- .
– Push down the stripping lever -arrow-. agen
AG. Volkswagen AG d
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– Insert fibre optic cable into the stripping hole. ed b y gu
ara
ris nte
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• The fibre optic cable must be flush with the aut rear of the cutting
h
ra
pliers. ss c ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
– Close fibre optic cable pliers as far possible and hold closed.
spec
es, in part or in w
– Push the stripping lever upwards -arrow-, and remove fibre

t to the co
optic cable.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
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Cut precisely (making a clean optic surface at kendgen AG
swa of cable).
ol
does
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yV gu
– Insert fibre optic cable -1- into the cutting
se d b hole. ara
nte
ri
ho eo
• The insulation must be lying againstaut stop of cutting station. ra
c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Close fibre optic cable pliers - VAS 6223/1- and remove cable.
rrectne
– Visually inspect cable-1- to make sure that it has been cut
correctly and that there are no burrs on the cross-cut surface
at end of cable.
ss o
cial p
f inform
mer
Note
atio
m
satelettronica
o
n
c
♦ Place the fibre optic cable only on surface or material that is
i
or
n thi
absolutely clean or keep it in your hand.
te
sd
iva
o
pr
c
♦ Use protective caps if there is a danger that the cross-cut sur‐
um
r
fo
face at the ends of the fibre optic cable will be soiled.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
Fitting brass pin contact to fibre optic cable. cop Vo
by lksw
cted agen
Prote AG.
– Change tool adapter -arrow-.

– Move safety catch on fibre optic cable pliers -arrow- so that
the word “Pin” can be seen.

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

– Close locking lever on fibre optic cable pliers -arrow-.
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– Push fibre optic cable into brass pin contact -arrow- as far as
ss
ce
e
spring-cushioned stop and close fibre optic cable pliers .

nl
pt
du
an
itte
y li
– Open fibre optic cable pliers and remove fibre optic cable to‐
erm
ab
gether with brass pin contact.
ility
ot p
wit
, is n
h re
Caution
hole
spec
es, in part or in w
satelettronica
Do not kink or excessively bend fibre optic cables (min. bend‐
t to the co
ing radius: 25 mm).
rrectness of i
l purpos
– Check that the brass pin contact -2- is correctly attached to

fibre optic cable -1-.
nform
ercia
• 4 crimping points must be visible on the brass connecting pin.

m
at
om
io
• Make sure that the brass pin contact cannot be pulled off fibre
n
c
in t
or
optic cable by hand.

his
ate
do
riv
• The cross-cut end surface of the fibre optic cable is

p
cum
or
0.01 … 0.1 mm behind the brass pin contact (visual inspec‐

f
en
ng
t.
tion). Cop
yi Co
py
t. rig
gh ht
pyri by
Vo
o
Note
c by lksw
cted agen
Prote AG.
♦ There are push-on couplings that are used to connect fibre

optic cables ⇒ Electronic Parts Catalogue .
♦ Installation of the new fibre optic cable in the cable harness
connector ⇒ page 131 .

Fitting corrugated tube onto fibre optic cable.

– Cut corrugated tube to a suitable length.
• Use cutting pliers - VAS 6228- or a sharp knife for cutting.
• Do not cut the corrugated tube with a paper cutter.
• The corrugated tube must be cut at a crest -arrow- not in a
trough.
• When the corrugated tube is installed, it must engage audibly
in the housing of the fibre optic cable.
– Insert fibre optic cable into pliers for fitting the corrugated tube
satelettronica
- VAS 6223/10- as shown in the illustration.
– Position pliers in place on the groove of the corrugated tube.
– Push pliers in groove along the circumference of the corruga‐
ted tube. This causes the fibre optic cable to be inserted in the
corrugated tube.
2.5.2 Detaching fibre optic cable fromn Acable

G. Volkswagen AG d
age
harness connector yV
olksw
oes
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ed
Removing thoris nte
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au ac
– Pull fibre optic cable connector off
ss the relevant control unit.
ce
e
nl
pt
– Release the locking mechanism in fibre optic cable connector

du
an
itte
-1- by pressing it.

y li
erm
ab
ility
– Release secondary locking element -2-, using a small screw‐

ot p
wit
driver.
, is n
h re
hole
– Remove fibre optic cable.

spec
es, in part or in w
t to the co
Caution
♦ Use protective caps from the case in order to protect the

rrectness of i
fibre optic cable against dust and dirt.

l purpos
♦ Use a new housing as the secondary locking element can

be damaged when the fibre optic cable is removed.
nform
ercia
♦ Take note of the arrows on the basic module for the as‐
m
signment of “IN” and “OUT”.

at
om
ion
c
in t
or
his
ate
Installing
do
priv
cum
or
Install in reverse order of removal, observing the following:

f
en
ng
t.
yi Co
op
– Install fibre optic cable in accordance with markings. C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
131
Prote AG.
2. Repairs to wiring harnesses and connectors
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
Ameo 2017 ➤ , Arteon oris 2018 ➤ , Atlas 2017 ➤ , Bora 1999 ➤
e nt,e Bora Varian ...
h eo
Electrical systemau-t general information - Edition 08.2019 ra
c
ss
ce
le
un
pt
an
d
itte
Note
y li
rm
ab
pe
ility
ot
♦ Push corrugated tube into plug-in housing until it engages au‐
wit
, is n
dibly.
h re
hole
spec
♦ Seal the open plug-in connection -2- for fibre optic cable with
es, in part or in w
the protective cap for cable harness connector - VAS 6223/9-
t to the co
-item 1-.
♦ The protective cap prevents soiling and mechanical damage
rrectness of i
at the cross-cut end of the fibre optic cable so that the trans‐
mission of light is not impaired.
l purpos
nform
ercia
2.6 Repair of aerial wires

m
a
com
tion in
r
2.6.1 Repair set, aerial cable VAS 6720

te o
thi
s
iva
do
r
Checking the aerial wire: ⇒ page 133

rp
cum
fo
en
ng
Changing tool adapter: ⇒ page 133

t.
yi Co
satelettronica
Cop py
t. rig
Cutting aerial wire: ⇒ page 133 opyri
gh by
Vo
ht
by c lksw
Stripping shielding: ⇒ page 134 Prote
cted AG.
agen
Stripping outer sleeve: ⇒ page 136

Stripping inner insulation: ⇒ page 137
Crimping inner conductor: ⇒ page 138
Crimping outer conductor: ⇒ page 140
♦ Repair set, aerial cable - VAS 6720-
The repair set, aerial cable - VAS 6720- makes it possible to attain
optimal repair quality in the repair of aerial wiring RG 174 (blue)
and RKT 031 (black). The set includes the respective stripping
tools and crimping tools for both aerial cables. In addition, the
case includes all the separate parts needed to connect the Gen‐
uine plug in nearly production quality. In this case, only the 0-
coded connector (green) is required. All other connecting wires
for the various infotainment systems can be found in ETKA (EL-
electrical connection elements) in plate 035-XX. These various
adapter aerial wires are specific to vehicle models and must al‐
ways be ordered separately. All the separate parts can be found
in the above-named plate for reordering. The compartments of
the case are labelled with the part numbers of the consumable
materials. The repair set is based on the existing adapters and
pliers system of the VAS 1978B.
Note
Additional information: ⇒ Operating manual, Repair set, aerial

cable - VAS 6720-

Checking the aerial wire:

Before beginning repairs, determine which aerial wire is affected
using the gauge.
♦ -1- System RG 174 = blue
♦ -2- System RTK 031 = grey
In both systems, the positioner of the adapters is colour-coded
accordingly.
Changing tool adapter:
– Select appropriate adapter according to check of aerial wire
⇒ page 133 .
– Open handles of pliers completely.
– Release the two locking pins -arrows- from handles of pliers

and pull them out.
satelettronica
– Insert required tool adapter from above -arrow- into handles
of pliers.
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
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au ra
ss c
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
– Lock adapter into handles of pliers by pressing in pins

hole
spec
-arrows-.
es, in part or in w
t to the co
Cutting aerial wire:

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

– Push aerial wire -2- into cutting mechanism -1-.

– Close tool and open it again.
– Pull aerial wire out of cutting mechanism.
Stripping shielding:
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Push locating pin -1- into rotary cutter to stop.

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

AG. Volkswagen AG d
agen oes
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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
ercia
satelettronica
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Push blade holder -1- against shaft of rotary cutter until it en‐
gages. The gap -2- beneath the blade holder is completely
closed.
– Hold aerial wire securely so that it cannot turn.
– Turn rotary cutter -3- approximately 2 times in direction of ar‐
row until it rotates easily.

satelettronica
AG. Volkswagen AG d
agen oes
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d b ara
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au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Pull release pin -1-. The blade holder is released and sepa‐
rates from aerial wire.
rrectne
– Push locating pin -2- into rotary cutter to stop. The aerial wire
is pressed out of rotary cutter.
ss o
cial p
– Remove shielding from aerial wire.

inform
mer
– Remove remnants of insulation from rotary cutter.

atio
om
Stripping outer sleeve:

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

satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
h
aut ra
– Push aerial wire -2- through notch -3- into tool adapter to stop
ss c
ce
e
-1-.
nl
pt
du
an
itte

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

ot p
wit
, is n
Stripping inner insulation:

h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
137
AG.
2. Repairs to wiring harnesses and connectors
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
satelettronica
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
ercia
– Push aerial wire -2- through notch -1- into tool adapter to stop.
m
a
com
tion in

r
te o
thi
– Pull out aerial wire -3-.

s
iva
do
r
rp
cum
Crimping inner conductor:

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

AG. Volkswagen AG d
agen oes
olksw not
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ara
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
satelettronica
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.
– Select appropriate adapter according to check of aerial wire

⇒ page 133 ⇒ page 133 .
– Tilt back swinging positioner -2-.
– Open positioning piece -3-. Positioning piece swings upwards.
– Push inner contact -1- into swinging positioner to stop and
loosen positioning piece. The inner contact is fixed in place.
– Tip swinging positioner inwards. The inner contact -4- is posi‐
tioned in the tool adapter.

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
satelettronica
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Push aerial wire -1- into inner contact -2- in tool adapter. Hold
swinging position in place while doing so.
– Close tool until it opens by itself.
– Open positioning piece -3- and pull out aerial wire.
Crimping outer conductor:

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
satelettronica
spec
es, in part or in w
t to the co
rrectness of i
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ate
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– Push sleeve -2- and outer contact -1- over inner conductor.
ht
pyri by
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The knurled contact part must be pushed under shielding -3-
c by lksw
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but over the aluminium foil. Prote AG.
– Push on outer contact -4- completely. Ensure proper seating

of female connector and pin.

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Prote AG.
– Push on sleeve -3- to outer contact.

– Open tool and tilt out swinging positioner -1-.
– Position mounted outer contact -2- in tool adapter in middle
notch on contact edge -4-.
– Pull out aerial wire.

AG. Volkswagen AG d
agen oes
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2.7 Repairs to contact housings and con‐ d by
Vol not
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nectors ise nte
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2.7.1 Notes on repairs to contact housings
an
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and connectors
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es, in part or in w
t to the co
♦ Allocation of the appropriate crimp contacts to the contact
rrectness of i
housings is by way of the part number stamped on the contact
housing. Listed in illustration 198 (electrical connecting ele‐
l purpos
ments) in ⇒ Electronic parts catalogue (ETKA) are the part

numbers for the contact housings in conjunction with the as‐
nform
ercia
sociated crimp contacts.

m
a
♦ Damaged contact housings must always be replaced.
com
tion in
satelettronica
♦ New contact housings can be ordered from the OTC in Kassel.
r
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s
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2.7.2 Repairs to contacts in contact housings
um
fo
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– If necessary, first open or disengage the secondary locking Cop py
t. rig
mechanism of the contact housing ⇒ page 147 . opyri
gh by
Vo
ht
by c lksw
– Disengage the contact (primary locking mechanism) using the Prote
cted agen
appropriate release tool ⇒ page 147 .
AG.
– Pull the contact by the single wire out of the contact housing.
– Select the yellow repair wire with the correct contact from the
wiring harness repair set .
– Place the wire to be repaired from the vehicle's own wiring
harness to one side (about 20 cm either side of the repair po‐
sition).
– Push the new contact of the repair wire into the contact hous‐
ing until it engages.
– Slide the single wire seal onto the repair wire.
Note
The small diameter of the single wire seal must face the contact
housing.
– Slide the single wire seal into the contact housing using the
correct assembly tool ⇒ page 144 .

– Trim the repair wire and the single wire of the vehicle's own
wiring harness accordingly using wire strippers - VAS 1978/3- .
– Strip the 6 - 7 mm of insulation from the end of the repair wire

and the vehicle's own single wire using the wire strippers.
– Crimp the stripped ends of the repair wire and single wire of
the vehicle's own wiring harness using the crimping pliers and
a crimp connector, as described in the chapter entitled “Wiring
open circuits with one repair position” ⇒ page 123 .
satelettronica
Note

slightly.
AG. Volkswagen AG d
♦ If the repair position was already wrapped, this section has to lkswagen oes
not
db
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has been carried out. or
ise nte
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h
ut ra
♦ Attach the repaired wiring harness with a cable tie,ssifa neces‐ c
ce
le
un
pt
motion.
an
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itte
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ab
pe
ility
2.7.3 Fitting single wire seals

ot
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spec
es, in part or in w
Note
t to the co
♦ Single wire seals prevent the ingress of moisture and dirt in

the contact housing. They are installed, for example, in the
rrectness of i
engine compartment and must always be reinstalled following

repairs.
l purpos
♦ As standard, the single wire seal is crimped together with the

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

a
com
tion in
♦ It is essential that the single wire seals are of the correct size
r
te o
thi
to fit the cross section of the repair wire. The outer diameter
s
iva
do
of the single wire seal is based on the socket diameter of the

r
rp
cum
contact housing. Only carry out the repair using the correct
fo
en
ng
assembly tool.
t.
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Cop py
ht. rig
rig ht
py by
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144
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Prote AG.
Rep. gr.97 - Wiring
olksw
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Assembling single wire seal: db
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– Disengage the contact locking tho mechanism using the appro‐ eo
priate release tool -A- and
s au then pull the wire with the single
ra
c
s
wire seal backwards -arrow- out of the contact housing.
ce
e
nl
pt
du
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itte
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erm
ab
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
– Cut off the old contact with the single wire seal from the vehi‐
l purpos
cle's own wiring harness.
nform
mercia
at
om
ion
c
in t
r
satelettronica
o
his
ate
do
priv
cum
for
en
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t.
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Cop py
t. rig
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pyri by
Vo
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cted agen
– Slide the repair wire with the new contact in the respective
Prote AG.
socket of the contact housing until it engages.
– Place the single wire seal -A- on the free end of the repair wire.
Note
The small diameter of the single wire seal must face the contact
housing.
– Slide the single wire seal -A- on the repair wire until it reaches
the contact housing.

– Slide the single wire seal -A- using the respective assembly
tool -B- fully into the contact housing.
– Trim the repair wire and the single wire of the vehicle's own
wiring harness accordingly using wire strippers - VAS 1978/3- .
– Crimp the stripped ends of the repair wire and single wire of
the vehicle's own wiring harness using the crimping pliers and
a crimp connector, as described inGthe
. Volkchapter
swagen Aentitled “Wiring
open circuits with one repair
lkswaposition”
gen A ⇒ page 123
G do .
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ris tee
satelettronica
tho or
au ac
ss ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
2.7.4 Repairs to contact housings using cut-

wit
, is n
h re
and-clamp method
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
♦ For technical reasons, the contact housings for cut-and-clamp

method can be supplied only with the cut-and clamp-contacts
l purpos
inserted.
♦ These contacts can be removed just like any other contact
nf
ercia
housing if they are not needed.

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

o
n in
c
contacts crimped on ⇒ Electronics parts catalogue (ETKA) .

or
thi
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Cop py
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Prote AG.

AG. Volkswagen AG d
swagen Electrical osystem
es n - general information - Edition 08.2019
olk o
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db ara
ise
2.8 Releasing and dismantling contact
r nte
tho eo
au ra
housings ss c
ce
le
un
pt
an
d
itte
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erm
2.8.1 Notes on releasing and dismantling con‐
ab
ility
ot p
tact housings
wit
is n
h re
ole,
spec
Note
t to the co
rrectne
♦ To release, always use the correct release tools. Under no
circumstances should the contacts be pulled out of the contact
ss o
housings with force.
cial p
f inform
♦ Damaged contact housings must always be replaced. New
mer
contact housings can be ordered from the OTC in Kassel.
atio
om
n
c
♦ As an aid to disengage the secondary locking elements, a
i
or
n thi
small screwdriver can be used.
te
sd
a
satelettronica
iv
o
pr
c
♦ The socket/pin assignment can be found stamped on the sec‐
um
r
fo
ondary locking mechanism or on the rear of the contact hous‐
en
ng
t.
yi
ing.
Co
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♦ For more detailed information about the locations of connec‐ yri
p by
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tors, see ⇒ Current flow diagrams, Electrical fault finding and
c by lksw
cted agen
Fitting locations.
Prote AG.

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

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

Example 2:
The housing catch is disengaged by opening a “flap” -arrow-.
Example 3:
The housing catch can be disengaged by detaching a “slide”
-arrow-.
satelettronica
2.8.3 Primary locking element
The primary locking mechanism is what fixes an individual crimp
contact in the contact housing.
If necessary, any housing catches in place (secondary locking
elements) must be released or removed prior to disengaging the
contacts using the prescribed tool ⇒ epage
n AG. V147 . agen AG
olksw
ag does
lksw n
The types of primary lockingbyelements
Vo shown as follows areotjust
gu
a
a few examples to showorithe
se different functions of primary lockingrante
d
element. au
th eo
ra
ss c
♦ Round connector systems ⇒ page 148
ce
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un
pt
an
d
♦ Flat connector systems ⇒ page 149

itte
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erm
ab
♦ Special connector systems ⇒ page 151

ility
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wit
is n

h re
vice can be gleaned from the table in the ⇒ operating instructions

ole,
spec
of -VAS 1978/35- .
t to the co
2.8.4 Round connector systems

rrectne
Note
ss

o
cial p

inform
contacts using the prescribed tool ⇒ page 147 .

mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
r
fo
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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cted agen
Prote AG.

– Insert the release tool appropriate for the contact housing in

the release port of the contact housing. gen AG
. Volkswagen AG
d wa oes
olks not
– Grab hold of the contact by the wire and push it lightlyby into the
V gu
ara
ed
contact housing -arrow-. or
is nte
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th
au ra
c
ss
ce
e
Note
nl
pt
du
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itte
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erm
By pushing the contact in the direction of the contact housing, the
ab
ility
locking tabs of the contact are lifted up by the housing edge and
ot p
wit
disengaged using the release tool.
, is n
h re
hole
spec
– At the same time, push the release tool in the direction of the es, in part or in w
contact housing -arrow- and pull out the released contact from
t to the co
the contact housing.
rrectness of i
– The release tool can be pulled out of the contact housing again
once the contact has been removed.
l purpos
nf
ercia
orm
satelettronica
m
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n in
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2.8.5 Flat connector systems
c by lksw
cted agen
Prote AG.
Note

Flat connector with one locking tab:

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

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

– At the same time, push the release tool in the direction of the
contact housing and pull out the released contact from the
Flat connector with two locking tabs:

– Grab hold of the contact by the wire and push it fully into the
satelettronica
Note

lkswage es n
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Asymmetrical:
wit
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hole

spec
es, in part or in w
t to the co
– Grab hold of the contact by the wire and push it lightly into the
rrectness of i
Note
l purpos

nf
ercia

rm
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pyri by
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Prote AG.

2.8.6 Special connector systems
Note

satelettronica
Faston contacts:
– Grab hold of the contact by the wire
en AG. V
and
olkswagenpush
AG doit lightly into the
contact housing. olkswag es n
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Note s au ra
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du
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ab

ility
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wit
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hole
spec
es, in part or in w

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

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
Ameo 2017 ➤ , Arteon 2018 ➤ut, Atlas 2017 ➤ , Bora 1999 ➤ , Bora Varian ...e or
ho
a ac
ss - Edition 08.2019
ce
e
nl
pt
du
an
GT 150/280 contacts:
itte
y li
erm
ab
– Insert the release tool appropriate for the contact housing un‐
ility
ot p
der the locking tab into the contact housing.
wit
, is n
h re
– Push the tool onto the limit stop -arrow- in the contact housing.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
The contact is ejected from the contact housing.

m
at
om
ion
c
once the contact has been ejected.
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
satelettronica
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
Contacts without locking tabs:

– Insert the release tool under the locking tab of the contact
housing.
– Push through the release tool with a light upward movement
-arrow- onto the limit stop.
The contact is ejected from the contact housing.

3 Contact surface cleaning set - VAS

6410-
3.1 Using contact surface cleaning set -

VAS 6410-
The contact surface cleaning set - VAS 6410- enables optimal
repair of the electrical systems and components in the vehicle.
The tools allow performing repair work in the area of the sensor
in wiring harnesses for threaded connections in the high-current
circuit (starting and charge current). The contact surface cleaning
set - VAS 6410- is matched to the structural features of the vehi‐
cles and ensures safe repairs while making the work easier at the
same time.
Note
The illustrations shown here are just a few examples of repair

work.
satelettronica
Contact surface cleaning set VAS 6410
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
3.1.1 Repairing ring terminals
ce
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un
pt
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itte
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ab
pe
ility
♦ VAG 1331
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
Note
s
iva
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cum
fo
♦ The use of penetrating fluid, contact spray or grease etc. is

en
ng
t.
yi
prohibited since the missing adhesion in the threads may
Co
Cop py
cause a torque excess and, therefore, the break of the threa‐
t. rig
gh ht
yri
ded connection.
p by
co Vo
by lksw
cted agen
♦ The grey sanding pads are suitable for light dirt and "soft sur‐
Prote AG.
faces". The red sanding pads are suitable for heavy dirt and
"hard surfaces".
3. Contact surface cleaning set VAS 6410 153

WARNING AG. Volkswagen AG d

agen oes
olksw not
byV gu
ara
d
Danger of injury! Observe warning notices and safety regula‐ orise nte
eo
tions ⇒ page 3 ! aut
h
ra
c
ss
ce
e
nl
pt
du
an
– Disconnect battery.
itte
y li
erm
ab
– Loosen cap nut and remove ring terminal from threaded con‐
ility
ot p
nection.
wit
, is n
h re
– Check ring terminal for corrosion, dirt etc.
hole
spec
es, in part or in w
– Select suitable adapter and suitable sanding pad.
t to the co
Note
rrectness of i
As an alternative, the sanding block may also be used.
l purpos
nform
ercia
Caution
m
satelettronica
at
om
io
Take care not to abrade excessively the tin coating and ensure
n
c
in t
r
that the copper does not appear. This could produce a galvanic
o
his
te
cell which destroys metal and causes faulty repair.

a
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
Note rig ht
py by
co Vo
by lksw
cted agen
As the thickness of the tin coating may differ according to the de‐
Prote AG.
sign, the cleaning process must be performed step by step and a

visual check of the ring terminal is necessary between the steps.
– Insert adapter into ring terminal and grind off corrosion and dirt
with circular movements.
– Check ring terminal and regrind if necessary.

– If necessary, remove punching burr on ring terminal using de‐

burrer.
– Tighten ring terminal to specified torque ⇒ Current flow dia‐
grams, Electrical fault finding and Fitting locations.
Note
Optimum contact is ensured when the components to be secured

are tightened to the specified torque after cleaning.
– Apply suitable anti-corrosion treatment to connection

⇒ page 158 .
– Reconnect battery.
AG. Volkswagen AG d
agen oes
WARNING olksw not
y V gu
d b ara
rise nte
Danger of injury! Observe warning
utho
notices and safety regula‐ eo
ra
tions ⇒ page 3 ! ss a c
ce
e
nl
pt
du
an
satelettronica
itte
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– Teach in electric windows again, enter radio code, set clock
erm
ab
and, if necessary, recode control units which emit code sig‐
ility
ot p
nals.
wit
, is n
h re
hole
spec
3.1.2 Repairing threaded connections
es, in part or in w
t to the co
♦ VAG 1331
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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cu
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f
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ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Note Prote AG.
♦ The use of penetrating fluid, contact spray or grease etc. is

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

tions ⇒ page 3 !

– Loosen cap nut and remove ring terminal from threaded con‐
nection.
– Check threaded connection for corrosion, dirt etc.
– Select suitable adapter and suitable sanding pad for threaded
connection.
Caution
Take care not to abrade excessively the tin coating and ensure
that the copper does not appear. This could produce a galvanic
cell which destroys metal and causes faulty repair.
Note
As the thickness of the tin coating may differ according to the de‐
sign, the cleaning process must be performed step by step and a
visual check of the ring terminal is necessary between the steps.
satelettronica
– Set adapter on threaded connection and grind off corrosion
and dirt with circular movements.
– Check threaded connection and regrind if necessary.
– Tighten connection and, if necessary, locating element again
to specified torque ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.
AG. Volkswagen AG d
agen oes
olksw not
V gu
Note d by ara
rise nte
tho eo
u ra
Optimum contact is ensured when the components
ss a to be secured c
ce
e
nl
pt
du
an
itte
y li
– Apply suitable anti-corrosion treatment to threaded connection
erm
ab
⇒ page 158 .
ility
ot p
wit
, is n
– Reconnect battery. h re
hole
spec
es, in part or in w
WARNING
t to the co

tions ⇒ page 3 !
rrectness of i
l purpos
– Teach in electric windows again, enter radio code, set clock

and, if necessary, recode control units which emit code sig‐
nform
ercia
nals.
m
at
om
io
3.1.3 Cleaning battery clamp and battery ter‐

n
c
in t
or
minal
his
ate
do
priv
cum
or

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

♦ VAG 1331
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
Note ss au ra
c
ce
e
nl
pt
The use of penetrating fluid, contact spray or grease etc. is pro‐
du
an
itte
hibited since the missing adhesion in the threads may cause a
y li
erm
ab
torque excess and, therefore, the break of the threaded connec‐
ility
ot p
tion.
wit
, is n
satelettronica
h re
hole
spec
WARNING
es, in part or in w
t to the co
tions ⇒ page 3 !
rrectness of i
l purpos
– Check battery clamp and battery terminal for corrosion or dirt.
nf
ercia
orm
– Clean battery clamp using wire brush of battery terminal clean‐
m
atio
m
er with circular movements.

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

– Clean battery terminal using underside of battery terminal

cleaner with circular movements.
WARNING

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

torque.
Note
Optimum contact is ensured when the components to be secured

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

board supply.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
ut
Note ss a ra
c
ce
e
nl
pt
du
♦ All threaded connections must be tightened to specified tor‐
an
itte
que.
y li
erm
ab
ility
♦ Always use hose supplied with anti-corrosive agent tin.
ot p
wit
, is n
♦ Use protection wax for cold area.
h re
hole
spec
♦ Use cavity sealing agent for warm area.
es, in part or in w
t to the co
♦ The sealing agent independently reaches the respective
points through capillary action.
rrectness of i
– Hold injector below ring terminal and spray pin all around.
l purpos
nform
mercia
at
om
ion
c
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or
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ate
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cum
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en
ng
t.
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Cop py
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Vo
o
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cted agen
Prote AG.

– Hold injector above ring terminal and spray pin and wiring eye
all around.
satelettronica
AG. Volkswagen AG d
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or eo
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pt
du
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erm
ab
ility
ot p
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
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n in
or c
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o
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159
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Prote
cted 3. Contact surface cleaning set VAS 6410
AG.
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AG. Volkswagen AG d
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4 Renewing Lambda probe Vo gu
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or eo
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Note
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du
an
itte
♦ Do not repair Lambda probe wires, since this can result in
y li
erm
ab
malfunctions.
ility
ot p
wit
♦ If necessary, replace attachment parts, cable ties or marking
, is n
h re
rings to match the uniform probe to the defective probe as
hole
spec
specified.
es, in part or in w
t to the co
♦ If necessary, identify the lambda probe by means of the pro‐
tective tube ⇒ page 162 .
rrectness of i
4.1 Renewing LSF Lambda probe (4-pin)
l purpos
Note
nform
mercia
at
om
io
satelettronica
c
in t
or
specified.
his
ate
do
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♦ Do not repair Lambda probe wires, since this can result in

p
cum
or
malfunctions.
f
en
ng
t.
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Cop py
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pyri by
– Remove the defective Lambda probe.
o Vo
by c lksw
cted agen
Prote AG.
– Place both Lambda probes next to each other so that the sen‐
sor housings are at the same height.

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

250 mm) to the size of the defective probe and secure with
cable ties -1-.
– Check that the connector housing of the Lambda probe is
compatible with the on-board supply side.
– If necessary, replace the on-board supply system connector
with the Lambda probe connector housing supplied
⇒ page 143
Note
lk swage es n
♦ The connector housing by V should only be replaced on older
o ot g
ua ve‐
hicles. On new vehicles, the connector housing coding match‐
d ran
ir se tee
o
es. auth or
ac
ss
♦ Observe pin assignment. For reasons of clarity, respective
ce
e
nl
pt
pins in new connector housing have a colour marking.
du
an
itte
y li
♦ Further notes can be found in the leaflet of the new Lambda
erm
ab
ility
probe.
ot p
wit
, is n
h re
satelettronica
– Install the new Lambda probe in the vehicle.
hole
spec
es, in part or in w
t to the co
4.2 Renewing LSU Lambda probe (6-pin)
rrectness of i
Note
l purpos

nf
ercia
specified.
orm
m
atio
♦ The wires should not be crimped or cut as otherwise the func‐

om
n in
tion of the Lambda probe will be impaired.

or c
thi
te
sd
iva
– Remove the old Lambda probe.

o
r
rp
cu
o
m
f
en
ng
– Place both Lambda probes next to each other so that the sen‐
t.
yi Co
sor housings are at the same height. Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4. Renewing Lambda probe 161

AG. Volkswagen AG d
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V gu
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tee
h
aut - Edition 08.2019 or
ac
ss
ce
e
nl
– Tie back any excess in the uniform probe length (approx. 50 -
pt
du
an
250 mm) to the size of the defective probe and secure with
itte
y li
cable ties -1-.
erm
ab
ility
ot p
– Install the new Lambda probe in the vehicle.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
4.3 Types of protective tube on uniform
nf
ercia
orm
Lambda probes
m
atio
om
n in
or c
thi
te
sd
Note
iva
o
r
rp
cu
o
m
f
In addition to identifying by way of the part number, the protective
en
ng
t.
yi Co
tube can also be used as a means of identification.
satelettronica
Cop py
t. rig
gh ht
pyri by
Vo
Type D1, 6 openings at 3.5 mm each
o
by c lksw
cted agen
Prote AG.
Only used on 4-pin LSF Lambda probes.
Type D2, 6 openings at 2 mm each
Only used on 4-pin LSF Lambda probes and 6-pin LSU Lambda
probes.
Type D4, 12 openings at 1.4 mm each

Only used on 4-pin LSF Lambda probes and 6-pin LSU Lambda
probes.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
satelettronica
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4. Renewing Lambda probe 163

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Service Department. Technical Information

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Electrical system - general information

Service Department. Technical Information

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

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

Copyright © 2019 Volkswagen AG, Wolfsburg K0059101320

All rights reserved.

Copyright © 2019 Volkswagen AG, Wolfsburg K0059101320

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

3.3 Battery charger VAS 5900 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

3.4 Battery charger VAS 5903 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

3.6 Battery charger VAS 5908 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

3.9 Totally discharged batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

92 - Windscreen wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

1 Washer fluid line hose couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

1.1 Windscreen and rear window washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

1.2 Headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

2.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

2.2 Repairing smooth pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

96 - Lights, bulbs, switches - interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

27 – Starter, current supply, CCS AG. Volkswagen AG d

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

electrical system must be performed after the 12 V battery is dis‐

connected. If voltage is detected, the high-voltage system must

1.2 Types of batteries

The description for the following batteries is for maintenance-

1.2.1 Battery with »standard« colour indicator

It is not permissible to test or charge batteries whose colour

It is not permissible to test or charge batteries whose colour

indicator is light yellow. Do not slave/jump start the vehicle!

Danger of explosion when checking and charging or slave/

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

1.2.3 Absorbent glass mat battery

♦ Always replace an absorbent glass mat battery with another

1.3 Warning notices and safety regulations

1.3.1 Dangers when handling vehicle batter‐

Therefore suitable measures must be taken to ensure that

may escape through vent valves is explosive. In extreme

♦ Batteries whose magic eye shows light yellow must be re‐

cutting operations and use naked lights in the vicinity of

1.3.2 Safety markings on battery

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

1.3.3 Working on airbag system

When work is performed on the airbag system (pyrotechnical

of the airbag and the belt tensioner.

on position - warning lights in dash panel will not light up - the