Electrical System General Information

Service
Workshop Manual
Alhambra 1996 ➤ , Alhambra 2001 ➤ ,
Alhambra 2011 ➤ , Altea 2004 ➤ ,
Altea XL 2007 ➤ ,
Altea XL Freetrack 2008 ➤ ,
Altea XL Freetrack 2009 ➤ ,
Arosa 1997 ➤ , Córdoba 1999 ➤ ,
Córdoba 2003 ➤ , Córdoba Vario 1999 ➤ ,
Exeo 2009 ➤ , Exeo ST 2009 ➤ ,
Ibiza 1999 ➤ , Ibiza 2002 ➤ ,
Ibiza 2008 ➤ , Ibiza ST 2010 ➤ ,
Inca 1996 ➤ , León 1999 ➤ ,
León 2006 ➤ , León 2009 ➤ ,
León 2013 ➤ , León ST 2013 ➤ ,
Mii 2012 ➤ , Toledo 1999 ➤ ,
Toledo 2005 ➤ , Toledo 2009 ➤ ,
Toledo 2013 ➤
Electrical system; General information
Edition 02.2015
Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
27 - Starter, current supply, CCS
92 - Windscreen wash/wipe system
94 - Lights, bulbs, switches - exterior
96 - Lights, bulbs, switches - interior
97 - Wiring
Alhambra 1996 ➤ , Alhambra 2001 ➤ , Alhambra 2011 ➤ , Altea 2004 ➤ , A ...
Electrical system; General information - Edition 02.2015
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 Attaching the terminals to the battery poles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Battery: verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Checking the different battery types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Check the colour indicator on the battery cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Battery tester with printer VAS 6161 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.5 Current absorption test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3 Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1 Battery charger VAS 5095 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2 Battery charger VAS 5900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.4 Charging battery with battery charger VAS 5904 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.6 Solar panel VAS 6102A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.7 Totally discharged batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4 Checking and servicing alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.1 Checking alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.2 Bosch alternator up to 2000 - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5 Bosch alternator from 2001 onwards - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6 Removing and installing voltage regulator - Bosch alternator from 2001 onwards . . . . . . 52
7 Bosch alternator from 2007 onwards - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8 Removing and installing voltage regulator - Bosch alternator from 2007 onwards . . . . . . 54
9 Checking carbon brushes - all types of Bosch alternators from 2001 onwards . . . . . . . . . . 55
10 Valeo alternator up to 2000 - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
11 Valeo alternator from 2001 onwards - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
12 Removing and installing voltage regulator - Valeo alternator from 2001 onwards . . . . . . . . 58
13 Checking carbon brushes - Valeo alternator from 2001 onwards . . . . . . . . . . . . . . . . . . . . 59
14 Removing and installing voltage regulator - Valeo alternator from 2007 onwards . . . . . . . . 60
15 Checking carbon brushes - Valeo alternator from 2007 onwards . . . . . . . . . . . . . . . . . . . . 61
16 Removing and installing poly V-belt pulley without freewheel . . . . . . . . . . . . . . . . . . . . . . 62
17 Pulley for Poly-V belt with free sprocket: removing and fitting . . . . . . . . . . . . . . . . . . . . . . 63
18 Cruise control system (GRA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
18.1 Activating and deactivating cruise control system (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . . 64
92 - Windscreen wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

1 Washer fluid hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.1 Disconnecting and connection hose couplings for the washer fluid lines . . . . . . . . . . . . . . 66
1.2 Servicing a smooth washer fluid pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.3 Servicing a washer fluid hose with corrugated tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
94 - Lights, bulbs, switches - exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

1 Information on the use and the safety of the gas discharge lamps . . . . . . . . . . . . . . . . . . 71
96 - Lights, bulbs, switches - interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

1 Vehicle Immobiliser ...................................................... 74
Contents i
1.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

1.2 Defective transponder or loss of key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
1.3 Renewing reader coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
1.4 Locking set change procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2 Towing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.1 Removing and installing connection socket for towing hitch - Version 1 . . . . . . . . . . . . . . 75
2.2 Removing and installing the socket for towing hitch - Version 2 . . . . . . . . . . . . . . . . . . . . 76
2.3 Removing and installing the socket for towing hitch - Version 3 . . . . . . . . . . . . . . . . . . . . 78
2.4 Towing unit connector terminals layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3 Cigarette lighter U1 , 12 V socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3.2 Removing and installing electric socket or cigarette lighter . . . . . . . . . . . . . . . . . . . . . . . . 82
3.3 Removing and installing spring pin and cigarette lighter illumination bulb L28 . . . . . . . . . . 84
3.4 Clamping sleeve: Removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
97 - Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1 Vehicle Diagnosis, Testing and Information Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1.1 Connecting the central diagnosis VAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.2 Safety warnings on use when operating vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2 Repairing wiring harnesses and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.1 General notes on the repair of the vehicle electric system . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.2 Wiring harness repair set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
2.3 Description of the tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2.4 Repairing cable harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.5 Repairing aerial wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
2.6 Repairing contact casings and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
2.7 Connector housing: Unlock and dismantle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
3 Lambdasonde: replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
3.1 Lambda probe with solid electrolyte LSF (4-pin): replace . . . . . . . . . . . . . . . . . . . . . . . . . . 131
3.2 Lambda probe universal LSU (6-pin): replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
3.3 Versions of the grounding wire for standard Lambda probes . . . . . . . . . . . . . . . . . . . . . . . . 133
4 Contact surface cleaning set VAS 6410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
4.1 Using the contact surface cleaning set VAS 6410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
ii Contents
27 – Starter, current supply, CCS

1 Battery
(ERL002651; Edition 02.2015)
WARNING
Injury risk! Remember warnings and safety instructions

⇒ page 3 .
Caution
To prevent damage to the battery and vehicle, the following

should be observed concerning types of battery ⇒ page 1 .
1.1 Fundamentals for batteries

To guarantee the longest life possible for the battery we recom‐
mend following the testing, maintenance and conservation in‐
structions in this manual
As well as providing energy for starting, the battery carries out
other storage and supplies energy for the vehicle's entire electri‐
cal network.
1.2 Types of batteries

General instructions
Caution
The batteries described next are batteries that require no main‐

tenance. Do not remove stickers nor add distilled water. Only
perform visual inspections. Observe the chapters related to
battery testing ⇒ page 6 .
1.2.1 Battery with »standard« colour indicator

It is a maintenance-free battery with electrolyte liquid (moist bat‐
tery).
WARNING
The batteries whose magic eye a clear yellow or clear colour

should not be tested nor charged. Do not perform an auxiliary
start.
The risk of explosion exists upon testing and charging or per‐
forming an auxiliary start.
These batteries must be renewed.
This battery is equipped with a magic eye. The different colours

shown by the magic eye gives information about the electrolyte
level and the state of the battery charge. Check the magic eye
⇒ page 7 .
1. Battery 1
1.2.2 Battery with »enhanced« colour indica‐

tor
It is a maintenance-free battery with electrolyte liquid (moist bat‐
tery).
Caution
Do not remove stickers nor add distilled water. Only perform

visual inspections. Observe the chapters related to battery
testing ⇒ page 6 .
WARNING
Batteries where the colour is light yellow must not be checked

nor charged. Do not perform an auxiliary start.
The battery is used for particular requirements in certain Start -

Stop vehicles. The battery can be identified by the lettering “EFB”
on the battery cover. “EFB” stands for »enhanced flooded bat‐
tery«.
An “EFB” battery may only be replaced with another “EFB” bat‐
tery.
The “EFB” battery is equipped with a colour display for checking
the electrolyte level.
Checking the colour indicator ⇒ page 7
Note
“EFB” batteries have been used in the smaller petrol engines with
stop-start systems and manual gearboxes since 05.2011.
1.2.3 Absorbent glass mat battery

Battery exempt from maintenance with fixed electrolyte, without
magic eye.
Lead acid battery with electrolyte immobilized in a glass fibre mat
(AGM). This is a sealed battery fitted with valves.
AGM is the abbreviation for Absorbed Glass Mat (absorbing glass
fibre).
The electrolyte fitting causes these batteries to not have magic
eye. AGM is the abbreviation of this battery type.
Note
AMG batteries must always be replaced by batteries of the same

type (with glass mat technology).
2 Rep. gr.27 - Starter, current supply, CCS

1.3 Warning notices and safety regulations

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

ies
Recognition and avoidance of dangers
The handling of batteries is dangerous. These dangers can be
avoided if the warnings on the battery, in the Operating manual
and in ELSA are heeded.
WARNING
♦ Personnel with little experience, for example apprentices

or placement personnel, should only carry out work on
batteries under the supervision of specialist personnel
such as experienced mechanics or workshop supervisors
or electricians specialized in the automobile field.
♦ Battery electrolyte is very corrosive and caustic. If the bat‐
tery is incorrectly handled, there is a danger that personnel
may be affected by the electrolyte. For this reason, always
provide adequate products that may be used to treat burns
caused by the electrolyte. For example, soap solution rep‐
resents a suitable agent for the treatment.
♦ If acid leaks from the battery, this may lead in burns to the
skin, the intake of acid and corrosion to the vehicle. In the
latter case components necessary for vehicle safety may
be damaged.
♦ Flammable gas is produced while charging the battery,
also, there is gas build-up while the battery is at rest fol‐
lowing charging; this gas is explosive. In extreme cases,
if handled carelessly, the battery may explode due to the
build up of explosive gas.
♦ In batteries where the magic eye of the is transparent or
light yellow must be replaced. They should not be tested
nor charged, you should not perform a jump start. The risk
of explosion exists upon testing and charging or perform‐
ing an auxiliary start.
♦ All sanding, welding or cutting work is prohibited close to
the battery due to the risk of sparks; never approach the
battery with any object that many ignite gasses (for ex‐
ample a lit cigarette). Avoid sparks caused by static elec‐
tricity charge. Always touch the bodywork before touching
the battery.
♦ Always carry out work on the battery only in well ventilated
and adapted areas.
1. Battery 3
1.3.2 Safety symbols on the battery

Safety symbols on the battery
1. - When handling the battery do not expose it to flames or
sparks; smoking is prohibited. Avoid sparks when handling cables
or electric equipment or sparks caused by electric discharge.
Avoid short circuits. For this reason no tool should ever be left on
the battery.
2. - Always use eye protection when handling the battery.
3. - Keep children well away from the battery and the electrolyte
4. - Disposal: used batteries are considered as special waste.
They must only be disposed of in adequate collection centres and
in accordance with the law.
5. - Never put used batteries into domestic rubbish containers.
6. - There is a danger of an explosion when working with batteries.
When charging, a highly explosive mix of gases is produced.
7. - The warning notes on the battery, the repair manual instruc‐
tions for the "Electric system, general information" found in ELSA
and the battery instructions manual must be observed at all times.
8. - The electrolyte of the battery is very corrosive, so gloves and
protective glasses should be worn. Never tip the battery over,
electrolyte may spill out of the gas release openings.
Batteries with battery monitoring control unit - J367-

For vehicles with a battery monitoring control unit - J367- , the
black charging terminal “-” must not be connected to the minus
pole of the battery. This should be connected to the earth con‐
nection in the engine compartment as indicated on the label.

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 when the ignition is switched
on.
Exception: for vehicles a battery in the passenger compart‐
ment, the ignition must be switched off
♦ Then cover negative terminal.
♦ A waiting period of 10 seconds is necessary after the bat‐
tery has been disconnected.
♦ Reconnecting the battery is carried out with the ignition on.
♦ No persons may be in the interior when the battery is re‐
connected.
Ensure, in this case, that you are not within the effective range
of the airbag and the belt tensioner.
If when reconnecting the battery and the ignition was not in the
on position - warning lights in dash panel will not light up - the
ignition may only be switched on (key/button) from the driver's
seat with the seat set in the rearmost position.
1.4 Attaching the terminals to the battery

poles.
Caution
To avoid damage to the battery poles and terminals the fol‐

lowing must be taken into account:
♦ The battery terminals must be fitted by hand, without forc‐
ing.
♦ The battery poles must not be greased.
♦ The terminals should be fitted so that the pole is flush with
the terminal or protrudes a little.
♦ Once the battery terminals have been tightened to the
prescribed torque, they must not be tightened again.
1. Battery 5
2 Battery: verification
WARNING

⇒ page 3 .
Caution

2.1 Checking the different battery types
2.1.1 Testing a battery with magic eye
WARNING

⇒ page 3 .
Verify the battery as follows:

1. Visual inspection ⇒ page 7
2. Check the colour that the “with 3 colour”, ⇒ page 7 or “2
colours” colour display shows ⇒ page 8 .
WARNING

start.
– Checking battery using battery tester with printer - VAS 6161-

⇒ page 10 .
3. Depending on the results of the battery test “perform a cur‐
rent absorption test” ⇒ page 14 .
2.1.2 Testing an Absorbed Glass Mat Battery

(AGM battery)
Verify the battery as follows:
– Checking battery using battery tester with printer - VAS 6161-
⇒ page 10 .
1. Depending on the results of the battery test “perform a cur‐
rent absorption test” ⇒ page 14 .

2.2 visual inspection
WARNING

⇒ page 3 .
Visual inspection of the exterior, the connections and the correct

seating of the battery before taking measurements.
Caution
♦ The battery may be damaged if it is not secured correctly.

♦ Damage caused by vibrations or jolts reduce the useful life
of the battery; this represents an explosion risk! The grill
plates may be damaged and the attachment strap could
damage the battery casing.
♦ Check that the battery is properly fitted and if necessary
tighten the securing bolt to prescribed torque .
The visual check is used to ascertain:

♦ If battery housing is damaged If the battery casing is damaged,
electrolyte may spill. Spilled electrolyte may cause serious
damage to the vehicle. The parts of the vehicle affected by
spilled electrolyte must therefore be treated with a product to
neutralize the acid or with soap solution immediately.
♦ If the poles of the battery (battery cable connections) have
deteriorated. If the battery poles are damaged, the necessary
connection to the terminals is no longer guaranteed. Also for
the battery pole terminal connections take into account the
necessity of applying the tightening torque specified in the
Repairs Manual “Electrical system” of the corresponding ve‐
hicle. If the terminals are not correctly connected and tight‐
ened then they may burn the cables. This could cause
considerable errors in the electrical system. The safe func‐
tioning of the vehicle is no longer guaranteed.
2.3 Check the colour indicator on the battery

cover
2.3.1 Checking colour indicator, “3-colour”
WARNING

⇒ page 3 .
General information about colour indicator:

Applies for all batteries with indexes “1J0”, “7N0” and “3B0”, that
have been installed as initial equipment and for all replacement
batteries 191 915 105 AB and from index “000 915 105 AX”
The magic eye may be used to check the level of electrolyte and
the charge status of the battery.
Before visually checking the electrolyte level, tap on the colour
display carefully and gently with the handle of a screwdriver. In
this way, the bubbles are removed which could distort the colour
2. Battery: verification 7
of the colour indicator. The colour display of the magic eye will
therefore be more accurate.
Note
♦ Bubbles could form under the magic eye, above all when the
battery has been recharged, that is, even when charging dur‐
ing the running of the vehicle. These bubbles distort the col‐
ours on the colour indicator.
♦ Since the colour indicator is only located in one battery cell,
the indicator also only applies to this battery cell. Determining
the exact condition of the battery is only possible by means of
a battery test ⇒ page 10 .
♦ The colour indicator can be located at various positions on the
battery.
Three different colour indications are possible:

♦ »Green«: the battery is sufficiently charged.
♦ »Black«, battery partly discharged, charge state < 65 % or
completely discharged
♦ »Transparent or yellow«: the battery must be replaced.
WARNING

start.
2.3.2 Checking colour indicator, “2-colour”
WARNING

⇒ page 3 .
General information about colour indicator:

The general introduction of the “2-colour” indicator took place
gradually in 2009. The “2-colour” indicator does not include
»green« to indicate the charge state.
The acid content of the battery can be checked using the magic
eye.
The battery charging status can no longer be checked using the
magic eye; a battery charging test must be carried out for this
purpose, ⇒ page 10
Before visually checking the electrolyte level, tap on the colour
display carefully and gently with the handle of a screwdriver. In
this way, the bubbles are removed which could distort the colour
of the colour indicator. The colour display of the magic eye will
therefore be more accurate.

Note
♦ Air bubbles can form under the sight glass, particularly when
a battery has been recharged, i.e. also when the battery has
been charged during normal vehicle operation. These falsify
the reading of the colour indicator.
♦ Since the colour indicator is only located in one battery cell,
the indicator also only applies to this battery cell. Determining
the exact condition of the battery is only possible by means of
a battery test ⇒ page 10 .
♦ The colour indicator can be located at various positions on the
battery.
Three different colour indications are possible:

♦ »Black«, the electrolyte level is okay
♦ »Colourless or light yellow«, electrolyte level too low. Battery
must be replaced.
WARNING

start.
2.4 Battery tester with printer - VAS 6161-

General description:
WARNING

⇒ page 3 .
There is no need to disconnect and remove the battery if the bat‐

tery tester - VAS 6161- is used.
The battery tester with printer - VAS 6161- is not an additional
load for the battery. It operates using the principle of dynamic
conductance.
All types of batteries are stored in the tester.
The data can be saved on an SC memory card.
The battery tester with printer - VAS 6161- can be updated with
the interface or the SD card to get the latest battery data from
Volkswagen.
The integrated thermosensor increases the quality of the test.
A 2D scanner is available as an option for reading the barcode on
the battery directly.
Note
Please observe the ⇒ operating instructions for the battery tester

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

- VAS 6161-
1 - Integrated printer
2 - Lever for paper compartment
3 - Paper slot
4 - LCD monitor with main menu
5 - Front panel with ON/OFF switch
6 - Connector for battery tester cable
7 - Slot for the memory card
8 - Infrared sensor for temperature
9 - Data transmitter for PC
2.4.2 Performing battery test using battery

tester with printer - VAS 6161- :
WARNING

⇒ page 3 .

Special tools and workshop equipment required

♦ Battery tester with printer - VAS 6161-
Perform battery test:
WARNING

start.
– Switch off ignition and all electrical equipment.

– On batteries that are equipped with a colour indicator, check
the latter ⇒ page 6 .
– Switch on the device.
– Connect the red terminal “+” of the tester to the positive pole.
– Connect the black terminal “-” of the tester to the negative pole.
Note
Ensure the perfect connection of the tester terminal clamps.
– Select one of the following functions:

♦ Test Genuine batteries in guarantee mode ⇒ page 12
♦ Test third-party batteries in service mode ⇒ page 13
Note
♦ The test is completed after about 10 seconds.

♦ The results of the test are printed .
♦ It is not necessary for the tester to cool down before performing
the next test.
2.4.3 Performing guarantee test
WARNING

start.
– Select “Guarantee test” in menu.

– Select “in vehicle” or “outside vehicle”.
– Select “on battery pole ” or “on auxiliary start connection ”.
– Scan in 2D code of battery or manually select battery type and
amperage.
– Measure the temperature. Hold temperature sensor about 5
cm above one battery terminal until temperature stabilises.
– Start test.
– Print out test report, if required.
2.4.4 Performing maintenance test
WARNING

start.
– Select “Maintenance test” in menu.

– Connect scanner.
Note
If no scanner should be available, the chassis number must be

noted on the test print-out by hand.
– Scan in vehicle identification number.

– Scan in 2D code of battery or select type and make manually
in menu.
– Measure the temperature. Hold the temperature probe about
5 cm above the terminal connection until the temperature is
constant.
– Start test.

2.4.5 Performing service test
Note
♦ The print-out may vary depending on software version.

♦ Please observe the⇒ operating instructions for the battery
tester with charger - VAS 6161- .
WARNING

start.
– Select “Service test” in menu.

– Select type of battery: “Normal”, “AGM”, “2*6V” or “Gel”.
– The standard: “CCA”, “JIS”, “DIN”, “SAE”, “IEC” or “EN” norm.
– Select battery value.
– Measure the temperature. Hold temperature sensor about 5
cm above one battery terminal until temperature stabilises.
– Start test.
2.4.6 Comments concerning test print out

1- Start test.
2- Battery test results.
3- Measured voltage
4- The measured value at cold start of the battery.
5- Setpoint value of the battery set on the battery tester for a
cold start.
6- Measured temperature of battery.
7- Location of battery
8- Connection location of battery set on tester.
9- Technology of the set battery.
Note
The test printout is required for warranty claims.
2.4.7 Analysis of the test results

Evaluation of guarantee and service test results obtained with
battery tester.
Battery test results Fault rectification
Battery in good condition Do not carry out any measures
on the battery.
Battery in good condition, Charge the battery
charge ⇒ page 17 If necessary, de‐
termine the cause of the dis‐
charge
Perform a current absorption Perform a current absorption
test test ⇒ page 14 . Completely
recharge battery ⇒ page 17
and repeat test.
Replace the battery. Disconnect the battery and re‐
test. The result “Replace bat‐
tery” can be caused by a loose
cable contact..
Battery cell damaged, replace Replace the battery.
Check connections Connect cable directly to bat‐
tery and not to auxiliary start
connection
Evaluation of battery test results for maintenance test.
Battery test results Fault rectification
Battery in good condition No action
Charge battery immediately Battery fully charged
⇒ page 17 .
Mark as damaged Mark as damaged.
Check tester connection. Disconnect the battery and re‐
test. The result “check connec‐
tion of the tester” may be
caused by a loose contact of
the cable.
Check connections Connect cable directly to bat‐
tery and not to auxiliary start
connection
Noises Wait until the measurement val‐
ue appears on the display.
2.5 Current absorption test
WARNING

start.

Note
♦ Check that the charger is in the correct charge mode for the
current absorption test result show no errors.
♦ VAS 5095 A ⇒ page 18
♦ VAS 5900 ⇒ page 22
♦ VAS 5903 ⇒ page 33
To obtain a faster battery status result, in the case of discharged

batteries you may analyse the battery absorption current during
the charge cycle to obtain the conclusion on whether the battery
should be replaced or should be submitted to a maximum charge.
Note
Perform a current absorption test using the battery tester with

printer - VAS 6161- as long as the test result “Perform a current
absorption test” appears on the display.
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 a current absorption test
Checking the current absorption capacity of a battery during the
charging procedure you may qualify at a short time if a battery is
partially or profoundly discharged ⇒ page 48 it may become new
again in operating conditions via a recharge.
Test requirements
♦ When charging the battery, this should have a temperature of
≥ +10 °C at minimum
♦ The charger should be able to supply at minimum a load cur‐
rent of 30A, as done for example with the VAS 5095A, VAS
5900, VAS 5903
♦ When charging with the battery charger - VAS 5095A- , the
current input of the battery must be measured using a current
clamp, e.g. VAS 5051B/7. The battery charger - VAS 5900-
and the battery charger - VAS 5903- show the power con‐
sumption on the device itself. Battery charger - VAS 5900-
performs the current draw test automatically with menu
guidance.
– Connect the battery to the battery charger or begin the charg‐
ing operation.
– Measure after five minutes the battery charge current.
Test result:
If the current input A lies above 10 % of the nominal power rating
Ah (e.g. > 6.1 A with a 61-Ah battery), the battery must be fully
charged and retested.
– Charge battery to the maximum if charging current is over a
10% of nominal capacity.
– A battery test has to be carried out after this has been standing
still for two hours ⇒ page 10 .
If the charging current is below a 10% of nominal capacity in amps
after 5 minutes of the beginning of charging cycle (that is, for a 50
Ah < 5A battery), battery must be replaced. In the cases of guar‐
antee and deference you must fill up the battery tester sheet and
save it together with the battery.

3 Charging the battery
WARNING

⇒ page 3 .
Caution

WARNING

start.
3.1 Battery charger - VAS 5095 A-

In this chapter the basic functions of the battery charger - VAS
5095 A- are described. Further information can be found in the ⇒
instruction manual of the battery charger - VAS 5095 A- .
Note
♦ You can not take a reading of the effective charge current with
this device. The charge current has to be measured externally
with an ampere clamp.
♦ Note the ⇒ instruction manual of the battery charger - VAS
5095 A- .
3.1.1 Description of battery charger - VAS

5095 A-
The battery charger - VAS 5095- is suitable for charging all 12V
batteries in the VW group.
3. Charging the battery 17

The battery is charged without current or voltage spikes. In this

way the onboard electronics are not affected. The battery can be
left in the vehicle during charging and does not have to be dis‐
connected from the onboard network.
Battery charger - VAS 5095 A-
1 - ON/OFF switch (0 = charger OFF)
2 - Charging current indicator (I > 12 A)
3 - Charge current indicator: partially charged battery > 90%
4 - Charge maintenance, green light if the battery is charged
5 - Fault indicator
6 - Backup function indicator
7 - Backup function/ normal operation switch
8 - Charge cable, red charge cable “+”; black charge cable “–”
9 - Battery type selector switch (charger base)
3.1.2 Charging battery with battery charger -

VAS 5095 A-
WARNING

⇒ page 3 .

♦ Battery charger - VAS 5095 A-
Caution
During the charge operation the battery type must always be

selected 2.4 V/Z (volts / battery cell). This applies for all bat‐
teries.
Note
The battery must have a temperature of at least 10 °C.

WARNING

start.

– Check the battery type selection on the battery types switch
⇒ page 17 . The switch must be set to 2.4 V/Z (volts / battery
cell).
– Connect the red charge clamp “+” of the charger to the positive
pole of the battery.
Note
On vehicles with Start / Stop function and battery monitor control

unit - J367- , the black charging terminal “-” must be connected
to the body earthing. Connecting it to battery negative terminal
will cause start/stop system to malfunction.
– Connect the black charge terminal “-” of the charger to the

negative pole of the battery.
– Switch on battery charger ⇒ page 17 .
The charge current indicators ⇒ page 18 -2- and -3- light up yel‐
low. If only one LED lights -3-, this means that the battery is
partially charged (approx. 90%).
If the green LED ⇒ page 18 -4- is lit this means that the charger
has switched to charge maintenance. The battery is charged.
– Switch off charging unit ⇒ page 17 .
– Remove the charge clamps from the terminals on the battery
poles.
3.1.3 Charging totally discharged battery with

battery charger - VAS 5095 A-
WARNING

⇒ page 3 .
The battery charger will automatically recognize seriously dis‐

charged batteries and will indicate a charge operation using low
current to preserve the battery. The charge current is automati‐
cally adjusted depending on the battery charge status.

Note
♦ Observe notes in chapter ⇒ page 48 .

♦ For vehicles that have not yet been registered, exhausted bat‐
teries must be replaced before being transferred. Previous
influences cannot be exempted.
♦ The battery voltage must be minimum 0.6 V.
WARNING

start.
– Charge the battery ⇒ page 18
3.1.4 Charging battery in support mode with

battery charger - VAS 5095A-
General notes:
The support mode provides the onboard supply with power when
the battery is removed or disconnected.
The ⇒ Instruction manual for the VAS 5095A will provide you with
more information for this.
Back-up power supply can be used in the following cases:
♦ Back-up power supply of on-board vehicle electrical systems
when the batteries is not installed
♦ Maintaining the voltage when the battery is replaced
♦ Ancillaries test without battery
WARNING

⇒ page 3 .
WARNING

start.

Caution
♦ The incorrect polarity protection is not active while “charg‐

ing extremely discharged batteries/backup function”. Con‐
nect the charge clamps with the correct polarity to the
terminals of the battery poles.
♦ This may provoke short circuit sparks.
♦ Risk of explosion exists because of this.
♦ Make sure that the charger terminals are correctly con‐
nected.
♦ Do not operate the START / STOP button if the charge
clamps are connected incorrectly. The charger may be
damaged.
– Remove battery
Caution
Always make sure that after removing the battery, that no con‐
tact is at hand between the positive terminal connected to the
charging clamp and the earth pole on the body. Furthermore,
possible contact of the battery clamps must be prevented.
– Connect the red charge terminal “+” to the positive terminal of

the vehicle.
Note

– Connect the black charge terminal “-” to the negative terminal

of the vehicle.
– Check the settings of the battery type on the selector switch
for back-up power supply / normal supply ⇒ page 17 . The
back-up power supply must be selected.
– Ensure the correct polarity of the charge clamps.
– Switch on the battery charging unit
The charge will begin to function in backup mode.
Quit the back-up power supply of the battery charger:
– Switch off the charger.
– Remove the black charge terminal “-” of the charger from the
negative terminal of the vehicle.
– Remove the red charge terminal “+” of the charger from the
positive terminal of the vehicle.
– Unplug the charger from the mains.

3.1.5 Charging battery in maintenance mode

with battery charger - VAS 5095 A-
WARNING

⇒ page 3 .
WARNING

start.
Using the function maintenance charge guarantees that the bat‐

tery charger - VAS 5095 A- has a safe charging (without surges)
and the maintenance charge of the battery.
– Proceed as for charging battery ⇒ page 18 .
Note
♦ If the battery is discharged by electric consumers during the

maintenance charge, the battery charger - VAS 5095 A- will
automatically ensure for the respective charging.
♦ The charge maintenance function may be executed without
any time limits.
♦ The battery will be available for operation at all times.
3.2 Battery charger - VAS 5900-
WARNING

⇒ page 3 .
WARNING

start.

5900- are described. Further information can be found in the ⇒
instruction manual of the battery charger - VAS 5900- .

Note
♦ When using this device you can not take a direct reading of
the effective charge current in the battery charger.
♦ Note the ⇒ instruction manual of the battery charger - VAS
5900- .

5900-
Battery charger - VAS 5900-
1 - Display
2 - Adjustment button “Up” ↑
3 - Adjustment button “Down” ↓
4 - START / STOP
5 - INFO

VAS 5900-
WARNING

⇒ page 3 .
WARNING

start.

♦ Battery charger - VAS 5900-

Note

– Plug the charger into the mains. The display will show the bat‐
tery type selected.
– Select the operation mode corresponding to the battery using
the INFO button.
The symbol -1- appears on the screen of the “standard wet battery
charge” or the symbol -2- for the “standard gel battery / Absorbed
glass mat battery charge”.
– Adjust the battery capacity (Ah) of the battery to be charged
using the respective “Up” ↑ or “Down” ↓ buttons.
– Connect the red charge clamp “+” to the positive pole of the
battery.
Note

unit - J367- , the black charging terminal - must be connected to
the body earthing. Connecting it to battery negative terminal will
cause start/stop system to malfunction.
– Connect the black charge terminal “-” to the negative pole of

the battery.
The charger will recognize the nominal voltage of the battery con‐
nected (6 V, 12 V or 24 V) and automatically begin the charge
operation.
As soon as the charge status is approx. 80 - 85% of the charge,

the charger starts the “final charge”. -1- appears on the display in
the fourth column. The battery is available for operation.

When a 100% charge is reached all the columns appear on

screen.
Note
♦ For battery type “Standard charge”, other consumers can be

connected parallel to the charging procedure. In this case the
charge operation will be prolonged.
♦ Depending on the type of battery in question, the charger will
switch after approx. 1 to 7 hours to the charge maintenance
mode. In order to reach a 100 percent charge status the bat‐
tery must remain connected to the charger all of the time.
Possible faults and troubleshooting:

1- The battery voltage displayed does not correspond to the
nominal voltage:
– Press and hold the button “Up” ↑ or “Down” ↓ , until the charge
operation begins.
nominal voltage-the charge operation has already begun:
– Press START / STOP twice.
operation begins again.
3- The charger does not detect any battery if the battery volt‐
age is less than 2 V.
The value displayed does not change.
The adjusted battery type and the amperes/hour (Ah) are dis‐
played.
Finish charging the battery:
– Press the START / STOP button.
positive pole of the battery.
3.2.3 Charging battery in service mode with

battery charger - VAS 5900-
WARNING

⇒ page 3 .

Caution
The operation mode “service charge” is not permitted for SEAT

vehicles because the voltage spikes may damage the onboard
electronics.
If “service charge” operation mode is used anyway the battery
must be disconnected from the onboard system.
WARNING

start.
Caution
For the charge process the operation mode corresponding to

the battery must be selected ⇒ Instructions Manual battery
charger - VAS 5900- .
The “battery charger ” is used to charge:
♦ The batteries with liquid electrolyte, whose magic eye ad‐
mits the charge (black or green magic eye).
The “service charge (SERV)” operating mode is only used in the

case of sulphated batteries. The battery is charged during this
operation with voltages > 14.4 V. In this way, a partial degradation
of the sulphate layer may be produced. After the charge you must
clearly check the indication in the magic eye colour before using
the battery ⇒ page 7 .
Note

– Plug the charger into the mains. The last selected operating
mode will appear on display ⇒ page 23 .
– Adjust with INFO the corresponding battery type.
The symbol -1- appears on the screen for the “wet battery service
glass mat battery service charge”.
battery.
Note


the battery.
operation.

As soon as the charge status is approx. 80 - 85% of the battery

voltage is reached, the charger starts the “final charge”. -1- ap‐
pears on the display in the fourth column. The battery is available
for operation.
Note
The success of the “service charge” depends on the level of sul‐

phate formation in the battery.

nominal voltage:
operation begins.
operation begins.
The operation mode and the amperes / hour (Ah) selected are
displayed.

WARNING

⇒ page 3 .
WARNING

start.

Caution

♦ For the charge process the operation mode corresponding
to the battery must be selected ⇒ Instructions Manual
battery charger - VAS 5900- .
♦ Totally discharged battery is not recognised by battery
charger ⇒ page 48 .
damaged.
Batteries with a voltage of less than 2 volts will not be recognised

automatically by battery charger - VAS 5900- .
Note

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


– Adjust with INFO the corresponding battery type.

via the respective “Up” ↑ or “Down” ↓ buttons.
battery.
Note


the battery.
– Press the START / STOP button for approx 5 seconds. The
option charge “extremely low battery/backup function is acti‐
vated”.
– Press the respective “Up” ↑ or “Down” ↓ button, to adjust the
respective battery voltage (6 V, 12 V or 24 V).
Note
After five seconds if no button is pressed the charger returns to

the main menu (select operation mode).
– Confirm the selected battery voltage with START / STOP .

Then the system will check if the charge clamps have been con‐
nected with the correct polarity.
– Ensure the correct polarity of the charge clamps using the
START / STOP button.
The charger will begin to charge the extremely low battery.


General notes:
The ⇒ Instruction manual for the VAS 5900 will provide you with


WARNING

⇒ page 3 .
WARNING

start.
Caution

nected.
damaged.
– Remove battery
Caution

the vehicle.

Note


of the vehicle.
vated”.
Note


The charger starts the back-up power supply.


with battery charger - VAS 5900-
Note

maintenance charge, the battery charger - VAS 5900- will au‐
tomatically ensure for the respective charging.
any time limits.
♦ Note the instructions provided by the battery manufacturer.

WARNING

⇒ page 3 .
WARNING

start.
If the battery is fully charged the battery charger - VAS 5900- will
begin the charge maintenance.
screen.
WARNING

⇒ page 3 .
WARNING

start.

5903- are described. Further information can be found in the ⇒
instruction manual of the battery charger - VAS 5903- .

Note
Note the ⇒ instruction manual of the battery charger - VAS 5903- .

5903-
1 - Display
2 - Adjustment button “Up” ↑
3 - Adjustment button “Down” ↓
4 - START / STOP
5 - INFO

VAS 5903-
WARNING

⇒ page 3 .
WARNING

start.


Note

the INFO button.
The symbol -1- appears on the screen of the “standard wet battery
glass mat battery charge”.
battery.
Note


the battery.
operation.
As soon as the charge status is approx. 80 - 85% of the charge,

the charger starts the “final charge”. -1- appears on the display in
the fourth column. The battery is available for operation.


screen.
Note
♦ For battery type “Standard charge”, other consumers can be

connected parallel to the charging procedure. In this case the
charge operation will be prolonged.
♦ Depending on the type of battery in question, the charger will
switch after approx. 1 to 7 hours to the charge maintenance
mode. In order to reach a 100 percent charge status the bat‐
tery must remain connected to the charger all of the time.

nominal voltage:
operation begins.
operation begins again.
The adjusted battery type and the amperes/hour (Ah) are dis‐
played.
3.3.3 Charge to refresh with the battery charg‐

er - VAS 5903-
WARNING

⇒ page 3 .

WARNING

start.
Caution
The operation mode “refresh charge” is not permitted for SEAT

vehicles, because the voltage spikes may damage the onboard
electronics.
If “refresh charge” operation mode is used anyway the battery
must be disconnected from the onboard system.
Caution
For the charge process the operation mode corresponding to

the battery must be selected ⇒ Instructions Manual battery
charger - VAS 5903- .
The “refresh charge” serves for:
♦ batteries with liquid electrolyte to which distilled water may
be added.
The “refresh charge” operation mode must not be used with
liquid electrolyte zero maintenance batteries.
The “refresh charge (ref)” operating mode is only used for batter‐
ies where a fault is presumed (e.g. sulphated batteries). This
operation charges the battery until the electrolyte reaches its
maximum density, reactivating the plates (breakdown of the sul‐
phate layer).
Note

the INFO button.
The symbol -1- appears on the screen for the “refresh electrolyte
battery charge” or the symbol -2- for the “gel battery/ glass fibre
technology battery refresh charge”.
battery.
Note


the battery.
operation.

As soon as the charge status is approx. 80 - 85% of the battery

voltage is reached, the charger starts the “final charge”. -1- ap‐
pears on the display in the fourth column. The battery is available
for operation.
Note
The success of the “refresh charge” depends on the level of sul‐

phate formation in the battery.

nominal voltage:
operation begins.
operation begins.
The operation mode and the amperes / hour (Ah) selected are
displayed.

WARNING

⇒ page 3 .
WARNING

start.

Caution

♦ For the charge process the operation mode corresponding
to the battery must be selected ⇒ Instructions Manual
battery charger - VAS 5903- .
♦ Totally discharged battery is not recognised by battery
charger ⇒ page 48 .
damaged.
Batteries with a voltage of less than 2 volts will not be recognised

automatically by battery charger - VAS 5903- .
Note

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



the INFO button.
battery.
Note


the battery.
vated”.
Note


The charger will begin to charge the extremely low battery.


General notes:


WARNING

⇒ page 3 .
WARNING

start.
Caution

nected.
damaged.
– Remove battery
Caution

the vehicle.

Note


of the vehicle.
vated”.
Note


The charger starts the back-up power supply.


with battery charger - VAS 5903-
Note

maintenance charge, the battery charger - VAS 5903- will au‐
tomatically ensure for the respective charging.
any time limits.
♦ Note the instructions provided by the battery manufacturer.

WARNING

⇒ page 3 .
WARNING

start.
If the battery is fully charged the battery charger - VAS 5903- will
begin the charge maintenance.
screen.

3.4 Charging battery with battery charger -

VAS 5904-
3.4.1 General description

WARNING

⇒ page 3 .
WARNING

start.
The battery charger -VAS 5904- carries out the charging without
current or voltage peaks. Batteries can therefore also be charged
when installed. Safety precautions must be observed when doing
so. The chargers have a back-up function enabling them to supply
power to on-board circuits.
If electrical equipment has to be periodically switched on when
performing work on the electrical system and for “Guided fault-
finding” mode, the battery must be charged using a charger with
back-up function so as not to damage the battery.
Further information about the battery charger can be found in the
⇒ instruction manual of the respective battery charger.


3.5.1 General description
WARNING

⇒ page 3 .
WARNING

start.
The battery charger - VAS 5906- has been especially designed

for charging in the vehicle power supply during the vehicle pre‐
sentation.
It has an automatic charging characteristic for starter batteries, 3
- 300 AH.
The maximum charging voltage of 14.4V is not surpassed in the
process. All consumers are supported with up to 30 Amps in the
on-board network by the buffer charging.
For permanent operation, the battery charger - VAS 5906-
switches to trickle charging after being fully charged.
The device is started fully automated and does not require any
settings. Only contact must be made with the charging terminal
and the mains cable.

VAS 5906-
WARNING

⇒ page 3 .
WARNING

start.

Overview of the operating unit:

1- Displays charging status 25 %.
5- Display ready
6- Button Start / Stop and Setup to cancel the charging proce‐
dure and re-establish. Access to the Setup menu and se‐
lection of the characteristic curve type (press for 10
seconds).
7- Displays irregularities.
– Place the charging device in the engine compartment or under
the vehicle.
– Connect the power cable to the charging device and the power
supply.
Charger is in no-load operation - ready light is on.
WARNING

⇒ page 3 .
– Switch ignition OFF.

– Connect the red charging cable to the positive battery terminal
“+”.
Note

– Connect the black charging cable to the negative battery ter‐

minal “-”.
The charging begins after approx. 2 seconds.
The LEDs show the charging status of the battery. When all lamps
have illuminated, the battery is charged.
Once the battery is charged, the battery charger - VAS 5906-
switches automatically to retention mode.
Caution
There is a risk of spark generation when the charging terminals

are removed too early. The charging stops by tapping on the
Start / Stop button.
– For ending the charging procedure, press the button Start /

Stop button.
– Remove the black charging cable from the negative battery
terminal “-”.

– Remove the red charging cable from the positive battery ter‐
minal “+”.
3.6 Solar panel - VAS 6102A-

with solar panel - VAS 6102A-
Solar panel VAS 6102A
The solar panel - VAS 6102A- supports the onboard network and
prevents self-discharge of the battery.
The solar panel - VAS 6102A- achieves a maximum voltage of
14.3 V and a maximum charge flow of 255 mA.
Batteries with lead and lead gel can be charged using the solar
panel - VAS 6102A- .
The solar panel - VAS 6102A- is connected to the diagnosis con‐
nection of the vehicle.
The frame has been provided with a green LED that indicates
operation. The brighter the LED illuminates, the stronger the
charging current.
An overcharging of the battery is not possible thanks to the inte‐
grated electronics.
– Attach the solar panel - VAS 6102A- to the interior mirror -1-.
– Place the lower part on the dashboard -2-.
Note
The solar panel - VAS 6102A- is not allowed to rest completely

on the dashboard. Only the bottom edge is allowed to rest. Laying
the complete surface on the dashboard will lead to the dashboard
changing its colour.
– Pull the fixing cable until the solar panel - VAS 6102A- is lo‐
cated near to the windscreen.
– Connect the solar panel - VAS 6102A- to the diagnosis con‐
nection of the vehicle. The connection is carried out in the
same way as the vehicle diagnostic, testing and information
system, ⇒ page 88
– Check the function of the solar panel - VAS 6102A- . The green
LED indicates that the solar panel - VAS 6102A- is ready for
operation.
3.7 Totally discharged batteries
WARNING

⇒ page 3 .
A battery is considered to be “extremely discharged” if the rest

voltage is less than 11.6 V.

WARNING

start.
Caution
♦ Completely discharged batteries freeze more easily.

♦ Frozen batteries should no longer be used.
Note
♦ Batteries which have not been used for a long time (e.g. in
stored vehicles), discharge themselves.
♦ In a completely flat battery the electrolyte is almost all practi‐
cally converted to water and the percentage of sulphuric acid
has been significantly reduced.
♦ Highly exhausted sulphated batteries, therefore the surface of
all battery plates are hardened.
♦ If an exhausted battery is charged immediately after discharg‐
ing, the formation of sulphate will be removed to a large extent.
♦ If these batteries are not recharged the plates become even
harder and their recharging capacity falls. As a consequence,
battery power is reduced.
– Check the resting voltage of the battery ⇒ page 17 .

4 Checking and servicing alternator
4.1 Checking alternator

– The alternator is checked in “Guided Fault Finding” function
under “Body/electrical system / 27 - Starter, current supply/
electrical components / C- Alternator, checking” ⇒ Vehicle di‐
agnostic tester.
4.2 Bosch alternator up to 2000 - exploded view
1 - Bolts
❑ 1 Nm
2 - Cover
❑ With three retaining tabs
3 - Bolts
❑ 2 Nm
4 - Voltage regulator
❑ Removing:
– Unscrew bolts -Pos. 1-
and remove the protec‐
tive cap -Pos. 2-.

and remove the voltage
regulator.
❑ Carbon brush wear limit:
5 mm
5 - Alternator

5 Bosch alternator from 2001 onwards - exploded view
Note
The alternators were introduced gradually.
1 - Alternator
❑ removing and fitting
⇒ page 52
❑ Checking brushes
⇒ page 55
3 - Bolt.
❑ 2.5 Nm
4 - Cover
5 - Nut
❑ 12 Nm
6 - Nut
❑ 30 Nm
7 - Bolt.
❑ 3 Nm
8 - Bolt.
❑ 1.5 Nm
5. Bosch alternator from 2001 onwards - exploded view 51

6 Removing and installing voltage reg‐

ulator - Bosch alternator from 2001
onwards
Removal:
– Remove alternator ⇒ Electrical system; Rep. gr. 27 .
– Unscrew bolt -1- and nuts -3- and -4-.
– Remove cover -2- of rear part of alternator.
– Remove bolts -arrows-.

– Remove voltage regulator.
Installation
– When positioning voltage regulator, ensure carbon brushes
are positioned correctly on contact surfaces.
Further installation is carried out in the reverse order, note the
following:
– Install alternator ⇒ Electrical system; Rep. gr. 27 .
• Tightening torque ⇒ page 51

7 Bosch alternator from 2007 onwards - exploded view
Note
The new alternators were introduced gradually.
1 - Nut
❑ 65 Nm
2 - Poly V-belt pulley
3 - Alternator
⇒ page 54
❑ Checking brushes
⇒ page 55
5 - Bolt.
❑ 1.5 Nm
6 - Cover
7 - Bolt.
❑ 3 Nm
8 - Bolt.
❑ 2.5 Nm
7. Bosch alternator from 2007 onwards - exploded view 53


ulator - Bosch alternator from 2007
onwards
Removal:
– Remove cover -1- of rear part of alternator.

– Remove voltage regulator -1-.
Installation
– When fitting the voltage regulator, take care that the brushes
are correctly applied to the contact surfaces.
following:

9 Checking carbon brushes - all types

of Bosch alternators from 2001 on‐
wards
Checking sequence
– Remove voltage regulator: Up to 2007 ⇒ page 52 ; from 2007
onwards ⇒ page 54 .
– Check length -a- of brushes.
• Wear limit: -a- = 5 mm.
– Install voltage regulator: Up to 2007 ⇒ page 52 ; from 2007
onwards ⇒ page 54 .
9. Checking carbon brushes - all types of Bosch alternators from 2001 onwards 55
10 Valeo alternator up to 2000 - exploded view
1 - Alternator
❑ Removing:
and remove the protec‐
tive cap -Pos. 4-.
– Unscrew bolt -Pos. 6-

and nuts -Pos. 7- and re‐
move the voltage regu‐
lator.
❑ Carbon brush wear limit:
5 mm
3 - Protective cap
4 - Cover
5 - Nut
❑ 2 Nm
6 - Bolt.
❑ 2 Nm
7 - Nut
❑ 2 off
❑ 3.5 Nm

11 Valeo alternator from 2001 onwards - exploded view
Note
The alternators were introduced gradually.
1 - Alternator
❑ Removing and instal‐
ling: Up to 2007
⇒ page 58 ; from 2007
onwards ⇒ page 60
❑ Checking carbon brush‐
es: Up to 2007
⇒ page 59 ; from 2007
onwards ⇒ page 61
3 - Bolt.
❑ 2 Nm
4 - Cover
5 - Protective cap
6 - Bolt.
❑ 2 Nm
11. Valeo alternator from 2001 onwards - exploded view 57


ulator - Valeo alternator from 2001
onwards
Removal:
– Disengage cover of rear part of alternator from studs
-arrows-.
– Unscrew screw -1- and double bolt -2-.

Installation
– Remove protective cap -2- of voltage regulator -1- by pressing
in -direction of arrow-.
– When positioning voltage regulator, ensure carbon brushes
are positioned correctly on contact surfaces.
– Fit new protective cap with voltage regulator installed.
following:

13 Checking carbon brushes - Valeo al‐

ternator from 2001 onwards
Checking sequence
– Remove voltage regulator ⇒ page 58 .
– Install the voltage regulator ⇒ page 58 .
13. Checking carbon brushes - Valeo alternator from 2001 onwards 59


ulator - Valeo alternator from 2007
onwards
♦ Feeler gauge, 0.3 mm
Removal:
– Disengage cover of rear part of alternator from studs
-arrows-.
– Unscrew screw -1- and double bolt -2-.

Installation
– Insert a feeler gauge of 0.3 mm -item 4- between the protective
cap -2- and the carbon brushes -3-.
– Pull the protective cap off until the stud keeps the carbon
brushes depressed.
– After installing voltage regulator, press protective cap on as
far as stop.
following:

15 Checking carbon brushes - Valeo al‐

ternator from 2007 onwards
♦ Feeler gauge, 0.3 mm
Checking sequence
– Remove voltage regulator ⇒ page 60 .
– Insert a feeler gauge of 0.3 mm -item 3- between the protective
cap -2- and the carbon brushes.
– Pull protective cover off voltage regulator -1- -arrow-.

– Press the carbon brushes -3- downwards using the feeler

gauge -4- when the protective cap is fitted -2-.
– Pull the protective cap off until the stud -arrow- keeps the car‐
bon brushes depressed.
– Install the voltage regulator ⇒ page 60 .
15. Checking carbon brushes - Valeo alternator from 2007 onwards 61

16 Removing and installing poly V-belt

pulley without freewheel
♦ Socket and key - 3310-
♦ 8 mm hexagon socket or TORX T50 socket

Removal:
– If fitted, press off protective cap on alternator pulley.
– Counterhold on securing nut using socket - 3310- and turn al‐
ternator shaft clockwise to loosen.
– Detach poly V-belt pulley.
Installation
Installation is carried out in the reverse order, noting the following:
– Turn alternator shaft anti-clockwise to tighten.
– Clip in the protective cap to the belt pulley of the alternator.
Tightening torque
Components Nm
Poly V-belt pulley to alternator 65

17 Pulley for Poly-V belt with free

sprocket: removing and fitting
♦ Adapter - 3400-
♦ 8 mm hexagon socket or TORX T50 socket

Removal:
– If fitted, press off protective cap on alternator pulley.
– Counterhold the pulley with multi-tooth adapter - 3400- and
rotate alternator shaft clockwise, in order to release it.
Installation
– Turn alternator shaft anti-clockwise to tighten.
– Clip in the protective cap to the belt pulley of the alternator.
Tightening torque
Components Nm
Poly-V belt pulley with free-wheel to alternator 80
17. Pulley for Poly-V belt with free sprocket: removing and fitting 63
18 Cruise control system (GRA)

The functions of the cruise control system are controlled by the
engine control unit.
– The cruise control system can be activated/deactivated
⇒ page 64 .
Detection and display of faults:
Cruise control related faults are communicated through the en‐
gine control unit.
For fault location, use the function “guided fault location” of the
information, measuring and fault diagnosis system - VAS 505X- .
18.1 Activating and deactivating cruise con‐

trol system (CCS)
Checking sequence
– Connect the vehicle diagnostic, testing and information sys‐
tem - VAS 5051B- 5052- 5052A- ⇒ page 88 .
Note
A fault message is shown on the display ⇒ Operating manual -

VAS 505X- .
– Press the Guided Functions key.

Indication on -VAS 505X- :

– Enter vehicle identification by touching the appropriate mes‐
sage line -1- in accordance with the selection prompt -A-.
The vehicle diagnostic, testing and information system - VAS
5051B- 5052- 5052A- then switches to the next selection step
(example; steps may also be skipped depending on vehicle mod‐
el):
Selection prompt Line to be selected
Select brand “SEAT”
Select model (example) “EXEO 09>”
Select model year (example) “2009 (9)”
Select version (example) “LIMOUSINE”
Select engine code (example) “CAGA 2,0TDI 105 kW”
If vehicle identification has
been implemented correctly,
press the → button to confirm.
Select vehicle system/function 01 - Engine electronics
(example)
Select vehicle system/function J220 - Activating or deactivat‐
ing CCS
– Continuation and note information on display of -VAS 5051A- .
After activation/deactivation:
– Press Go to key.
– Select “End” function in list.
– Switch off ignition and separate diagnostic connection.
Note
If entry into “Guided functions” mode is not possible as described

with older engine control unit generations, the presence/absence
of the cruise control system is programmed in the engine control
unit hardware.
18. Cruise control system (GRA) 65

92 – Windscreen wash/wipe system

1 Washer fluid hoses
Note
For information concerning repairing of connections, hoses and

joints, see the ⇒ Electronic spare parts catalogue (ETKA)
1.1 Disconnecting and connection hose

couplings for the washer fluid lines
Different hose couplings are used to connect hoses to washer
fluid pumps and spray jets or as disconnection points.
Non-secured hose coupling
– Pull the two coupling elements apart to separate connection.
– To connect, press the two coupling elements firmly together
until they engage audibly and palpably.
Secured hose coupling with circlip

– To separate connection, turn circlip -1- 90° -arrow- and detach
hose connection.
– To connect, attach hose connection and turn circlip -1-
-arrow- until it engages.
Secured hose coupling with circlip version 1

– To disconnect the circlip connector -1- pull up around 1 mm
-arrow- and disconnect the hose connection.
– To connect, attach hose connection and press in circlip until it
engages.
66 Rep. gr.92 - Windscreen wash/wipe system

Secured hose coupling with circlip version 2

– To separate connection, lift circlip -1- -arrow- and detach hose
connection.
– To connect, attach hose connection and press in circlip until it
engages.
Hose coupling for headlight washer system with circlip

– To separate connection, press circlip -1- -arrow- and detach
hose connection.
– To connect, press and hold circlip -arrow- and attach hose
connection.
– Check whether connection is properly engaged by pulling on
hose without pressing circlip.
Hose coupling for headlight washer system with hose clip (with
lug fastener)
– To separate connection, use side-cutting pliers to sever hose
clip -1- and detach hose connection.
– To connect, slip a new hose clip onto hose, attach hose con‐
nection and fit hose clip using hose clip pliers - V.A.G 1275- .
Hose coupling for headlight washer system with spring clip

– To separate connection, open spring clip -1- using hose clip
pliers - V.A.G 1921- and detach hose connection.
– To connect, open spring clip using hose clip pliers - V.A.G
1921- and attach hose connection.
1.2 Servicing a smooth washer fluid pipe
Note
Smooth pipes with a diameter of 5x1 mm or 6x1 mm can be serv‐

iced using an EPDM hose (Ethylene Propylene Diene Monomer)
⇒ Electronic parts catalogue .
1. Washer fluid hoses 67

– Cut off the faulty part of the smooth hose requiring repair with
a straight cut.
– Choose an appropriate EPDM hose -2- and hose clamp ⇒
Electronic parts catalogue .
– Cut the EPDM hose -2- so that the ends of the smooth hose
-1- and -3- can be inserted approximately 10 mm into the
EPDM hose -2-.
– Use cable fastenings -1- to hold the repaired area in place.
– Check operation and test for leaks.
1.3 Servicing a washer fluid hose with cor‐

rugated tube
Note
Corrugated pipes connecting piece can be repaired using shrink-

fit hose. The replacement parts can be found in the ⇒ electronic
parts list .

♦ Hot air blower, 220 V/ 50 Hz - VAS 1978/14- from wiring har‐
ness repair set - VAS 1978B- or

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

♦ Cutting pliers - VAS 6228-
♦ Connection piece - 1J0 955 875 R-

♦ Connection piece - 1J0 955 875-
Note
♦ The repaired area should not be pulled or bent.

♦ If the faulty area is over 20 mm, a new piece of corrugated
hose should be fitted and the following operations carried out
twice:
Checking sequence
– Cut washer fluid hose at point of damage using cutting pliers
- VAS 6228- .
– Select the appropriate connecting pieces -2- and -3- from the
parts catalogue ⇒ Electronic parts catalogue .
– Push the connecting piece -2- in in the end of the hose -1-;
Repeat the process for the other end of the hose.
1. Washer fluid hoses 69

– Cut the shrink-fit hose -5- so that it covers at least 20 mm of

the corrugated hose at both ends.
– Position the shrink-fit hose -5- to one end of the washer fluid
line.
– Connect the ends -2 and 3- of the washer fluid line.
– Push shrink hose over connection pieces on washer fluid
hose.
– Provide at least 20 mm on both ends -Dimension x-.

– After pushing on, the shrink-fit hose must be shrink-fitted using
the hot-air blower, 220 V/ 50 Hz - VAS 1978/14- or the hot-air
blower - VAS 5179- or the hot-air blower - V.A.G 1416/- .
• The shrink hose must be heated starting from the centre and
working outwards until it is sealed tight.
• Set hot air blower to appropriate temperature as indicated in
operating instructions.
• When shrink-fitting, ensure no other wires, plastic components
or insulating materials are damaged by the hot nozzle.
– Check operation and test for leaks.

94 – Lights, bulbs, switches - exterior

1 Information on the use and the safety
of the gas discharge lamps
– When performing mounting work in the main headlight with
gas discharge lamps you must observe the following:
♦ Notes on dangerous high voltage/currents ⇒ page 71
♦ Notes on pressure, temperature, radiation/arcs ⇒ page 72
♦ Assembly notes for gas discharge bulbs ⇒ page 73
♦ Disposal regulations for gas discharge bulbs ⇒ page 73
♦ Protective glasses
♦ Gloves
WARNING
Before performing any work that affects the parts of the gas
discharge headlights marked with a yellow high voltage symbol
you must disconnect the battery earth strap.
The dipped headlight must then be switched on and then off
again. This eliminates the possibility of any existing residual
voltage.
The gas discharge headlamp control unit should never function
without the gas discharge lamp.
The gas discharge lamps can only be used in the headlamps
due to high voltages (above 28,000 V when the lamp is switch‐
ed on) and temperatures.
WARNING
♦ Never replace lamps if you are not well versed with the
corresponding procedure, the preventive measures for
safety and the tool
Indications related to high voltage / dangerous currents
WARNING
The lighting system control units, the connectors or compo‐

nents in the lamp holder area carry a dangerously high voltage.
Operating the control unit and the starter unit is permitted only
with the bulb fitted.
1. Information on the use and the safety of the gas discharge lamps 71
WARNING
• Switch off ignition and all electrical loads, and pull out ig‐
nition key.
• When working on headlight system, ensure that there is
no voltage in any components, including the dissipation of
residual voltage after the headlights are switched off.
• The residual voltages are discharged by again switching
the dipped beam on and off, after having removed the
contact key.
• It should be established that for work in the headlamp
system you can not switch on the lights.
Indications related to pressure, temperature, and radiation/volt‐

age arcs
WARNING
• The lamp should only be made to function in the headlamp

casing (tactile isolation protection because it is a very hot
lamp; absorption of UV radiation; avoiding the danger of
fire; anti-explosion protection).
• The lamp glasses may reach very high temperatures - risk
of burn injuries.
• Do not look directly into the light beam; UV light beams
from gas discharge bulbs have approx. 2.5 times more
power than halogen bulbs.
• Avoid looking at the beam (risk of being blinded); your vi‐
sion may be affected during a prolonged time.
WARNING
• Avoid the contact with broken glass bulbs.

• The H7 bulbs and the gas discharge lamps (xenon and
bixenon) are subject to pressure and may explode when
being replaced - risk of suffering injuries.
• The use of protective gloves and goggles is compulsory
when removing and installing gas discharge lamps.
72 Rep. gr.94 - Lights, bulbs, switches - exterior

Indications related to the mounting of gas discharge lamps
Caution
♦ Before replacing a bulb it is necessary to always deacti‐

vate first the affected electrical consumer.
♦ Switch off ignition and all electrical loads, and pull out ig‐
nition key.
♦ Do not touch the bulb glass directly with the fingers; use
clean textile material gloves. The substances of a finger‐
print that would stay on the bulb evaporate with the heat
of the lamp switched on and will be deposited in the re‐
flector, which affects the luminous capacity of the head‐
lamp.
♦ A bulb should only be replaced by another of the same
version. The denomination is marked in the lamp socket
or on the lamp glass.
♦ Correctly fit the connectors upon mounting and observe
that the connection is firmly seated.
Norm related to the management of gas discharge lamps waste
WARNING
• The gas discharge lamps should be eliminated as special

waste; never get rid off gas discharge lamps via domestic
rubbish.
• The gas discharge lamps contain metallic mercury (Hg)
and traces of Thalium; they should not be destroyed.
• These components should be moved to a residual dis‐
posal in accordance with national law.
• Dispose the residue only in special containers for this pur‐
pose, giving it to the unit in charge of its reception.
1. Information on the use and the safety of the gas discharge lamps 73
96 – Lights, bulbs, switches - interior

1 Vehicle Immobiliser
1.1 General instructions

The immobilizer control unit is integrated into the instrument clus‐
ter, i.e. the immobilizer control unit can only be renewed together
with instrument cluster ⇒ Electrical system; Rep. gr. 90 .
– To renew control unit, select the “Replacement” function for
the appropriate control unit in “Guided Functions” mode ⇒ Ve‐
hicle diagnostic tester.
1.2 Defective transponder or loss of key

♦ The transponder is integrated into the vehicle key and cannot
be renewed separately.
♦ The complete vehicle key must be replaced if the transponder
is defective.
– Order a new replacement key, with the specific vehicle lock
number, from the distribution centre or importer, basing this on
the vehicle identification number.
– Match all vehicle keys in the “Guided Functions” mode ⇒ Ve‐
hicle diagnostic tester.
1.3 Renewing reader coil

♦ The reader coil is integrated into the lock cylinder and cannot
be renewed separately.
♦ The complete lock cylinder must be renewed if the reader coil
is defective.
– Order a replacement lock cylinder, with the specific vehicle
lock number, from the distribution centre or importer, basing
this on the vehicle identification number.
1.4 Locking set change procedure

The vehicle keys can only be matched in the “Guided Functions”
mode ⇒ Vehicle diagnostic tester.
74 Rep. gr.96 - Lights, bulbs, switches - interior

2 Towing unit
2.1 Removing and installing connection

socket for towing hitch - Version 1
Removal:
– Switch off ignition and remove key.
– Remove the fixing plate connection terminal.
Terminal connection with contact switch for rear disconnectable

fog light - F216- :
– Unplug the connector -2- for the disconnectable rear fog light
contact switch - F216- and remove the connection-1- outside
of the towing current supply - U10- .
Terminal connection without contact switch for rear disconnecta‐

ble fog light - F216- :
– Remove the multiple connectors -1- from the connection box
-2- in the -direction of the arrow-.
Version 1
– Unblock the safety clips -arrows- and later the fixing clips -1-
and -3 ... 5-.
– Remove the fixing cage of the connectors -2-.
2. Towing unit 75
Version 2
– First unclip the retaining lugs -arrows- and later the fixing clips
-1, 2, 3, 4, 6, 7-.
– Remove the fixing cage of the multiple connector -5-.
Installation
Note
Make sure the joint gaskets are not damaged -1- and -3-.
– Introduce the connectors -4- until they audibly engage in the

fixing cage -2-.
2.2 Removing and installing the socket for

towing hitch - Version 2
Removal:
Note
The cable ties must be installed in their same place again.

– Fold up the towing hitch and engage in place.
– Cut the cable ties -1- and loosen screws -2- and -4-.
– Pull the socket of the towing hitch -3- out in the
-direction of the arrow-.

– Turn the cover -1- counter clockwise -arrow- and remove the
socket -3-.
– Remove the rubber cover -2-.
– Release the retaining clips -arrows- and remove the multiple

connector -2- from the socket -1-.
– Release the retaining clips -arrows- and remove the cage -1-
of the multiple connector -3-.
Note
Remove the retaining bracket carefully to prevent the contacts

-2- of the multiple connector disconnecting from the wiring har‐
ness..
2. Towing unit 77
Installation
– The retaining bracket -1- can only be pushed over the multiple
connector -3- in one position.
• The guide pins -4- can only be applied to the retaining bracket
in one position; the connector -2- must be fitted in the retaining
bracket for this purpose.
– Insert the retaining bracket until you can hear the multiple
connector engaging.
2.3 Removing and installing the socket for

towing hitch - Version 3
Removal:
– Fold the towing hitch electrically and lock in position ⇒ Oper‐
ating instructions of the respective vehicle
– Remove the socket from the fixing plate.
– Loosen the rubber cover -2- of the socket.
– Release the retaining clips -arrows- and remove the multiple

connector -2- from the socket -1-.

– Release the retaining clips -arrows- and remove the cage -1-
of the multiple connector -3-.
Note
Remove the retaining bracket carefully to prevent the contacts

-2- of the multiple connector disconnecting from the wiring har‐
ness..
Installation
– The retaining bracket -1- can only be installed on the multiple
connector -3- in one position.
• The guide pins -4- can only be applied to the retaining bracket
in one position; the connector -2- must be fitted in the retaining
bracket for this purpose.
– Insert the retaining bracket until you can hear the multiple
connector engaging.
2. Towing unit 79
2.4 Towing unit connector terminals layout

1- Terminal BL (left turn signal indicator)
2- Terminal NSL (rear fog light)
3- Terminal 31 (earth)
4- Terminal BR (right turn signal indicator)
5- Terminal 58 R (right taillight)
6- Terminal 54 (brake light)
7- Terminal 58 L (left taillight)
8- Terminal RF (reversing light)
9- ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations
10 - ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations
locations
locations
locations
Terminal connection with contact switch for rear disconnectable
fog light - F216- :
Terminal connection layout, in the contact switch for rear discon‐
nectable fog light - F216- ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.

3 Cigarette lighter - U1- , 12 V socket
3.1 Assembly overview
Caution
If excessive force is exerted on sockets without illumination,

the retaining sleeve may be damaged.
Only illuminated sockets (cigarette lighter) can be removed
with the puller T 40148.
The puller does not manage to release the locking lugs of
sockets without illuminated retaining sleeve.
Usually sockets without illumination cannot be removed with‐
out being damaged.
1-
2 - Cigarette lighter
3 - Cigarette lighter socket
⇒ page 82
4 - Lamp W 5 12V 1.2 Watt
5 - Spring pin
⇒ page 84
6 - Lamp holder
7 - Support for the bulb carrier
8 - 12V socket
⇒ page 82
9 - Spring pin
⇒ page 86
10 - Fastening nut, tension
sleeve
11 - Spring pin
⇒ page 86
3. Cigarette lighter U1 , 12 V socket 81

3.2 Removing and installing electric socket

or cigarette lighter
Note
Removal and installation work is the same for all sockets and will
therefore only be described for a socket for the cigarette lighter.
Caution
When disassembling the socket using the extractor T 40148,

deviations in quality to the bracket of the clamping sleeve may
result when too much pressure is applied.

♦ Extractor - T40148-
Removing:
– In the case described, remove the cigarette lighter, the ciga‐
rette lighter dummy, etc. from the socket.
Note
For illustration purposes the socket in the figure is shown after

removal.
Caution
The socket of the clamping sleeves can be influenced.

Take care for the correct fitting of the extractor otherwise the
retaining tabs of the clamping sleeve will not engage.

– Push the extractor -arrow- into the socket until the retaining
tags -1- engage in the recess -2-.
– Turn knurled wheel -3- clockwise to end stop.

• The piston -2- moves upwards, the locking tag -1- in the ex‐
tractor - T40148- opens -arrows- and fixes itself to the socket
in this way.
– Pull the spindle -1- in the -direction of the arrow-.

– Pull out the 12 V electric socket
Caution
When using the thrust piece, ensure that no surrounding com‐

ponents are damaged.
When pulling out the electric socket, observe the length of the
cable.
The electric cables for the socket can be influenced.
– Remove the connector from the socket.
Note
Depending on the space requirement, the vehicles are equipped

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

– Separate the extractor - T40148- from the 12 V electric socket.

– Disengage the retainer tabs of the extractor by pressing the
spindle -1- in -the direction of arrow B-. Then the extractor
-2- must be unlocked by briefly turning it anticlockwise
-arrow A-. Remove the extractor from the electric socket.
Note
Take care that the locking tag of the extractor is not spread.
Caution
The cigarette lighter might be ejected out of the socket after

the heating phase.
By inserting the extractor, the retaining springs of the electric
socket are pressed apart and the retaining momentum is re‐
duced.
After removing the retaining spring from the electric socket,
carefully press them together again and check if the cigarette
lighter remains in its removal position after the heating proce‐
dure.
– Carefully press the retaining springs of the electric socket to‐

gether -arrows-.
– Check if the cigarette lighter,remains in its removal position
after the heating procedure and is not catapulted into the ve‐
hicle compartment.
Fitting:
Installation is carried out in reverse order.
3.3 Removing and installing spring pin and

cigarette lighter illumination bulb - L28-
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. One version where the light bulb can be replaced
individually and one where the individual light bulb change is
not possible. In this case, the bulb carrier has to be replaced
together with the light bulb.

Removing:
– Removing the electric socket ⇒ page 82 .
– Press the retaining tabs together -arrows-.
– Remove the clamping sleeve with light bulb holder.
– Press in the clamping sleeves -arrows- and help along using

a screwdriver with flat end.
– Clip out the light bulb carrier -2- from the clamping sleeve
-1-.
– Remove the light bulb carrier -2- from its bracket -3-.
– The retaining tags -1- and -2- slacken.
– Open the light bulb holder.

– Pull out the light bulb -1- in the -direction of the arrow-.
Fitting:

3.4 Clamping sleeve: Removing and instal‐

ling
Note
♦ Clamping sleeves for 12 V electric sockets do not have illumi‐

nation
♦ There are several versions
Removing:
– Removing the electric socket ⇒ page 82 for all versions.
The version “fixed with clips” is used for fixing the electric socket
to switches of the centre console, the storage brackets and the
centre console.
– Lift the cover -1-.
– Press the retaining tabs together -arrows-.
– Remove the clamping sleeves.
The version “with thread” is used for fixing the electric socket to
plush textiles (luggage compartment trim).
Remove the rear left storage bracket ⇒ Bodywork, interior fitting

work; Rep. gr. 70 ; Rear storage bracket
– Slacken the plugs -1- using the removal lever - T20043- .
– Partially remove the trim.

– Unscrew the retaining nuts -1-.
– Remove the clamping sleeve -2- in the direction of the
-arrow-
Fitting:

97 – Wiring
1 Vehicle Diagnosis, Testing and Infor‐
mation Systems
The description of the setup is carried out for the valid installa‐
tions: For more information, see ⇒ Catalogue of company tools
and equipment
Note
Observe the latest operating instructions for the vehicle diagnosis

tester, which are displayed after selecting the “Administration”
and “Operating Manual” keys.

♦ Vehicle diagnostic, testing and information system - VAS
5051B-
5052A-
6150 / VAS 6150A-
6150B Profesional-
6150B Startline-
♦ Vehicle diagnostic, testing and information system - VAS 6160

Premium-
♦ 5 m line - VAS 5051/6B-
♦ 3m line - VAS 5051/5A-
1. Vehicle Diagnosis, Testing and Information Systems 87

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

-
Note
Installation location of the diagnosis connector of the different

models is described in the manual Electric System Rep. Gr. 97 of
the respective vehicle.
Connecting vehicle diagnostic tester - VAS - :

– Apply handbrake.
– In vehicles with automatic gearbox, move the selector lever in
position “P” or “N”.
– In vehicles with manual gearbox put the gear lever in neutral.
– With the ignition switched off, connect the vehicle diagnosis
tester - VAS - to the diagnostic terminal on the vehicle.
Online system test
The following processes are performed with this test program:
♦ Line connection system test
♦ Check of user authorization
♦ Test of correct connection to SEAT database
Prerequisite: tester must have an online connection (network
connection):
Connecting vehicle diagnostic tester - VAS -
– Select the operating mode “Guided fault finding” on vehicle
diagnosis tester - VAS - .
– Using “GoTo” button, select “Functions/components” and then
the following menu options in succession:
♦ Body
♦ Vehicle electrics
♦ Self-diagnosis compatible systems
♦ Immobiliser
♦ Uses
♦ Online system test
88 Rep. gr.97 - Wiring

Note
♦ All the described work instructions, such as adaptations and

coding, may be carried out using the vehicle diagnosis tester
- VAS - .
♦ The necessary work instructions can be accessed via “Guided
Fault Finding” and “Guided Functions”.
♦ Additional information:⇒ Self-study programme No. 75 ;
♦ Observe the latest operating instructions for vehicle diagnosis
tester - VAS - and successor models, which are displayed after
selecting the “Administration” and “Operating Manual” keys.
1.2 Safety warnings on use when operating

vehicle
WARNING
Accidents can be caused if the driver is distracted by test

equipment or if test equipment is not secured.
Injuries can also be caused if the passenger's airbag is trig‐
gered in a collision.
• During testing or measuring operations using a vehicle di‐
agnosis tester - VAS - , there is a risk of serious or even
fatal injury.
• The use of the vehicle diagnosis tester - VAS - while driv‐
ing causes distraction.
• There is an increased risk of injury if test and measuring
equipment is not secured.
• If the vehicle diagnosis tester - VAS - is situated in the
activation area of an airbag during testing or measuring
operations, serious or even fatal injury may result if an
airbag is triggered!
• For trail or test runs, a second person should be in the
back seat of the vehicle, to operate the vehicle diagnosis
tester - VAS - .
The vehicle diagnosis tester - VAS - -1- will be operated by a

second skilled worker as described when driving.
1. Vehicle Diagnosis, Testing and Information Systems 89

2 Repairing wiring harnesses and con‐

nectors
2.1 General notes on the repair of the vehi‐

cle electric system
Caution
The instructions in the repair manual for disconnecting and

connecting the battery must be followed .
WARNING
There are tools that have a safety, which should be placed over
the point of these after using them, to protect the point and the
personnel.

2. Repairing wiring harnesses and connectors 91

♦ For all repair work take into account the updated information
that is included in the corresponding Repairs Manual.
♦ The legal requirements of each country should be taken into
account.
♦ Before working on the electrical system, disconnect the bat‐
tery earth strap. By disconnecting the earth strap (power in‐
terrupted), safety is guaranteed while working on the electrical
system. The battery positive wire need only be disconnected
for removal of the battery.
♦ Before starting a repair, it is important to identify and rectify
the cause of damage (e.g. sharp edges on body panels, de‐
fective electrical components, corrosion, etc.).
♦ For further information (for example: fitting and removing parts
and components) see the corresponding Repair Manual.
♦ Soldering is not permitted during repairs to the onboard net‐
work.
♦ Wiring harness and connector repairs to vehicle electrical sys‐
tem should be carried out using wiring harness repair set - VAS
1978 B- and previous versions only. Only use yellow wires
from wiring harness repair set - VAS 1978 B- .
♦ The wiring harness repairs can not be taped with the original
tape of the proper vehicle wiring harness and should be
marked with a yellow coloured tape. This indicates a previous
repair.
♦ As a general rule, crimped connections cannot be repaired. If
necessary, fit a new wire alongside the defective wire. After
closing the pressure connection, you should shrink it with the
hot air blower to avoid the entry of moisture.
♦ It is obligatory to take into account the specific indications in
case of repairs on wiring harnesses of airbag systems and belt
tensioners, fibre optic cables, CAN bus wires, aerial wires and
wires with sections smaller than 0.35 mm2 ⇒ page 103 .
♦ A function test must be performed after each repair. If neces‐
sary, query and delete the fault memory and reset the systems
to zero.
♦ If possible, do not remove any earth straps to the bodywork
(danger of corrosion)
♦ Wiring harness repair set - VAS 1978 B- and previous versions
do not cover all wiring cross sections that occur in the vehicle.
If the necessary wire section does not exist, use the next sec‐
tion of greater size.
♦ Screened wires can be repaired. Wiring for camera systems
are the exception. When these wires are damaged, they must
be replaced completely.
♦ In different places of the vehicle, principally in the engine com‐
partment, wiring resistant to heat are mounted. The heat re‐
sistant wiring may be recognised by its softer and flat coloured
isolation. For the repair of these wires only use others that are
also heat resistant.

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

The Repair kit for wiring harnesses - VAS 1978 B- enables opti‐
mum quality in repairs to the vehicle electrical system. Using the
tools, repairs to connectors and wiring open circuits can be car‐
ried out. For this use complete repair wiring with contacts already
strung together and joined to the vehicle wiring harness via pres‐
sure connections. A threaded clamp with three interchangeable
inserts and a hot air blower to contract the pressure connections
allow a perfect electrical connection.
Note
Additional information:
⇒ Instruction manual cable harness repair kit - VAS 1978 B-
2.2.2 Complementary equipment - VAS

1978/50-
The complementary equipment - VAS 1978/50- is needed to up‐
date the “old” wiring repair kit - VAS 1978- to the new level of the
wiring repair kit - VAS 1978A- . The complementary kit contains
4 mounting tools and 10 unlocking tools, as well as the new threa‐
ded pressure connections clamp with interchangeable heads for
the 0.35 mm - 2.5 mm - VAS 1978/1-1- , 4.0 mm- 6.0 mm - VAS
1978/2A- and the interchangeable head for JPT contacts (Junior
Power Timer) - VAS 1978/9-1- . It also includes stickers with new
information, a new instruction manual, crimped connections for
0.35mm2 cable cross-sections and a roll of adhesive felt tape.
2.2.3 Wiring harness repair set - VAS 1978B-

The new wiring harness repair kit - VAS 1978 BA- permits an op‐
timum repair in the vehicle electrical system. Using the new pliers,
repairs to connectors and wiring open circuits can be carried out.
For this use complete repair wiring with contacts already strung
together and joined to the vehicle wiring harness via different
types of pressure connections. A new threaded clamp with inter‐
changeable heads a hot air blower to contract the pressure con‐
nections allow a perfect electrical connection.
Note
Additional information:
⇒ Instruction manual cable harness repair kit - VAS 1978 A-

The upgrading set - VAS 1978/50- is required to upgrade the “old”
wiring harness repair set - VAS 1978- to the same standard as
the wiring harness repair set - VAS 1978A- .

2.2.4 Set of release tools - SAT 2100A-

The kit - SAT 2100A- serves to release the different primary and
secondary locks of the vehicles of the SEAT group. The kit is
formed by 9 different tools to unlock or correctly mount, e.g. round
connectors, flat contacts with one or two seals or hermetic gas‐
kets for terminals.
The adequate designation of the unlocking tools for the corre‐
sponding locks may be consulted in the table of the ⇒ instructions
manual of the -SAT 2100A- .
2.3 Description of the tools
WARNING
Injury risk!
♦ Observe the stickers in the vehicle warning about compo‐
nents exposed to high voltages. Remaining voltage must
be dissipated before commencing repair work.
♦ 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.
Caution
♦ Pay attention to the relevant regulations in the individual

countries.
♦ By disconnecting the battery earth wire, safety is ensured
when carrying out work on the vehicle electrical system.
With ignition switched off, disconnect earth wire at battery
⇒ Electrical system; Rep. gr. 27 .
♦ Before starting repair work, it is vital to eliminate the cause
of the damage in question, e.g. body parts with cutting
edges, faulty electrical loads, rust etc.
Note
♦ Do not loosen earth straps on body if this can be avoided

(danger of corrosion).
♦ Other information, like for example installing and removing
different components, is provided in the corresponding Repair
Manual.

2.3.1 Full clamp with insert

The full clamp without insert - VAS 1978/1- , with the insert for the
full clamp - VAS 1978/2- , is a component of the wiring harness
repair kit - VAS 1978 B- and is used to close the pressure con‐
nectors in the repairs of wiring harnesses.
Colour of the pres‐ Pressure connec‐ Wiring cross section
sure connectors tor cavity colour
Yellow colour Yellow colour 0.35 mm2
red red 0.5 mm2 - 1.0 mm2
Blue colour Blue colour 1.5 mm2 - 2.5 mm2
Yellow colour Yellow colour 4.0 mm2 - 6.0 mm2
Note
♦ As an alternative you may also use the threaded clamp (basic

body) - VAS 1978/1-2- in combination with the interchangea‐
ble heads -VAS 1978/1-1- or -VAS 1978/2A- ⇒ page 97 .
♦ Make sure you use the correct cavity for the pressure con‐
nector used.
♦ Do not put pressure on the isolating sheet of the wires.
2.3.2 Release tools for contacts

The different unlocking tools serve to remove the different con‐
tacts of the contact casing without damaging them.
You will find a selection of unlocking tools in the repair kit - VAS
1978 B- . The unit - VAS 1978/35- contains the complete kit of
these tools ⇒ page 94 .
WARNING
There are tools that have a safety, which should be placed over
the point of these after using them, to protect the point and the
personnel.
Unlock and disarm the contact casings ⇒ page 123 .
2.3.3 Assembly tools for seal rings for termi‐

nals
The mounting tools serve to be able to introduce the terminal
sealing rings fully in the contact casing, without damaging them,
to obtain in this way a total seal between the individual wire and
the contact casing.
You will find four mounting tools for terminal sealing rings in the
kit - VAS 1978 B- .
Assembly of seal rings for individual cables ⇒ page 121 .

2.3.4 Wire strippers - VAS 1978/3-

The wire strippers - VAS 1978/3- serve to peel and correctly cut
the wires.
The wire stripper - VAS 1978/3- is a components of the kit - VAS
1978 B- .
The wire strippers have an adjustable end in its mouth, in which
you may adjust the desired longitude of the insulation of the wire
to remove.
Stripping off insulation
– Adjust the adjustable end of the stripper mouth to the desired
length that you wish to peel.
– Introduce the end of the wire from in front up to the end of the
mouth of the stripper and close the pliers.
– Again open the pliers and remove the peeled wire end.
– In case necessary, cut the wires with the cutting plier function
of the upper part of the wire stripper.

2.3.5 Hot air blower, 220 V / 50 Hz - VAS

1978/14-
Caution
When shrink-wrapping the pressure connections, care should

be taken to avoid damaging other cables, plastic parts or in‐
sulation material with the hot nozzle of the pistol.
Consult previously the instructions manual of the hot air blow‐
er!
The hot air blower 220 V / 50 Hz - VAS 1978/14- is used together

with the shrink element - VAS 1978/15- to shrink fit the crimp
connections. After closing the pressure connection, you should
shrink it with the hot air blower to avoid the entry of moisture.
The hot air blower 220 V / 50 Hz - VAS 1978/14- is a component

of the kit - VAS 1978 B- .
Shrink the pressure connection with the hot air blower, 220 V/ 50
Hz - VAS 1978/14- ⇒ page 106 , or ⇒ page 107 .
2.3.6 Crimping pliers - VAS 1978/1A-

The threaded clamp - VAS 1978/1A- or the threaded clamp (basic
body) - VAS 1978/1-2- together with the interchangeable head
0.35-2.5mm/2 - VAS 1978/1-1- , or the interchangeable head
4.0-6.0mm/2 - VAS 1978/2A- is used to close the pressure con‐
nections of the wiring harness repair kit.
Crimp the pressure connections with the threaded clamp - VAS
1978/1A- ⇒ page 107 .
The threaded clamp (basic body) - VAS 1978/1-2- has available
the following interchangeable heads:
♦ Head adapter 0.35 mm2 - 2.5 mm2 - VAS 1978/1-1-
♦ Head adapter 4.0 mm2 - 6.0 mm2 - VAS 1978/2A-
♦ Interchangeable head for JPT contacts - VAS 1978/9-1-
In combination with the interchangeable head for contacts JPT -
VAS 1978/9-1- use the threaded clamp to thread the individual
wire contacts for repairing the wires with sections smaller than
0.35 mm2 ⇒ page 103 .
Substitute the interchangeable head:
– Fully open the threaded clamp.
– Unclasp the locking pins -arrows- of the basic body of the

threaded clamp.

– Place the necessary interchangeable head from above

-arrow- in the basic body of the threaded clamp.
– Lock the interchangeable head introducing the pins -arrow- in

the basic body of the threaded clamp.
2.4 Repairing cable harnesses
Note
♦ Take note of the general indications to perform repairs in the

vehicle electrical system ⇒ page 90 .
♦ You will not find all the wiring sections included in the vehicle
in the kit - VAS 1978 B- . If the necessary wire section does
not exist, use the next section of greater size.

2.4.1 Instructions for the repair of wiring har‐

nesses
Note
♦ Only repair cable harnesses and connections of the onboard

network using the - VAS 1978 B- .
♦ Soldering is not permitted during repairs to the onboard net‐
work.
♦ Repairs to the wire harness can only be carried out with yellow
wires.
♦ The wiring harness repairs can not be taped with the original
tape of the proper vehicle wiring harness and should be
marked with a yellow coloured tape.
♦ The presence of wires and yellow coloured isolating tape is a
signal of repair work done.
♦ As a general rule, crimped connections cannot be repaired. If
necessary, fit a new wire alongside the defective wire.
♦ After closing the pressure connection, you should shrink it with
the hot air blower to avoid the entry of moisture.
♦ Screened wires should not be repaired. When these wires are
damaged, they must be replaced completely.
♦ In different places of the vehicle, principally in the engine com‐
partment, wiring resistant to heat are mounted. The heat re‐
sistant wiring may be recognised by its softer and flat coloured
isolation. For the repair of these wires only use others that are
also heat resistant.
♦ It is obligatory to take into account the specific indications in
case of repairs on wiring harnesses of airbag systems and belt
tensioners, fibre optic cables, CAN bus wires, aerial wires and
wires with sections smaller than 0.35 mm2 .
♦ When possible, connect the contacts affected only once as
with each connection, there is a risk that the golden contact is
damaged.
Additional instructions for the repair of cables for airbags and

seatbelt pretensers ⇒ page 99
Complementary notes on CAN-bus cable repairs ⇒ page 102
Complementary notes on aerial cable repairs ⇒ page 102
Complementary notes on the repair of cables with a cross-section
lower than 0.35 mm2 ⇒ page 103
2.4.2 Repair of airbag and seat belt pretensor

cables
Together with the wiring harness general repair, for the repairs of
the belt pretensioners and airbag system wiring harnesses take
into account the following instructions:

WARNING
♦ Airbag systems and seatbelt tensioners can be damaged.

♦ If the cable harness of the airbag and seatbelt pretensors
is not correctly repaired, this may damage the working of
the passenger protection systems.
♦ When repairing the cable harness of the airbag and the
pretensing of the seatbelts, only use the contacts, con‐
nectors and cables supplied for this ⇒ Parts catalogue
(ETKA) .

Note
♦ Repair the air bag cables and seat belt tension devices using
only the cable harness repair kit - VAS 1978 B- .
♦ Observe the stickers in the vehicle warning about components
exposed to high voltages. When repairing, the residual voltage
must be removed ⇒ Bodywork- interior installation work; Rep.
gr. 69 ; Passenger protection .
♦ In the wiring harnesses for the airbags and belt pretensioners
you can only perform two repair points. Repair points increase
the electrical resistance of the cable and may cause self-di‐
agnosis faults in the system.
♦ In repairs to the airbag and seatbelt pretension harnesses, the
crimped connections must be shrink wrapped to avoid the risk
of corrosion.
♦ Repairs to the wire harness can only be carried out with yellow
wires.
♦ Do not tape again the repaired point in the proper vehicle wir‐
ing harness and identify the repair point in a clear manner with
yellow isolating tape.
♦ The repair points around an airbag or seatbelt must be at least
30 cm away from the next plug casing. In this way, and due to
the yellow insulating tape, repairs that have been carried out
before are quickly recognised.
♦ The wiring leading to the trigger units (airbags) is twisted in
series at intervals of 20 mm ±5. This interval is guaranteed in
series production using standardised wrenches for cable pairs
and must be observed in the repair sections for twisted cables.
♦ When performing repair work, the wires to the igniter units
(airbag) should have the same length. When twisting the ca‐
bles -1- and -2- the distance A = 20 mm ±5 must be maintained
in all cases.
♦ No lengths should be of more than B=100mm long without
twisting, for example, in the area of welded connections
-arrow-.

2.4.3 Repairing CAN bus cables

♦ An unshielded two-wire line -1- and -2- with a cross section of
0.35 mm2 or 0.5 mm2 is used for the CAN bus wiring.
♦ The colour codes of the CAN-bus cables are indicated in the
following table:
Powertrain CAN, high wire Orange/black
Convenience CAN, high wire Orange/green
Infotainment CAN, high wire Orange/violet
Cable CAN-Low (all) orange/brown
♦ The CAN-bus wiring repair may be performed with a repair
wire with the adequate section and with twisted wires “green/
yellow” or “white/yellow” of the Spares Catalogue ⇒ Spares
Catalogue (ETKA) .
♦ In case of repairs, both bus cables should be of the same
length. When braiding cables -1- and -2- keep the distance
A=20mm
♦ No lengths should be of more than B=50mm long without
braiding, for example, in the area of welded connections
-arrow-.
♦ Stick an isolating tape of yellow colour in the repaired area to
identify that a repair has been performed.
2.4.4 Renewal of aerial wiring

A new concept has been developed for repairing aerial cables.
From now on, the spare parts available are junction cables of dif‐
ferent lengths and different adaptor cables instead of a complete
aerial cable.
♦ These parts are listed in the ⇒ Spare Parts catalogue (ETKA):
Special Catalogue; Electrical Connections; Original Accesso‐
ries; Sub-Group 35 from Sheet No. 035-20 .
♦ These original spare parts can be used for all aerial cables and
all cable sections that need to be replaced.
♦ The connector casings for aerial wires are only available as
spares in only one colour, even though they can be used for
any colour of the aerial connectors.
♦ Repairs do not include replacement of individual antenna con‐
nectors.
♦ These cables should be used retroactively for SEAT models,
regardless of the section of the aerial cable.
♦ All adapter and connection wires are suitable for all transmitter
and receiver signals.
♦ This repair concept can also be used for checking or for future
installation.

Overview of aerial cable installation

E.g. the cable that goes from the radio to the aerial is faulty. The
following wires are required for the repair:
1- Adaptor cable, for connection to the radio. Length approx.
30 cm
2- Junction cable; available in different lengths
3- Adaptor cables, for connection to the aerial. Length approx.
30 cm
Assembly of a new aerial cable:
Note
Depending on the automobile’s equipment, the aerial cable may

be subdivided into various sections by the aerial selection control
units, the traffic station control units or the aerial amplifiers. In all
cases, only the faulty section should be replaced.
– Pull defective aerial wire connections off units.

– Find out where the faulty cable runs through the vehicle and
measure the total length of the aerial connection to be re‐
placed in the vehicle.
Total length of aerial connection = length of adapter leads -1- and

-3- required as well as connecting wire -2-
– To calculate the length of the junction cable required -2-, sub‐
tract 60 cm from the total length measured for the aerial
connection.
– Order the adapter cables -1- and -3- and the connection cable
-2- necessary in the calculated length as Original Spare Parts
according to the Spare Parts catalogue.
– 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.
– Lay out and fit the union wire -2- very near the series wiring.
Note
The aerial cables should not be bent excessively. The bending

radius must be minimum 50 mm.
– Connect the junction cable to the adaptor cables.

– Carry out an operation test.
2.4.5 Repair of cables with a cross-section

lesser then 0.35 mm2
In the repair of wires with a cross section lower than 0.35 mm2 it
is obligatory to twist the new contacts with the twisting clamp for
contacts JPT - VAS 1978/9A- or the twisting clamp (basic body)
- VAS 1978/1-2- with interchangeable head for contacts JPT -
VAS 1978/9-1- mounted. Due to the low current levels in this lines
(in the region of millionths or thousandths of Amperes), poorly
connected contacts may cause resistance, which can lead to er‐
rors or faults in the respective system. The most common appli‐
cations for these contacts are:

♦ Lambda probe
♦ Engine speed sender
♦ Air mass meter
Using the crimping pliers for JPT contacts - VAS 1978/9A- or
crimping pliers (basic body) - VAS 1978/1-2- with the interchange‐
able head for JPT contacts installed - VAS 1978/9-1- , the correct
connection between the line contact and the seal for the single-
wire sealing (SEAT) is guaranteed. This tool must only be used
for the purpose described.
Note
The repair cables have crimped contacts in standard or gilded

version. The same version used in series production must always
be used when repairing the contact.
Connect a new contact with sealing ring for single-wire sealing

– Use the interchangeable head for JPT contacts - VAS
1978/9-1- in the crimping pliers (basic body) - VAS 1978/1-2-
⇒ page 95 .
– Attach the sealing ring for single-wire sealing to the repair line.
Note
The smaller diameter of the sealing ring for single-wire sealing

must point towards the contact to be connected.
– Open the crimping pliers and insert the end of the repair line
into the stripper opening of the crimping pliers.
– Fully close the crimping pliers.

– Again open the pliers and remove the stripped wire end.

– Push the sealing ring for single-wire sealing towards the strip‐
ped wire end until it lies on the wire sleeve.
– Insert the new contact into the mount of the crimping pliers.
– Insert the end of the stripped wire with the sealing ring for sin‐
gle-wire sealing in position onto the new contact up to the
“Wire-Stop”.
– Crimp the contact, the wire and the sealing ring for single-wire
sealing by fully closing the crimping pliers.
– Reopen the crimping pliers and remove the crimped contact.
Correct crimping can be confirmed by the clean imprint of the wire

and the sealing ring for single-wire sealing at the contact and on
the rear, an imprint is visible, indicating the correct execution of
the crimping using the correct tool.

2.4.6 Cable break with single repair point

Repair point with single crimp connection
– Expose the wire to be repaired (approx. 20 cm on both sides
of the repair point).
– Remove the adhesive tape from the wiring harness, use a
knife if necessary.
– Remove the damaged wire section using the cable stripper -

VAS 1978/3- .
Note
When both ends of the vehicle cable are too short for a single
crimped connection due to the cut-out defective cable section ,
connect a repair wire section of the corresponding length using
two crimped connections ⇒ page 107 .
– Strip the cable ends using the strippers 6 - 7 mm.
– Push the crimper onto both stripped wire ends of the vehicle
and seal the connection using the crimping pliers.
Note
♦ Make sure the correct indentation for the crimped connections

is selected ⇒ page 95
After closing the pressure connection, you should shrink it with

– Attach the shrinking kit for the hot air blower - VAS 1978/15-
to the hot air blower 220 V/ 50 Hz - VAS 1978/14- .

– Heat up the crimped connection using the hot air blower from
the centre outwards until it is completely sealed and adhesive
is leaking from the ends.
Caution

er!
Note
♦ Where several wires need repair, care must be taken that the
crimped connections do not lie directly next to each other. To
prevent an excessively large wiring harness circumference,
the crimped connections are offset.
♦ If the repair point has already been taped, this point must be
retaped following the repair using adhesive tape.
♦ Secure the repaired cables, if necessary use a cable tie to
prevent rattling noises in the vehicle during driving .
2.4.7 Cable break with double repair point

Repair point with used cable section
– Expose the wire to be repaired at two points (approx. 20 cm
on both sides of each repair point).
knife if necessary.
– Expose the yellow repair wire on the damaged cable and cut
down the repair wire using the stripper - VAS 1978/3- to the
required length.
– Cut-out the damaged wire section from the individual vehicle
cable.

– Strip the cable ends using the strippers 6 - 7 mm.

– Attach the crimped connection to one side of the vehicle cable
and to the other side of the repair line .
– Using the crimping pliers, seal off the crimped connection with
both cable ends.
– Then repeat this operation at the other end of the repair cable.
Note
♦ Make sure the correct indentation for the crimped connections

is selected ⇒ page 95
After closing the pressure connection, you should shrink it with

– Attach the shrinking kit for the hot air blower - VAS 1978/15-
to the hot air blower 220 V/ 50 Hz - VAS 1978/14- .
– Heat up the crimped connection using the hot air blower from
the centre outwards until it is completely sealed and adhesive
is leaking from the ends.
Caution

er!
Note

2.5 Repairing aerial wiring
2.5.1 Repair set, aerial cable VAS 6720

Checking the aerial wire: ⇒ page 109
Changing tool adapter: ⇒ page 109
Cutting aerial wire: ⇒ page 110
Stripping off insulation ⇒ page 110
Stripping outer sleeve: ⇒ page 113
Stripping inner insulation: ⇒ page 114
Crimping inner conductor: ⇒ page 115
Crimping outer conductor: ⇒ page 117
♦ 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 instructions for repair kit,

aerial wire - 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 109 .
– Open handles of pliers completely.

– Release the two locking pins -arrows- from handles of pliers

and pull them out.
– Insert required tool adapter from above -arrow- into handles

of pliers.
– Lock adapter into handles of pliers by pressing in pins

-arrows-.
Cutting aerial wire:
– Push aerial wire -2- into cutting mechanism -1-.

– Close tool and open it again.
– Pull aerial wire out of cutting mechanism.
Stripping off insulation

– 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.

– 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.

– Pull release pin -1-. The blade holder is released and sepa‐
rates from aerial wire.
– Push locating pin -2- into rotary cutter to stop. The aerial wire
is pressed out of rotary cutter.
– Remove shielding from aerial wire.
– Remove remnants of insulation from rotary cutter.
Stripping outer sleeve:

– Push aerial wire -2- through notch -3- into tool adapter to stop
-1-.
– Pull out aerial wire -4-.
Stripping inner insulation:

– Push aerial wire -2- through notch -1- into tool adapter to stop.
– Pull out aerial wire -3-.
Crimping inner conductor:

– Select appropriate adapter according to check of aerial wire

⇒ page 109 ⇒ page 109 .
– 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.

– 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:

– Push sleeve -2- and outer contact -1- over inner conductor.
The knurled contact part must be pushed under shielding -3-
but over the aluminium foil.
– Push on outer contact -4- completely. Ensure proper seating
of female connector and pin.

– 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.

2.6 Repairing contact casings and connec‐

tors
2.6.1 Notes for repairing contact casings and

connectors
Note
♦ Take note of the general indications to perform repairs in the

vehicle electrical system ⇒ page 90 .
♦ The assignment between the stop contacts and contact cas‐
ings is carried out using the number marked on the contact
casing. Page 198 (electrical connections) of the ⇒ Spare Parts
Catalogue (ETKA) lists the numbers of the contact casing in
combination with the respective correct stop contacts.
♦ Damaged contact casings must always be renewed.
♦ New contact casings can be ordered from Kassel (OTC).
2.6.2 Repair of contacts in terminal contact

holder casings
– If necessary, first open or release the primary lock on the con‐
tact holder casing ⇒ page 123 .
– Release the terminal contact (primary lock) using the appro‐
priate release tool ⇒ page 93 .
– Remove the contact from the contact holder casing cable.
– Use the yellow repair wire with the correct contact for the Wir‐
ing Harness Repair Kit .
– Expose the repair point on the wiring harness to be repaired
(approx. 20 cm on both sides of the repair point).
knife if necessary.
– Insert the new terminal contact of the repair cable into the
contact holder casing until it slots into place.
– Attach the sealing ring for single-wire sealing to the repair line.
Note

must point towards the contact holder casing.
– Insert the terminal seal ring in the contact holder casing using
the appropriate assembly tool ⇒ page 104 .

– Cut down the repair wire and the wiring harness of the vehicle
as required using the wire stripper - VAS 1978/3- .
– Strip the ends of the repair wire and the vehicle cable using
the stripper 6 - 7 mm.
– Press the stripped ends of the repair wire and the vehicle wir‐
ing harness together using the crimping pliers and a crimped
connector, as described in the section “Cable break with single
repair point” ⇒ page 106 .
Note
2.6.3 Installing the sealing ring for single-wire

sealing
Note
♦ Sealing rings for single-wire sealing prevent the ingress of wa‐

ter and dirt in the contact casing. These are used, for example,
in the engine compartment and as a general rule, must be re‐
fitted following a repair.
♦ In series production, the sealing ring for single-wire sealing is
crimped to the contact together with the cable; in the event of
repair. this is not the case. Prior to crimping the repair cable,
the sealing ring for single-wire sealing must be affixed to the
wire.
♦ Sealing rings for single-wire sealing must fit precisely onto the
cross-section of the repair wire to be used. The external di‐
ameter of the sealing ring for single-wire sealing is determined
using the diameter of the contact casing chamber as a basis.
Only use the appropriate installation tool for assembly.

Installing the sealing ring for single-wire sealing:

– Release the contact lock using the correct release tool -A- and
pull the cable with the sealing ring for single-wire sealing
-arrow- to the rear and out of the contact casing.
– Cut off the old contact with the sealing ring for single-wire
sealing from the vehicle wiring harness.
– Insert the new repair wire with the new contact into the contact
holder casing until it latches into place.
– Push the sealing ring for single-wire sealing -A- onto the free
cable end piece.
Note

must point towards the contact holder casing.
– Push the sealing ring for single-wire sealing -A- onto the repair
wire up to the contact casing.

– Push the sealing ring for single-wire sealing -A- using the cor‐
rect assembly tool -B- as far as the stop on the contact casing.
– Cut down the repair wire and the wiring harness of the vehicle
as required using the wire stripper - VAS 1978/3- .
– Press the stripped ends of the repair wire and the vehicle wir‐
ing harness together using the crimping pliers and a crimped
connector, as described in the section “Cable break with single
repair point” ⇒ page 106 .
2.6.4 Repairing contact casings using cutting

and edging techniques
Note
♦ For technical reasons, contact casings using cutting and edg‐

ing technology can only supplied with the cutting and edging
contacts used .
♦ As with all contact casings, these contacts can be removed if
they are not required.
♦ Repair wire is available to which the corresponding contacts
have already been connected ⇒ Spare Parts Catalogue (ET‐
KA) .

2.7 Connector housing: Unlock and disman‐

tle
2.7.1 Instructions for unlocking and disman‐

tling connector housings
WARNING
Injury risk!
♦ 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.
Note
♦ Observe general information on repairs to vehicle electrical

system ⇒ page 90 .
♦ To release, always use the correct release tools. Under no
circumstances should contacts be removed from the connec‐
tor housing by force.
♦ Always renew damaged connector housings.
♦ As an aid to disengage the secondary locking mechanisms, a
small screwdriver can be used.
♦ The assignment of the connections is partly stamped on the
secondary lock or on the rear of the connector housing.
♦ For more detailed information about the locations of connec‐
tors, see ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
♦ For correct release tools for corresponding locking devices,
refer to ⇒ Operating instructions for -VAS 1978/35- .
2.7.2 Secondary lock

♦ The secondary locking device is a securing element designed
to secure all the wires in a connector housing. If a connector
housing is fitted with a secondary locking device, this must
always be opened or removed using the specified tool before
releasing and extracting individual crimp connectors.
♦ The secondary locking device is of a different colour as the
rest of the connector housings. This makes it easier to identify
the secondary locking mechanism and clarifies its intended
function.
♦ The types of connector housings shown here are only a se‐
lection designed to illustrate examples of the various operating
principles of the secondary locks.

Example 1:
– Release the housing securing element by removing the
“comb” -arrow-.
Example 2:
– Release the housing securing element by opening the “flap”
-arrow-.
Example 3:
– Release the housing securing element by disengaging a
“slide” -arrow-.
2.7.3 Primary lock

♦ The primary lock is the means of engaging a crimp contact in
the connector housing.
♦ If necessary, any housing catches in place (secondary locking
mechanisms) must be released or removed prior to disengag‐
ing the contacts using the prescribed tool ⇒ page 124 .
♦ The types of primary locking mechanisms shown as follows
are just a few examples to show the different functions of pri‐
mary locking mechanism.
♦ For correct release tool for corresponding locking device, refer
to ⇒ Operating instructions for -VAS 1978/35- .

2.7.4 Primary locking device with round con‐

nector systems
Checking sequence
Note
If necessary, any housing catches in place (secondary locking

mechanisms) must be released or removed prior to disengaging
the contacts using the prescribed tool ⇒ page 124 .
– Insert the corresponding release tool into the release duct in

– Take hold of connector at wire and press it slightly into con‐
nector housing -left arrow-.
Note
Pressing the contact towards the connector housing causes the

retainer tabs of the contact to be lifted off the housing shoulder,
enabling them to be released with the release tool.
– At the same time press the release tool towards the connector
housing -right arrow- and remove the released contact.
– After the contact has been removed from the connector hous‐
ing, remove the release tool.
2.7.5 Primary locking device with flat connec‐

tor systems
Checking sequence
Note


Flat connector with one locking tab:

nector housing -arrow-.
Note

retainer tab of the contact to be lifted off the housing shoulder,
enabling it to be released with the release tool.
housing -arrow- and remove the released contact.
Flat connector system with two insert tongue

– Hold the contact on the cable and insert it as far as possible
into the connector housing -arrow-.
Note


Asymmetrical:
nector housing -arrow-.
Note

2.7.6 Primary locking device with special con‐

nector systems
Checking sequence
Note

Faston contact tabs:

the connector housing -arrow-.
– Take hold of the contact on the wire and press it slightly into
connector housing.
Note


GT 150/280 contacts:
– Insert the corresponding release tool under the release tab in
– Insert the tool by pressing it to the stop -arrow- into the con‐
nector housing.
• The contact is pressed out of the connector housing.

Contacts without tongues

– Insert the release tool under the release tab in the connector
housing.
– Push through the release tool with a light upward movement
-arrow- onto the limit stop.

• The contact is pressed out of the connector housing.


3 Lambdasonde: replace
Note
♦ The wires of the Lambda probe may not be repaired. This may
lead to malfunctions.
♦ Where required, the standard probe can be provided with the
supplied parts, cable ties or cable straps. The probe must be
used as a reference when doing so.
♦ Identify the lambda probe by way of the protective tube as re‐
quired ⇒ page 133 .
3.1 Lambda probe with solid electrolyte LSF

(4-pin): replace
Note

♦ The wires of the Lambda probe may not be repaired. This may
lead to malfunctions.
– Removing the damaged Lambda probe.

– Position both Lambda probes of the same model next to each
other so that the housing of the sensors are located at the
same height.
3. Lambdasonde: replace 131

– Shorten the protruding part of the cable of the standard probe

along the length of the damaged probe, fold over the protrud‐
ing part (about 50 - 250 mm) for this purpose in order to rotate
and fix with cable ties -1-.
– Check if the connector housing of the Lambda probe is com‐
patible with the part of the onboard network.
– If necessary, replace the plug connector of the onboard net‐
work with the connector housing included in the delivery of the
Lambda probe ⇒ page 120 .
Note
♦ The connector housing only has to be renewed in older vehi‐

cles. The coding of the connector housing with new vehicles
matches.
♦ Make considerations for the assignment of the contacts. For
the purpose of clarity, the pins of the connector housing are
marked with colours.
♦ You can find detailed information for this topic in the leaflet
enclosed with the new Lambda probe.
– Install the new Lambda probe in the vehicle.
3.2 Lambda probe universal LSU (6-pin): re‐

place
Note

♦ The lines may never be twisted nor shortened as this may
cause the Lambda probe to malfunction.
– Remove old Lambda probe.

– Position both Lambda probes of the same model next to each
other so that the housing of the sensors are located at the
same height.

– Shorten the protruding part of the cable of the standard probe

along the length of the damaged probe, fold over the protrud‐
ing part (about 50 - 250 mm) for this purpose in order to rotate
and fix with cable ties -1-.
– Install the new Lambda probe in the vehicle.
3.3 Versions of the grounding wire for stand‐

ard Lambda probes
Note
Next to identifying using the spare part number, it can also be

identified using the grounding wire.
Version D1, 6 drill holes, each 3.5 mm

Only used with the 4-pin Lambda probes LSF.
Version D2, 6 drill holes, each 2 mm
Only used with the 4-pin Lambda probes LSF and 6-pin Lambda
probes LSU.
Version D4, 12 drill holes, each 1.4 mm
3. Lambdasonde: replace 133

Only used with the 4-pin Lambda probes LSF and 6-pin Lambda
probes LSU.

4 Contact surface cleaning set - VAS

6410-
4.1 Using the contact surface cleaning set -

VAS 6410-
The contact surface cleaning set - VAS 6410- delivers optimum
quality when repairing the vehicle electrics. With the tools inclu‐
ded, repairs can be carried out around the contact maker of the
wiring harness for the screw connections of the high-current cir‐
cuit (starter circuit and charging current circuit). The contact sur‐
face cleaning set - VAS 6410- is adapted to the vehicle
dimensions, thus guaranteeing safety and ease during repair
works.
Note
Any images of repair work shown are provided for information as

examples only.
Contact surface cleaning set VAS 6410
4.1.1 Servicing wiring lugs

♦ Torque wrench kit - SAT 8010-
Note
♦ Never use rust dissolvers, contact sprays or grease etc. as an

excessive tightening torque will be used when tightening due
to the lack of thread grip, which may lead to a broken screw
connection.
♦ The grey sanding pads are used to treat lightly soiled areas
and "soft surfaces". The red sanding pads are used to treat
heavily soiled areas and "hard surfaces".
4. Contact surface cleaning set VAS 6410 135

WARNING

⇒ page 3 .
– Disconnect battery.
– Loosen domed nut and remove the lug from the bolted con‐
nection.
– Check the lug for rust and contamination.
– Select the correct adapter and the correct sanding pad.
Note
Sanding paper can also be used.
Caution
Makes sure that the zinc plating is not worn down too greatly
so that the copper becomes visible. This can lead to a galvan‐
ised component that destroys the metal, rendering any repair
work impractical.
Note
Due to the strength of the galvanising layers, cleaning must be

carried out in several stages with intermediate visual inspections
of the cable lug.
– Attach the adapter to the lug and remove the rust and con‐
tamination with circular movements.
– Check the lug and rework if necessary.

– Remove any possible resultant burrs with the deburrer.

– Retighten the cable lug to the recommended tightening torque,
⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐
cations
Note
For optimum contact, the elements must be tightened to the cor‐

rect tightening torque after cleaning.
– Treat the connector using a suitable preservative,

– Reconnect the battery.
WARNING

⇒ page 3 .
– Initialise the electric window, enter the radio code, set the time
and if necessary, recode any control units registering a fault.
4.1.2 Servicing screw connections

♦ SAT 8010
Note
♦ Never use rust dissolvers, contact sprays or grease etc. as an

excessive tightening torque will be used when tightening due
to the lack of thread grip, which may lead to a broken screw
connection.
♦ The grey sanding pads are used to treat lightly soiled areas
and "soft surfaces". The red sanding pads are used to treat
heavily soiled areas and "hard surfaces".
WARNING

⇒ page 3 .

– Loosen domed nut and remove the lug from the bolted con‐
nection.
– Check the screw connection for rust and contamination etc.
– Select the correct adapter and sanding pad for the screw con‐
nection.
Caution
Makes sure that the zinc plating is not worn down too greatly
so that the copper becomes visible. This can lead to a galvan‐
ised component that destroys the metal, rendering any repair
work impractical.
Note
Due to the strength of the galvanising layers, cleaning must be

carried out in several stages with intermediate visual inspections
of the cable lug.
– Attach the adapter to the screw connection and remove the

rust and contamination with circular movements.
– Check the screw connection and rework if necessary.
– Tighten the screw connection and if necessary retighten the
connection to the prescribed tightening torque, ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations
Note

– Treat the screw connection using a suitable preservative.

– Reconnect the battery.
WARNING
Injury risk! Remember warnings and safety instructions .
– Initialise the electric window, enter the radio code, set the time
and if necessary, recode any control units registering a fault.
4.1.3 Clean the battery terminals and poles


♦ SAT 8010
Note
Never use rust dissolvers, contact sprays or grease etc. as an

excessive tightening torque will be used when tightening due to
the lack of thread grip, which may lead to a broken screw con‐
nection.
WARNING
Injury risk! Remember warnings and safety instructions .
– Check the battery terminals and poles for rust and dirt.
– Clean the terminal using circular movements of the steel wire
brush of the pole terminal cleaner.
– Clean the poles with circular movements with the underside of

the pole terminal cleaner.
WARNING

⇒ page 3 .
– Reconnect the battery and secure the pole to the correspond‐

ing tightening torque.
Note


4.1.4 Treat with preservative
Caution
The onboard network will be damaged if it is not treated with a

preservative.
Note
♦ All screw connections must be tightened to the appropriate

tightening torque.
♦ The small tube supplied with the bottle must always be used
to apply the preservative.
♦ In cold climate zones, preservative wax is used.
♦ In hot climate zones, body cavity protection is used.
♦ The preservative is drawn in automatically via capillary attrac‐
tion up to the point at which it is required.
– Hold the nozzle below the cable lug and spray around the pin.
– Hold the nozzle above the cable lug and spray around the pin.

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Service

Service Department. Technical Information

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

92 - Windscreen wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

94 - Lights, bulbs, switches - exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

96 - Lights, bulbs, switches - interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

1.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

27 – Starter, current supply, CCS

Injury risk! Remember warnings and safety instructions

To prevent damage to the battery and vehicle, the following

1.1 Fundamentals for batteries

1.2 Types of batteries

The batteries described next are batteries that require no main‐

1.2.1 Battery with »standard« colour indicator

The batteries whose magic eye a clear yellow or clear colour

This battery is equipped with a magic eye. The different colours

1.2.2 Battery with »enhanced« colour indica‐

Do not remove stickers nor add distilled water. Only perform

Batteries where the colour is light yellow must not be checked

The battery is used for particular requirements in certain Start -

1.2.3 Absorbent glass mat battery

AMG batteries must always be replaced by batteries of the same

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

1.3 Warning notices and safety regulations

1.3.1 Dangers when handling vehicle batter‐

♦ Personnel with little experience, for example apprentices

1.3.2 Safety symbols on the battery

Batteries with battery monitoring control unit - J367-

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

1.3.3 Working on airbag system

When work is performed on the airbag system (pyrotechnical

1.4 Attaching the terminals to the battery

To avoid damage to the battery poles and terminals the fol‐

Injury risk! Remember warnings and safety instructions

To prevent damage to the battery and vehicle, the following

2.1 Checking the different battery types

2.1.1 Testing a battery with magic eye

Injury risk! Remember warnings and safety instructions

Verify the battery as follows:

The batteries whose magic eye a clear yellow or clear colour

– Checking battery using battery tester with printer - VAS 6161-

2.1.2 Testing an Absorbed Glass Mat Battery

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

2.2 visual inspection

Injury risk! Remember warnings and safety instructions

Visual inspection of the exterior, the connections and the correct

♦ The battery may be damaged if it is not secured correctly.

The visual check is used to ascertain:

2.3 Check the colour indicator on the battery

2.3.1 Checking colour indicator, “3-colour”

Injury risk! Remember warnings and safety instructions

General information about colour indicator:

Three different colour indications are possible:

The batteries whose magic eye a clear yellow or clear colour

2.3.2 Checking colour indicator, “2-colour”

Injury risk! Remember warnings and safety instructions

General information about colour indicator:

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

Three different colour indications are possible:

The batteries whose magic eye a clear yellow or clear colour

2.4 Battery tester with printer - VAS 6161-

Injury risk! Remember warnings and safety instructions

There is no need to disconnect and remove the battery if the bat‐

Please observe the ⇒ operating instructions for the battery tester