D3E802072D0-Electrical Equipment General Information

Service
Repair Manual
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
27 - Battery, Starter, Generator, Cruise Control
92 - Wiper/Washer Systems
94 - Exterior Lights, Switches
96 - Interior Lights, Switches
97 - Wiring
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Technical information should always be available to the foremen and mechanics, because their
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careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
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All rights reserved.

No reproduction without prior agreement from publisher.
Copyright 2015 Volkswagen AG, Wolfsburg D3E802072D0

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Contents
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27 - Battery, Starter, Generator, Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.1 Battery Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.2 Battery General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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1.3 Warnings and Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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1.4 Battery Post/Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Battery, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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2.1 Different Types of Batteries, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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2.2 Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.3 Color Display in Battery Cover, Checking, Visual Indicator . . . . . . . . . . . . . . . . . . . . . . . . 10
2.4 Battery Tester with Printer VAS5097A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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2.5 Battery Tester VAS6161 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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2.6 Midtronics Battery Tester MCR340VKT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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2.7 Battery Test with Vehicle Diagnostic Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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2.8 Current Draw Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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2.9 Battery, Checking Resting Voltage, Vehicles in Storage or Inventory . . . . . . . . . . . . . . . . 30
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3 Battery, Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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3.1 Battery Charger VAS5095A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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3.2 Battery Charger VAS5900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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3.5 Battery Tester Charger Kit GRX3000VAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.6 Solar Battery Maintainer VAS6102A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.7 Severely Discharged Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4 Cruise Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.1 Cruise Control System Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.2 Cruise Control System, Activating and Deactivating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
92 - Wiper/Washer Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1 Washer Fluid Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.1 Windshield and Rear Window Washer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.2 Headlamp Washer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
1.3 Washer Fluid Hoses, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2 Joint-Free Wiper Blade Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.1 Joint-Free Wiper Blade Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
94 - Exterior Lights, Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

1 HID Headlamp Usage and Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
96 - Interior Lights, Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

1 Cigarette Lighter and Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1.1 Overview - Cigarette Lighter, 12 V Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1.2 Cigarette Lighter U1 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.3 Socket Illumination Bulb L42 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1.4 Cigarette Lighter Illumination Bulb L28 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 86
2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
97 - Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1 Vehicle Diagnosis, Testing and Information Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Contents i
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
1.1 Description of Vehicle Diagnosis, Testing and Information Systems . . . . . . . . . . . . . . . . . . 89

1.2 Connect the Vehicle Diagnostic Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.3 Vehicle Diagnostic Tester, Connecting, Golf MY 1998 through 2003 . . . . . . . . . . . . . . . . 90
2 Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2.1 Wiring Harnesses and Connectors, Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2.2 Vehicle Electrical System, General Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.3 Wiring Harnesses, Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3 Connector Housings, Releasing and Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.1 Connector Housings, Releasing and Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.2 Connector Housings and Connectors, Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4 Contact Surfaces, Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4.1 Contact Surface Cleaning Set VAS6410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
5 Antenna Wires, Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
5.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
5.2 Overview - Antenna Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
5.3 New Antenna Wire, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
6 Fiber-Optic Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
6.1 Fiber-Optic Cables, Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
6.2 Fiber-Optic Cable, Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
6.3 Fiber-Optic Cable, Disconnecting from Wiring Harness Connector . . . . . . . . . . . . . . . . . . 130
7 Heated Oxygen Sensor, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
7.1 Heated Oxygen Sensor, Replacing, 4-Pin Universal Oxygen Sensor . . . . . . . . . . . . . . . . 131
7.2 Heated Oxygen Sensor, Replacing, 6-Pin Universal Oxygen Sensor . . . . . . . . . . . . . . . . 131
7.3 Oxygen Sensor Unit Protective Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
8 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
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ii Contents
27 Battery, Starter, Generator, Cruise Control

1 Battery
(Edition 01.2015)
1.1 Battery Types, page 1
1.2 Battery General Information, page 3
1.3 Warnings and Safety Precautions, page 3
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1.1 Battery Types
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1.1.1 Battery with Visual
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1.1.2 AGM Battery, page 2
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1.1.3 EFB Battery with Visual Indicator, Enhanced ,
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1.1.1 Battery with Visual Indicator, Stand
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Maintenance-free Battery - A- with fluid electrolyte (wet battery)
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Do not remove any of the labels on the battery and do not add
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distilled water. Perform only a visual inspection. Note the chap

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Do not check or charge a Battery - A- when the visual indicator

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has no color or is bright yellow. Jump starting must not be
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There is a risk of explosion during testing, charging or jump
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These Batteries - A- must be replaced.
This Battery - A- has a color display (visual indicator). The colors

in the visual indicator show the Battery - A- charge and electrolyte
level.
Visual indicator, checking. Refer to
2.3 Color Display in Battery Cover, Checking, Visual Indicator,
page 10 .
Using approved battery chargers, all tests can be performed on
these batteries. Observe the settings on the battery charger. Re
fer to 2 Battery, Checking, page 7 .
1. Battery 1
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1.1.2 AGM Battery
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Maintenance-free Battery - A- with fixed electrolyte (AGM battery)
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Caution
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Lead-acid battery, where the electrolyte is fixed in an absorbent
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glass mat (AGM). The Battery - A- is closed and equipped with
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breather valves.
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AGM is the English abbreviation for absorbent glass mat.
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These Batteries - A- cannot have a visual indicator due to the fixed
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electrolyte. AGM is on the Battery - A- to identify it.
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When replacing an AGM battery, another AGM battery must be
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AGM batteries. Observe the settings on the battery charger. Refer gh ht
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1.1.3 EFB Battery with Visual Indicator, En
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Maintenance-free Battery - A- with fluid electrolyte (wet battery)
Caution
WARNING

used!
starting.
The Battery - A- is installed in certain Stop/Start vehicles due to

special requirements. EFB is written on the battery cover to
identify this battery.
EFB stands for Enhanced Flooded Battery (enhanced wet
battery).
An EFB battery may only be replaced with another EFB battery.
An EFB battery has a visual indicator for checking the battery
electrolyte level.
2 Rep. Gr.27 - Battery, Starter, Generator, Cruise Control

Note
EFB batteries are being installed in smaller gasoline engines with

the Stop/Start system and a manual transmission from 05/2011.
Visual indicator, checking. Refer to

page 10 .
Using approved battery chargers, all tests can be performed on
EFB batteries. Observe the settings on the battery charger. Refer
to 2 Battery, Checking, page 7 .
1.2 Battery General Information

To guarantee a long service life, the Battery - A- must be checked,
serviced and maintained as described in this manual.
The Battery - A- supplies the power to start the engine. The Bat
tery - A- also acts as a power reserve for the entire vehicle
electrical system.
Note
Refer to Self Study Program No. 234 ; Battery .
Caution
In order to prevent damage to the Battery - A- or vehicle, ob

serve the battery type information. Refer to
1.1 Battery Types, page 1 .
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1.3 Warnings and Safety Precautions, page 3 .
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1.3 Warnings and Safety Precautions

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1.3.1 Dangers When Working with Batteries, page 3

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1.3.2 Battery Safety Label, page 5

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1.3.3 Working on Airbag System, page 5
1.3.1 Dangers When Working with Batteries

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Recognizing and Preventing Risks

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Batteries - A- present risks. Read the warnings on the Battery -

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A- label, in the Owner's Manual and in ELSA to prevent these

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1. Battery 3
WARNING
Personnel instructed in protection, such as a trainee or an

apprentice, may only perform work on vehicle Batteries -
A- under supervision of technical personnel, for example,
a master automotive technician or a master automotive
electrician.
Acid has strong corrosive properties. If Batteries - A- are
handled inappropriately, there is a risk that personal injury
may result from exposure to harmful electrolyte influen
ces. Therefore, suitable remedies for acid damage must
be kept readily available. Soapy water would be a suitable
remedy. wage
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If electrolyte drips out from theedBattery
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burned by acid and the vehicle thoris may be affected by acid nte
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erosion and corrosion. It sisau a possibility that safety-related ra
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vehicle components can be damaged.
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When charging and when resting after charging, explosive
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gas is present. In extreme cases, if the Battery - A- is han
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battery to explode.
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Replace a Battery - A- if the visual indicator has no color
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or is bright yellow. They may not be tested or charged
and jump starting may not be used. There is a risk of ex
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plosion during testing, charging or jump starting.
Producing sparks by sanding, welding, cutting and open
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flames, (also from smoking near the battery) is forbidden.
Producing sparks through electrostatic discharge must al
so be avoided. Always touch the vehicle body before
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touching the Battery - A- .
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Only perform Battery - A- procedures in suitable and well- f inform

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1.3.2 Battery Safety Label

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1- When workingorinis the area of the Battery - A- , fire, sparks,
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open flame aand
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working with
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tools should not be rested on the Battery - A- .
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2- Wear protective eyewear when working on the Battery - A- .
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3- Always keep acid and Batteries - A- out of the reach of chil
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4- Disposal: old batteries require special disposal. They may
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only be disposed of at a suitable collection facility and only
in consideration of legal regulations.
5- Do not dispose of old batteries in household waste.
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6- When handling Batteries - A- , there is a risk of explosion.
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Battery - A- charging produces a highly explosive gas mix

ture.
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7- Always follow instructions on the Battery - A- , in the Parts
rm
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Catalog and in the Owner's Manual.
atio
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8- Danger of burns: battery acid is severely corrosive, there

or
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fore protective gloves and eyewear must be worn when
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working on the Battery - A- . The Battery - A- must not be

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tipped because acid may spill from the ventilation openings.
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WARNING
AG.
When working on the airbag system (pyrotechnic components,

Airbag Control Module - J234- , wiring), the ground cable must
be disconnected with the ignition switched on.
Exceptions: On vehicles with a battery in the vehicle interior,
the ignition must be switched off.
Then cover the negative terminal.
After disconnecting the battery, a wait time of 10 seconds
is required.
The battery must be connected with the ignition switched
on.
There must be no one inside the vehicle when connecting
the battery.
Make sure in this case to keep oneself away from the airbag
deployment and belt tensioner zones.
If the ignition is not switched on after reconnecting the battery
(the indicator lamps in the instrument cluster do not illuminate),
the ignition (key/button) may only be switched on while sitting
in the driver's seat in the rearmost position.
1. Battery 5
Electrical Equipment General
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1.4 Battery Post/Terminal
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In order to prevent damage to the battery terminals and battery
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Never use force to attach the battery terminals by hand.
h re
hole
Do not apply grease to battery posts.
spec
es, in part or in w
t to the co
The battery terminal clamps should be mounted so that
the battery terminal sits flush with the clamp or protrudes
out of it.
rrectness of i
After tightening the battery terminal clamps to the speci
fied torque, the threaded connections must not be tight
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ened again.
nform
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Terminal clamp tightening specification. Refer to Electrical

m
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Equipment; Rep. Gr. 27 ; Battery; Battery Assembly Overview .
on
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2 Battery, Checking
2.1 Different Types of Batteries, Checking, page 7
2.2 Visual Inspection, page 9
page 10
2.4 Battery Tester with Printer VAS5097A , page 12
2.5 Battery Tester VAS6161 , page 18
2.6 Midtronics Battery Tester MCR340VKT , page 24
2.7 Battery Test with Vehicle Diagnostic Tester, page 28
2.8 Current Draw Test, page 28
2.9 Battery, Checking Resting Voltage, Vehicles in Storage or
Inventory, page 30
2.1 Different Types of Batteries, Checking

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2.1.1 Battery with Color Display,Vol Visual Indicator, Checking,
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2.1.3 EFB Battery, Checking, page 8

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2.1.1 Battery with Color Display, Visual Indi
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WARNING
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Risk of injury. Follow all warning messages and safety pre
cautions. Refer to
rrectness of i
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Perform the Tests in the Following Sequence:

nform
ercia
1. Visual inspection. Refer to

2.2 Visual Inspection, page 9 .
m
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2. Color display test

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Three colors. Refer to

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2.3.1 3-Color Visual Indicator, Checking, through 03/2008,

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Two colors. Refer to t. Cop py
2.3.2 2-Color Visual Indicator, Checking, from 04/2008,
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WARNING

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2. Battery, Checking 7
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The Battery Tester with Printer - VAS5097A- is no longer
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warranty testing. Only the Battery Tester - VAS6161- is still being
s
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un
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3. Battery load test using
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Battery Tester with Printer - VAS5097A- . Refer to
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2.4.3 Battery Load Test, page 13 .
hole
spec
Battery Tester - VAS6161- . Refer to es, in part or in w
t to the co
2.5 Battery Tester VAS6161 , page 18 .
Midtronics Battery Tester - MCR340VKT- (USA/Canada only).
Refer to
rrectness of i
2.6 Midtronics Battery Tester MCR340VKT , page 24 .
l purpos
4. Depending on the result of the battery load test, perform

current draw test. Refer to
nform
ercia
2.8 Current Draw Test, page 28 .

m
2.1.2 AGM Battery, Checking
a
com
tion in
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WARNING
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cautions. Refer to Cop py
1.3 Warnings and Safety Precautions, page 3 . ht. rig
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Note
The Battery Tester with Printer - VAS5097A- is no longer used for

used.

Battery Tester - VAS6161- . Refer to
2.5 Battery Tester VAS6161 , page 18 .
Refer to
2.6 Midtronics Battery Tester MCR340VKT , page 24 .
3. Depending on the result of the battery load test, perform
2.8 Current Draw Test, page 28 .
2.1.3 EFB Battery, Checking
WARNING
Risk of injury. Follow all warning messages and Safety Pre

cautions.

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The Battery Tester with Printer - VAS5097A- is no longer used for
es, in part or in w
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rrectness of i
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Battery Tester - VAS6161- . Refer to
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2.5.3 Battery Test, Performing using Battery Tester

m
VAS6161 , page 19 .
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Refer to
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2.6.3 Battery Test, Performing using Midtronics Battery

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Tester MCR340VKT , page 25 .

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3. Depending on the result of the battery load test, perform t. Cop py
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2.2 Visual Inspection
AG.
WARNING

cautions. Refer to
Before any extensive measurements are taken, visually inspect

the exterior of the battery, the connections, and the secure in
stallation of the Battery - A- .
For each vehicle. Refer to Maintenance ; Booklet for informa
tion regarding the battery.
Caution
An improperly secured Battery - A- can lead to damage.

Excessive vibration due to an improperly secured battery
will reduce the battery service life, and the battery hold-
down bracket could damage the battery housing and lead
to electrolyte leakage.
Make sure the Battery - A- is secure. If required, tighten
the mounting bolt to the tightening specification.
Visual Inspection Points:

Damage to the battery case. Acid can leak out if the case is
damaged. Battery acid that has leaked out can cause severe
damage to the vehicle. Acid that has leaked onto any part of
the vehicle should be immediately treated with acid neutralizer
or soap solution.
Damage on the battery poles. If the battery terminals are dam
aged, contact with battery terminals clamps cannot be guar
anteed. When connecting the battery terminal clamps, always
keep the tightening specification for the corresponding vehicle

from the repair manual in mind. Refer to Electrical Equip
ment; Rep. Gr. 27 ; Overview - Battery . If the battery post
clamps are not correctly installed and secured, the wiring may
burn. Substantial malfunctions to the electrical system are a
consequence. Safe operation of the vehicle can no longer be
guaranteed.
2.3 Color Display in Battery Cover, Check

ing, Visual Indicator
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2.3.1 3-Color Visual Indicator, Checking, through 03/2008, lkswagen oes
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2.3.2 2-Color Visual Indicator, Checking, from 04/2008,tho page eo
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2.3.1 3-Color Visual Indicator, Checking, un
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WARNING
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Visual Indicator General Information:
ss
The visual indicator provides information concerning the electro
o
cial p
f
lyte level and the Battery - A- charge level.
inform
mer
To obtain an accurate reading, gently tap the charge indicator with
atio
m
a screwdriver handle or rock vehicle slightly. By doing this, the air

o
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bubbles that occur normally during battery charging (even during
i
or
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vehicle operation) that adversely affect charge indicator reading

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will be displaced. Thereby, the color indicator of the visual indi

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Air bubbles can form under the visual indicator, especially if a
Prote AG.
Battery - A- was recharged or if the Battery - A- was charged

while driving. These bubbles may cause the visual indicator to
read inaccurately.
As the charge indicator is located in a single cell, the indication
is only valid for that cell. An exact assessment of the battery
condition should always be confirmed through a battery test.
Refer to 2.4.3 Battery Load Test, page 13 .
The visual indicator can be installed at various locations on top
of the Battery - A- .
There Are Three Possible Color Indications:

Green: the Battery - A- is sufficiently charged.
Black: the Battery - A- is partially charged, the charge level
is less than 65% or discharged.
No color/bright yellow: the Battery - A- must be replaced.

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2.3.2 2-Color Visual Indicator, Checking,
ss o
from 04/2008
cial p
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atio
WARNING
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Visual Indicator General Information:
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The green visual indicator for the charge level indicator is no
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longer used for these Batteries - A- . Only black or no color or
bright yellow are used.
The visual indicator shows the Battery - A- electrolyte level.
It is no longer possible to read the Battery - A- charge level using
the visual indicator. It is necessary to perform a battery test. Refer
to 2.4.3 Battery Load Test, page 13 .
To obtain an accurate reading, gently tap the charge indicator with
a screwdriver handle or rock vehicle slightly. By doing this, the air
bubbles that occur normally during battery charging (even during
vehicle operation) that adversely affect charge indicator reading
will be displaced. Thereby, the color indicator of the visual indi
cator is more accurate.
Note
Air bubbles can form under the visual indicator, especially if a

Battery - A- was recharged or if the Battery - A- was charged
while driving. These bubbles may cause the visual indicator to
read inaccurately.
As the charge indicator is located in a single cell, the indication
is only valid for that cell. An exact assessment of the battery
condition should always be confirmed through a battery test.
Refer to 2.4.3 Battery Load Test, page 13 .
The visual indicator can be installed at various locations on top
of the Battery - A- .
Two Visual Indicators Are Possible

black: the electrolyte level is OK
No color or light yellow: electrolyte level too low. Replace
the Battery - a- .
WARNING

used!
starting.
2.4 Battery Tester with Printer - VAS5097A-

2.4.1 General Information, page 12
2.4.2 Battery Tester with Printer VAS5097A Device Descrip
tion, page 13
2.4.3 Battery Load Test, page 13
2.4.4 Cold Crank Amps Table, page 15
2.4.5 Battery Load Test Results, page 16
2.4.6 Printed Test Results Explanations, page 17
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2.4.7 Test Result Evaluation,
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2.4.1 General Information
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t to the co
It is not necessary to disconnect or remove the Battery - A- when

using the Battery Tester with Printer - VAS5097A- .
The following Batteries - A- can be tested using the Battery Tester
rrectness of i
with Printer - VAS5097A- :

l purpos
80 to 499 A cold crank amps according to German Industry

Standardization DIN (Deutsche Industrie Norm). Refer to 1).
nform
ercia
95 to 574 A cold cranking output according to IEC (Interna

tional Engineering Consortium)
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136 to 855 A cold cranking output according to EN/ SAE (Eu

in t
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ropische Norm/ Standard of Automotive Engineers)

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1) Batteries - A- with cold crank amps greater than 499 A according to DIN can
cum
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be tested with the setting for 499 A according to DIN.

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The Batteries - A- are tested by being loaded with current that Cop py
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corresponds to the starter current of a vehicle. Under this load,
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the Battery - A- is evaluated and the measured results are output cop Vo
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Prote AG.
Note
Read the Battery Tester with Printer - VAS5097A- Operating In

structions and Battery Tester with Printer - VAS5097A- Quick
Reference Guide label on the Battery Tester with Printer -
VAS5097A- and the cold crank amps table. Refer to
2.4.4 Cold Crank Amps Table, page 15 .

Battery Tester with Printer - VAS5097A- device description.

Refer to
2.4.2 Battery Tester with Printer VAS5097A Device De
scription, page 13 .
Battery load test. Refer to
Cold crank amps table. Refer to agen
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2.4.4 Cold Crank Amps Table, page 15 . olksw not
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Battery load test results. Refer to horis nte
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2.4.5 Battery Load Test Results, page 16au.t ra
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Printed test results explanations. Refer to
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2.4.6 Printed Test Results Explanations, page 17 .
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Test result evaluation. Refer to
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2.4.7 Test Result Evaluation, page 17 .
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2.4.2 Battery Tester with Printer - VAS5097A-
hole
spec
Device Description
es, in part or in w
t to the co
Battery Tester with Printer - VAS5097A-
1- LED green, Device in use
rrectness of i
2- LED red, Device connected with terminals reversed
l purpos
3- LED red Battery cannot be tested, the Battery - A- must be

replaced.
nf
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4- Start button
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5- Cold cranking output selector switch
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6- ON/OFF function switch

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7- Sliding switch (battery hook-up to the Battery - A- /at jump
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Cop py
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8- Paper-feed -button
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agen
2.4.3 Battery Load Test

Special tools and workshop equipment required
Battery Tester with Printer - VAS5097A-
WARNING

cautions. Refer to
Always note the TPL 2012182.
Procedure
WARNING

wage
has no color or is bright yellow. Jump starting must
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There is a risk of explosion during testing,au charging or jump
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ac
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Note
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es, in part or in w
The Battery - A- temperature must be at least 10 C.
t to the co
rrectness of i
Caution
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Turn off the ignition and all electrical equipment.

Remove the key.
nform
mercia
at
om
io
Check the visual indicator on Batteries - A- with visual indica
n
c
in t
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tor. Refer to
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te
2.1.1 Battery with Color Display, Visual Indicator, Check

a
do
riv
ing, page 7 .
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cum
for
en
ng
Switch on the Battery Tester with Printer - VAS5097A- . Refer

t.
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op
to C py
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gh
ht
pyri by
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Determine the cold crank amps according to specifications on
the Battery - A- in ampere (A) according to DIN and determine
the Battery Tester With Printer - VAS5097A- adjustment range
using the table. Refer to
2.4.4 Cold Crank Amps Table, page 15 .
Note
If the Battery - A- does not state this value in DIN but rather in IEC
or EN/SAE, then convert the value using the table (refer to
2.4.4 Cold Crank Amps Table, page 15 ) or the table on the
Battery Tester with Printer - VAS5097A- .
Set the cold crank amps with the cold crank amps selector
switch. Refer to
Set the measuring range (80 to 379 A or 380 to 499 A) using
the ON/OFF switch. Refer to
Note
Batteries - A- with cold crank amps greater than 499 A according

to DIN can be tested with the setting for 499 A according to DIN.

Connect the red terminal (+) to the positive terminal of the

Battery - A- .
Connect the black terminal (-) to the negative terminal for the
Battery - A- .
Note
Make sure the test terminals make good contact!

Note TPL 2012182 for the Battery Tester with Printer -
VAS5097A- .
Using the sliding switch, select the test clamp connection

point. Refer to
1- Direct connection to the Battery - A-
2- Connection on the battery jump start terminal
Check if the cold crank amps indicated on the Battery - A-
matches the selected value on the Battery Tester with Printer
- VAS5097A- .
Press the Start -button. Refer to agen
AG. Volkswagen AG d
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2.4.2 Battery Tester with Printer VAS5097A Device olksw
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scription, page 13 . ise
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The green LED lights up. Refer to sa
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ac
2.4.2 Battery Tester with Printer VAS5097As Device Descrip
ce
le
tion, page 13 . The test program runs automatically. The test

un
pt
an
d
results are output through the printer. Refer to

itte
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2.4.5 Battery Load Test Results, page 16 . If the Battery
rm
ab
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ility
Tester with Printer - VAS5097A- does not start, (the LED does not
ot
come on and there is no print out), then charge the Battery - A- .
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Refer to 3 Battery, Charging, page 31 .
hole
spec
Switch off the Battery Tester with Printer - VAS5097A- . Refer
es, in part or in w
to
t to the co
rrectness of i
Remove the test terminals.
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Note nform
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The test is over after approximately 20 seconds.

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The results of the test are output through the printer.

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Only perform the test once. Repeating the test will not produce
iva
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accurate results.
rp
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The Battery Tester with Printer - VAS5097A- needs 30 mi

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nutes to cool off before it is ready for the next measurement.
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2.4.4 Cold Crank Amps Table
Prote AG.
Cold Crank Amps in A

EN/ SAE IEC DIN
136 177 95 124 80 104
178 219 125 154 105 129
220 261 155 184 130 154
262 303 185 214 155 179
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EN/ SAE ss IEC DIN
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304 345 215 244 180 204
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346 387 245 274 204 229
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388 429 275 304 230 254
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430 471 305 334 255 279
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472 513 335 364 280 304
spec
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514 555 365 394 305 329
t to the co
556 597 395 424 330 354
598 639 425 454 355 379
rrectness of i
640 657 455 464 380 389
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658 675 465 474 390 399

676 693 475 484 400 409
nform
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694 711 485 494 410 419

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712 729 495 504 420 429
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730 747 505 514 430 439
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748 765 515 524 440 449

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838 855 565 574 490 499. Refer to 2).
AG.
2) Batteries - A- with cold crank amps greater than 499 A according to DIN can be tested with the setting for 499 A according to DIN.
2.4.5 Battery Load Test Results

By placing the battery under a strong load during the Battery - A-
load test, the battery voltage will be reduced.
If the Battery - A- is good, the voltage drops only to the speci
fied minimum voltage.
If the Battery - A- is defective or weakly charged, the battery
voltage will drop very quickly to below the specified minimum
voltage.
After testing, this low voltage level is maintained for a lengthy
period and only increases again slowly.
accurate results.
In order to be able to test another/additional Battery - A- , the
Battery Tester with Printer - VAS5097A- must cool down for
approximately 30 minutes for the test result to be correct.

2.4.6 Printed Test Results Explanations

1- Measuring range set on the Battery Tester with Printer -
VAS5097A- gen AG
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2- Diagram, the -arrow- points to the Battery
d b - A- status.
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3- Test result tho eo
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4- Battery - A- voltage during the battery load test.
ce
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5- Vehicle data and date. For tester to fill out.
d
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The printed test results are required for warranty claims.
t to the co
accurate results.
rrectnes
2.4.7 Test Result Evaluation
s o
cial p
f inform
Printout Measures
mer
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Starting power very good Battery - A- is OK.

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Starting power good Battery - A- is OK.
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Starting power sufficient Evaluation performed by the

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2.8 Current Draw Test,

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page 28 . Cop py
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Starting power insufficient Evaluation performed by the
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current draw test. Refer to by c lksw
cted agen
2.8 Current Draw Test, Prote AG.
page 28 .
Starting power very insufficient Evaluation performed by the
2.8 Current Draw Test,
page 28 .
Cannot be tested Charge the Battery - A-
and perform the test again.
Refer to
3 Battery, Charging,
page 31 .
2.5 Battery Tester - VAS6161-

2.5.2 Battery Tester VAS6161 Device Description, n AG. Volkswagen AG do
page 19 olkswage es n
o V t gu
by ara
2.5.3 Battery Test, Performing using Battery
ris Tester VAS6161
ed nte
, page 19 utho eo
ra
a c
ss
2.5.4 Maintenance Test, Performing, page 20
ce
e
nl
pt
du
an
2.5.5 Service Test, Performing, page 21 itte
y li
erm
ab
2.5.6 Warranty Test, Performing, page 22
ility
ot p
wit
2.5.7 Explanation of Test Results, page 22
, is n
h re
hole
2.5.8 Test Result Evaluation, page 22
spec
es, in part or in w
t to the co
rrectness of i
WARNING
l purpos

cautions. Refer to
nform
mercia
at
om
ion
It is not necessary to disconnect or remove the Battery - A- when
c
in t
or
using the Battery Tester - VAS6161- .
his
ate
do
riv
The Battery Tester - VAS6161- does not charge the Battery - A- .

p
cum
or
It is working according to the principle of dynamic conductivity.

f
en
ng
t.
yi Co
op
The Battery Tester - VAS6161- stores all battery types. C py
t. rig
gh ht
yri by
The data can be stored on an SD memory card. cop Vo
by lksw
cted agen
Prote
The Battery Tester - VAS6161- can be updated via an interface
AG.
or a SD card, so that all battery data from Volkswagen is always

current.
The integrated infrared sensor (measuring the battery tempera
ture) increases the quality of the measurements.
As an option, there is a scanner available, which can be used to
read the bar code on the Battery - A- .
Note
Observe the Battery Tester - VAS6161- Operating Instructions.
Battery Tester - VAS6161- device description. Refer to

2.5.2 Battery Tester VAS6161 Device Description,
page 19 .
Battery test. Refer to
2.5.3 Battery Test, Performing using Battery Tester
VAS6161 , page 19 .
Maintenance test, performing. Refer to
2.5.4 Maintenance Test, Performing, page 20 .
Service test, performing. Refer to
2.5.5 Service Test, Performing, page 21 .
Warranty test, performing. Refer to
2.5.6 Warranty Test, Performing, page 22 .

Printed test results explanations. Refer to

2.5.7 Explanation of Test Results, page 22 .
Test result evaluation. Refer to
2.5.8 Test Result Evaluation, page 22 .
2.5.2 Battery Tester - VAS6161- Device De

scription
Battery Tester - VAS6161-
1- Internal printer
2- Operating lever for the paper tray
3- Paper slot
4- Main menu display
5- Control Field with ON/OFF Button (power), Cursor Buttons
for Selecting
6- Connection for the battery tester cable
7- Slot for the SD memory card
8- Infrared temperature sensor
9- PC file transmitter n AG. Volkswagen AG do
lkswage es n
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byV ua
2.5.3 Battery Test, Performing using Battery
d ran
ir se tee
tho
or
Tester - VAS6161- ss
au ac
ce
le
un
pt
an
d
itte
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erm
ab
ility
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wit
is n
WARNING
h re
ole,
spec
t to the co
cautions. Refer to
rrectne
Procedure
ss o
cial p
WARNING f inform
mer

atio
m

o
n
c
i
or
used!
thi
te
sd
va

i
o
pr
cum
starting.
r
fo
en
ng
t.
yi Co
These Batteries - A- must be replaced. t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
Turn off the ignition and all electrical consumers and remove
the ignition key.
tor. Refer to
Electrical Equipment General Information - Editionen01.2015
AG. Volkswagen AG
ag does
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2.1.1 Battery with Color Display, Visual Indicator,
ed
b Check ara
nte
ing, page 7 . oris eo
th
au ra
c
Switch on the Battery Tester - VAS6161-ss . Refer to
ce
le
un
pt
an
page 19 .
d
itte
y li
rm
ab
Connect the red terminal (+) to the positive terminal of the
pe
ility
Battery - A- .
ot
wit
, is n
h re
Connect the black terminal (-) to the negative terminal for the hole
spec
Battery - A- .
es, in part or in w
t to the co
Note
rrectness of i
l purpos
Select one of the following:
nform
ercia
Maintenance test (only on new vehicles before becoming in

ventory). Refer to
m
a
com
ti
2.5.4 Maintenance Test, Performing, page 20 .
on in
r
te o
thi
Service test. Refer to
s
iva
2.5.5 Service Test, Performing, page 21 .
do
r
rp
cum
fo
Warranty test. Refer to
en
ng
t.
yi
2.5.6 Warranty Test, Performing, page 22 .
Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
Note Prote
cted AG.
agen
The test is over after approximately 10 seconds.

The results of the test are output through the printer.
The Battery Tester - VAS6161- does not have to cool down
before taking the next measurement.
Switch off the Battery Tester - VAS6161- . Refer to

page 19 .
2.5.4 Maintenance Test, Performing
WARNING

used!
starting.
Procedure
Select Maintenance Test.
Connect the scanner.

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

results.
Scan the VIN.

Select at the battery pole or at the battery jump start termi
nal.
Section vehicle model.
Scan the barcode or manually select the type and manufac
turer in the menu.
Determine the temperature above the Battery - A- . Hold the
infrared sensor approximately 5 cm above the battery pole
until the temperature
agenis stable.
AG. Volkswagen AG d
o w es n
olks ot g
Start the test.
ed
by
V ua
ran
ris tee
tho the test notes.
Printauout or
ac
ss
2.5.5 Service Test, Performing ce
e
nl
pt
du
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itte
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erm
ab
WARNING ility
ot p
wit
, is n

h re
hole

spec
used!
es, in part or in w
t to the co

starting.
rrectness of i

l purpos
Procedure
nform
ercia
Select Service Test.

m
at
om

on
c
nal.
in t
or
his
ate
Section vehicle model.

do
priv
cum
or
Determine the temperature above the Battery - A- . Hold the

f
en
ng
t.
yi
infrared sensor approximately 5 cm above the battery pole
Co
op py
until the temperature is stable. t. C rig
gh ht
pyri by
Vo
Select battery type (Normal, AGM, 2*6 V or Gel).
co lksw
by
cted agen
Prote AG.
Select Norm (CCA, JIS, DIN, SAE, IEC or EN).
Start the test.
Print out the test notes.
2.5.6 Warranty Test, Performing
WARNING

used!
starting.
Procedure
Select Warranty Test.
Select inside the vehicle or outside of the vehicle.
. Volkswagen AG
nal. swa
gen AG does
olk not
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Section vehicle model. e db ara
nte
ris
ho eo
Determine the temperature
aut above the Battery - A- . Hold the ra
c
infrared sensor approximately
ss
5 cm above the battery pole
ce
le
until the temperature is stable.

un
pt
an
d
itte
y li
Select battery type (Normal, AGM, 2*6 V or Gel).
erm
ab
ility
ot p
Select battery capacity.
wit
is n
h re
Start the test.
ole,
spec
Print out the test notes. t to the co
2.5.7 Explanation of Test Results

1- Type of test
rrectne
2- Test result
ss
3- Measured voltage
o
cial p
f inform
4- Battery - A- measured cold start value

mer
atio
5- Battery - A- cold start value set on the Battery Tester -

om
VAS6161-
c
i
or
n thi
te
6- Temperature measured above the Battery - A-

sd
iva
o
pr
cum
r
7- Battery - A- component location

fo
en
ng
t.
yi Co
8- Battery terminal clamp position set on the Battery Tester - t. Cop py
VAS6161-
rig
gh ht
pyri by
Vo
o
by c
9- Selected battery type
lksw
cted agen
Prote AG.
Note
The printed test results are required for warranty claims.

Evaluating the battery test results for the Warranty and Service
Tests
Battery test result Measure
Battery - A- good No measure on the Battery - A- .


Battery - A- good - recharge Charge the Battery - A- (re
fer to
page 31 ) and determine
why the battery is discharg
ing.
Perform a current draw test gen AG. VPerform
olkswagenaAcurrent
G do draw test.
olksw
a
Refer to es n
ot
yV 2.8 Current DrawguTest,
db ara
rise page 28 . nte
tho e or
au ac
ss Charge the Battery - A- and
ce
e
perform the test again. Re

nl
pt
du
an
fer to
itte
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erm
ab
ility
page 31 .
ot p
wit
, is n
Battery - A- , replacing Disconnect the Battery - A-
h re
hole
spec
es, in part or in w
The result replace the battery
t to the co
can occur due to a weak cable
contact.
rrectness of i
Battery cell faulty - replace Replace the Battery - A- .
Refer to Electrical Equip
l purpos
ment; Rep. Gr. 27 ; Battery;

Battery, Removing and In
stalling .
nf
ercia
Check the connection Attach the test terminals di orm

m
atio
rectly to the Battery - A- and
om
n in
not to the battery jump start

or c
thi
terminal.
te
sd
iva
o
r
rp
cu
Evaluating the battery test results for the Maintenance test

o
m
f
en
ng
t.
yi
Co
Cop py
t. rig
gh
Battery - A- good No measure
ht
pyri by
Vo
o
by c lksw
Battery - A- , charge immedi cted Charge the Battery - A- . Re
agen
Prote AG.
ately fer to
page 31 .
Mark as defective Mark the Battery - A- as de
fective.
Check the tester connection Disconnect the Battery - A-
The result check the tester

connection can occur because
the cable contact from the test
terminals is weak.
Check the connection Attach the test terminals di
rectly to the Battery - A- and
not to the battery jump start
terminal.
Noises Wait until the measured value
appears in the display.
2.6 Midtronics Battery Tester -

MCR340VKT-
2.6.1 General Information, page 24 AG. Volkswagen AG d
agen oes
lksw not
2.6.2 Midtronics Battery Tester MCR340VKT Device bDescrip yV
o gu
ara
tion, page 24 rise
d
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u
2.6.3 Battery Test, Performing using Midtronics
ss a Battery Tester ra
c
MCR340VKT , page 25
ce
e
nl
pt
du
an
2.6.4 Test Result Evaluation, page 26
itte
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erm
ab
2.6.5 Midtronics Battery Tester MCR340VKT Troubleshoot
ility
ot p
ing, page 27
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
WARNING
rrectness of i
cautions. Refer to
l purpos
nf
ercia
o
Observe the Midtronics Battery Tester - MCR340VKT- Operating
rm
m
Instructions.
atio
om
n in
c
Midtronics Battery Tester - MCR340VKT- device description.

or
thi
e
Refer to
t
sd
iva
2.6.2 Midtronics Battery Tester MCR340VKT Device De
o
r
rp
cu
o
m
f
en
ng
t.
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Battery test. Refer to t. Cop py
rig
gh ht
yri by
Tester MCR340VKT , page 25 . cop Vo
by lksw
cted agen
Prote
Troubleshooting. Refer to
AG.
2.6.5 Midtronics Battery Tester MCR340VKT Trouble

shooting, page 27 .
2.6.2 Midtronics Battery Tester -

MCR340VKT- Device Description
Only Volkswagen approved battery testers may be used to test
Batteries - A- in Volkswagen vehicles. Use the Midtronics Battery
Tester - MCR340VKT- in the USA and Canada.
Read all safety precautions and operating instructions in the Mid
tronics Battery Tester - MCR340VKT- .
Further information can be found under Self Study Program
No. 234 ; Battery .
The following charging and analysis procedures apply to all Bat
teries - A- , all battery installed locations (engine compartment or
luggage compartment) and all battery purposes (for the starter or
for the second/convenience battery).
Always observe the following points:
Safety precautions
Midtronics Battery Tester - MCR340VKT- set-up guidelines
Display menu
Display button and LED
Procedure in the Midtronics Battery Tester - MCR340VKT-
Operating Instructions

2.6.3 Battery Test, Performing using Midtron

ics Battery Tester - MCR340VKT-
WARNING

cautions. Refer to
1.3 Warnings and Safety Precautions, pagesw3a.gen AG. Volkswagen AG does
k not
Vol gu
d by ara
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ris
utho eo
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a
WARNING ss c
ce
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nl
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du
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ab
used!
ility
ot p
wit
, is n
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starting.
hole
spec
es, in part or in w
t to the co
Requirements
rrectness of i
Read the device description. Refer to
l purpos
2.6.2 Midtronics Battery Tester MCR340VKT Device De

nform
ercia
Visually check the battery. Refer to

m
at
om
ion
c
Open the hood or cover for other component locations of the
in t
or
his
Battery - A- .
ate
do
priv
c
Select the battery type (standard or AGM).
um
for
en
ng
t.
Remove the covers on the Battery - A- from the positive and
yi Co
op py
negative terminals. t. C rig
gh ht
pyri by
Use a fender protector or some type of cover before using any
co Vo
by lksw
cted
equipment inside the engine compartment or inside the pas
agen
Prote AG.
senger compartment.
Close all the doors.
Note

Refer to Midtronics Battery Tester - MCR340VKT- Operating
Instructions.
Procedure
WARNING

used!
starting.
the ignition key.
tor. Refer to
2.1.1 Battery with Color Display, Visual Indicator, Check
ing, page 7 .
Switch on the Midtronics Battery Tester - MCR340VKT- . Refer
to Midtronics Battery Tester - MCR340VKT- Operating In
structions.
. Volkswagen AG
a gen AG d
Connect the red terminalVo(+)
lkswto the positive terminalesof
o
nothe
t gu
Battery - A- . ed
by ara
n ris te
Connect the black tho eo
au terminal (-) to the negative terminal for the r ac
Battery - A- . ss
ce
le
un
pt
an
d
itte
y li
Note
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
Select warranty test in the menu.
es, in part or in w
t to the co
rrectness of i
Note
l purpos
If the test results are needed to process a warranty claim, use the
print function on the Midtronics Battery Tester - MCR340VKT- .
nform
mercia

a
com
tion in
Write down the Battery - A- DIN value taken from the battery
r
te o
thi
label. If the label does not state a DIN value, then enter the
s
iva
do
SAE value.
r
rp
cum
fo
en
g
Enter the DIN value in the Midtronics Battery Tester -

n
t.
yi Co
MCR340VKT- and perform a battery test. Refer to Midtronics . Cop py
Battery Tester - MCR340VKT- Operating Instructions.
ht rig
rig ht
py by
co Vo
If using an SAE value, go to other in the menu and change
by lksw
cted agen
Prote
DIN to SAE. Refer to the Midtronics Battery Tester -
AG.
MCR340VKT- Operating Instructions.

Switch off the Midtronics Battery Tester - MCR340VKT- .
Note
Always use the DIN value on the battery label! Otherwise the test
result will be incorrect.

Battery test results
Battery - A- good None
Good - charge Charge the Battery - A- . Re
fer to
page 31 .


Use Incharge Charge the Battery - A- . Re
fer to
page 31 .
Battery - A- , replacing Replace the Battery - A- .
stalling .
Battery cell defective AGReplace
. Volkswagthe Battery - A- .
en AG
lkswage
n
Refer to Electrical
does
not Equip
byV
o
gu
aa
ed Battery, Removing and rIn nte
oris eo
auth stalling . ra
ss c
2.6.5 Midtronics Battery Tester -
ce
e
nl
pt
du
an
MCR340VKT- Troubleshooting
itte
y li
erm
ab
ility
ot p
Sometimes the display shows the malfunction or the messages
wit
, is n
based on the condition.
h re
hole
The following is a list of the most frequent displayed messages
spec
together with suggested solutions.
es, in part or in w
t to the co
Refer to the Midtronics Battery Tester - MCR340VKT- Operating
Instructions for any messages not listed.
rrectness of i
Display Message Measure
l purpos
No display Make sure the Midtronics

Battery Tester -
nf
ercia
MCR340VKT- test terminals

or
are attached securely to the

m
m
atio
battery terminals.
om
n in
or c
Make sure the battery poles

thi
te
sd
a
are tightened to the tighten

iv
o
r
rp
cu
ing specification (refer to

o
m
f
Electrical Equipment; Rep.

en
ng
t.
yi
Gr. 27 ; Overview - Battery )
Co
Cop py
and are not corroded.
t. rig
gh ht
pyri by
Vo
co lksw
by
Prote
cted Charge the Battery - A- . Re
agen
fer to
AG.
page 31 .
System noises Switch off all electrical con
sumers.
Wait until all electrical equip

ment, which are monitored
by the Vehicle Electrical
System Control Module -
J519- , are switched off.
Remove the key.
Disconnect any doubtful or

standard production electri
cal equipment from the ve
hicle electrical system.
Wait a few minutes and then check again. Refer to
Tester MCR340VKT , page 25 .
Note
If the test was performed at the battery jump start terminal and
the message still does not go away, then perform the test directly
on the Battery - A- .
2.7 Battery Test with Vehicle Diagnostic

Tester
Vehicle Diagnostic Tester
The Battery - A- can also be checked using the Vehicle Diagnostic
Tester when it is installed and without being connected to a bat
tery charger.
Test Prerequisites
No battery charger connected
Battery - A- is connected.
Battery temperature at least +10 C (50 F).
Procedure
Connect the Vehicle Diagnostic Tester . Refer to
1.2 Connect the Vehicle Diagnostic Tester , page 89 .
Select Guided Fault Finding .
Use the GO TO button to select the function/component se
lection and the following menu options one after the other:
Body
Electrical Equipment
01 - OBD-capable systems
61 - battery monitoring agen
AG. Volkswagen AG d
oes
olksw not
V gu
Follow the instructions in the d bdisplay.
y ara
rise nte
ho eo
2.8 Current Draw Test ut ra
s a c
s
ce
le
un
pt
an
d
WARNING
itte
y li
rm
ab
pe
ility

ot
wit

, is n
h re
used!
hole
spec

es, in part or in w
t to the co
starting.
rrectness of i
l purpos
Make sure the correct charging mode is set on the battery charger
so the current draw test is not inaccurate.
nform
ercia
Battery Charger - VAS5095A- . Refer to

3.1.3 Battery, Charging with Battery Charger VAS5059A ,
m
a
com
page 32 .
ion in
r
te o
Battery Charger - VAS5900- . Refer to

thi
s
iva
3.2 Battery Charger VAS5900 , page 37 .

do
r
rp
cum
fo

en
ng
t.
3.3 Battery Charger VAS5903 , page 48 .
yi Co
Cop py
t. rig
gh ht
yri by
28
cop Vo
by lksw
Rep. Gr.27 - Battery, Starter, Generator, Cruise Control Prote
cted AG.
agen
In order to receive an indication as quickly as possible of the bat

tery condition of discharged Batteries - A- , a conclusion can be
made during the charging process using the Battery - A- current
draw as to whether the Battery - A- should be replaced or charged
completely.
Note
In the case of the Battery Tester - VAS6161- , the current draw

test must always be conducted when the test result conduct cur
rent draw test appears in the display.
The current draw test should always be performed if the test using
the Battery Tester with Printer - VAS5097A- had the following re
sults:
1- Starting power sufficient
2- Starting power insufficient
3- Starting power very insufficient
4- cannot be tested - charge the Battery - A- and perform the
test again
5- Battery Tester with Printer - VAS5097A- does not turn on
(no LED, no printout)
Depending on the test results Battery Tester with Printer -
VAS5097A- (refer to 2.4.7 Test Result Evaluation, page 17 ),
additional test steps or work for a clear evaluation of the battery
charge must be made.
By checking a current draw capacity on a Battery - A- during the
charging procedure, it can be determined in a short time whether
a partially discharged or severely discharged Battery - A- can be
come operable again by further charging. Refer
wage
n AG. to
Volkswagen AG
does
3.7 Severely Discharged Batteries,
yV
olkspage 68 . not
gu b ara
ed
Test Prerequisites thoris nte
e or
au ac
When charging a battery,
ss the temperature of the battery must
ce
be at least 10 C.
le
un
pt
an
d
itte
The charger must be able to deliver at least 30 A charge cur

y li
erm
ab
rent, such as on the Battery Charger - VAS5095A- / Battery

ility
ot p
Charger - VAS5900- / Battery Charger - VAS5903- .

wit
is n
h re
When charging with the Battery Charger - VAS5095A- , the

ole,
Battery - A- current draw must be measured using a current

spec
probe ( Test Instrument Set - Current Clamp - 100A -

t to the co
VAS6356/4A- ).
The Battery Charger - VAS5900- and the Battery Charger -
VAS5903- indicate the current draw. The Battery Charger -
rrectne
VAS5900- automatically performs the menu- guided current

draw test.
ss o
Procedure
cial p
f inform
Connect the Battery - A- to the Battery Charger and start the

mer
atio
charging process.
om
n
c
Measure the Battery - A- charge current after five minutes.

or
n thi
te
sd
va
Test Result
i
o
pr
cum
r
fo
The charge current must be above 10% of the nominal capacity

en
ng
t.
yi
5 minutes after charging begins.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Example:
With a 60 Ah battery, the charge current must be greater than 6 A
5 minutes after charging begins.
Charge the Battery - A- completely when the charge current is
greater than 10% of the nominal capacity.
Let the Battery - A- sit for two hours and then perform the bat
tery load test. Refer to 2.4.3 Battery Load Test, page 13 .
If the charge current is less than 10% of the nominal capacity (less
than 6 A for a 60 Ah battery) five minutes after starting the charg
ing, then replace the Battery - A- . Refer to Electrical Equip
ment; Rep. Gr. 27 ; Battery; Battery, Removing and Installing .
In warranty and Goodwill cases, fill out the battery test sheet
and keep it with the Battery - A- .
2.9 Battery, Checking Resting Voltage, Ve

hicles in Storage or Inventory
Special tools and workshop equipment required agen
AG. Volkswagen AG d
oes
olksw not
Analog/Digital Multimeter - FLU83III- d by V gu
ara
rise nte
tho eo
au ra
WARNING ss c
ce
le
un
pt
an
d
itte
y li
cautions. Refer to
erm
ab
ility
ot p
wit
is n
h re
ole,
The resting voltage may only be measured on vehicles in storage
spec
or inventory within the scope of the prescribed maintenance and
t to the co
care work as an assessment criteria for the Battery - A- condition.
The resting voltage measurement serves to determine whether it
is necessary to recharge the Battery - A- on vehicles in storage
rrectne
or inventory. Refer to Maintenance Tables Service for Vehicles
in Storage or Inventory.
ss o
Test Conditions
cial p
f inform
The Battery - A- may not be charged or discharged for at least
mer
atio
two days.
om
n
c
Procedure
or
n thi
te
sd
a
Measure the Battery - A- resting voltage using the Analog/

iv
o
pr
Digital Multimeter - FLU83III- .

um
r
fo
en
ng
t.
yi
Test result
Co
Cop py
t. rig
gh ht
yri
No Load Voltage Charge Level Battery - A- Charge
p by
co Vo
by lksw
cted agen
11.60 V 0% Discharged. Performance capacity diminished completely.
Prote AG.
Charging totally discharged batteries. Refer to
3.7 Severely Discharged Batteries, page 68 .
Measured Value Required Actions

Resting voltage greater than or Resting voltage OK
equal to 12.5 V
Resting voltage lower than 12.5 Charge the Battery - A- . Re
V fer to
page 31 .

3 Battery, Charging
3.1 Battery Charger VAS5095A , page 31
3.2 Battery Charger VAS5900 , page 37
3.5 Battery Tester Charger Kit GRX3000VAS , page 61
3.6 Solar Battery Maintainer VAS6102A , page 67
3.7 Severely Discharged Batteries, page 68
3.1 Battery Charger - VAS5095A-

3.1.2 Battery Charger VAS5059A Device Description,
page 32
3.1.3 Battery, Charging with Battery Charger VAS5059A , en AG. Volkswagen AG
page 32 olks
wag does
no
V t gu
by ara
3.1.4 Severely Discharged Battery, Charging withriseBattery
d
nte
Charger VAS5059A , page 34 au
tho eo
ra
ss c
3.1.5 Battery Charger VAS5059A Support Mode, page 34
ce
le
un
pt
an
d
3.1.6 Battery Charger VAS5059A Maintenance Charging,

itte
y li
page 36
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
WARNING
es, in part or in w
t to the co
cautions. Refer to
rrectness of i
l purpos
In order to prevent damage to the Battery - A- or vehicle, ob

serve the battery type information. Refer to
1.1 Battery Types, page 1 .
nform
mercia
a
com
tion in
r
WARNING
te o
thi
s
iva
do
r
rp

cum
fo

en
ng
t.
yi
used!
Co
Cop py
ht. rig
rig ht
py by
o Vo
starting. by c lksw
cted agen
Prote AG.
The charge current cannot be read on the Battery Charger -

VAS5095A- . The charge current must be measured externally
with a current probe ( Test Instrument Set - Current Clamp - 100A
- VAS6356/4A- ).
Observe the Battery Charger - VAS5095A- Operating Instruc
tions.
Battery Charger - VAS5095A- device description. Refer to
page 32 .
3. Battery, Charging 31
AG. Volkswagen AG d
agen oes
lksw not
Charge the Battery - A- . Refer to byV
o gu
ara
3.1.3 Battery, Charging with Batteryris Charger VAS5059A ,
ed
nte
page 32 . aut
ho eo
ra
ss c
Severely discharged Battery - A- , charging. Refer to
ce
e
nl
3.1.4 Severely Discharged Battery, Charging with Battery
pt
du
an
itte
Charger VAS5059A , page 34 .
y li
erm
ab
Support mode. Refer to
ility
ot p
3.1.5 Battery Charger VAS5059A Support Mode,
wit
, is n
h re
page 34 .
hole
spec
Buffer mode/maintenance charging. Refer to
es, in part or in w
3.1.6 Battery Charger VAS5059A Maintenance Charging,
t to the co
page 36 .
3.1.2 Battery Charger - VAS5059A- Device
rrectness of i
Description
l purpos
The Battery Charger - VAS5095A- is designed to charge all 12 V

Batteries - A- in the VW group.
nf
ercia
orm
The battery is charged without amperage or voltage surges.
m
atio
m
Thereby the on-board electronics will not be affected. It is not

o
n in
c
necessary to remove the Battery - A- from the vehicle or be dis

or
thi
e
connected from the electrical system during charging.

t
sd
iva
o
r
rp
cu
Battery Charger - VAS5095A-
o
m
f
en
ng
t.
yi
1- ON/OFF -Switch (0 = OFF)
Co
Cop py
ht. rig
2- Charge current display (I greater than 12 A)
rig ht
py by
co Vo
by lksw
cted
3- Battery - A- charge current display, partially charged (great
agen
Prote AG.
er than 90 %)
4- Maintenance charging, lights up green when the Battery -
A- is charged
5- Interference indicator
6- Support mode indicator
7- Support Mode/Normal Mode selector switch
8- Charge cable: red charging clamp (+), black charging clamp

(-)
9- Battery Type change switch (on the bottom of the unit)
3.1.3 Battery, Charging with Battery Charger

- VAS5059A-
WARNING

cautions. Refer to
Caution
While charging, always set the battery type to 2.4 V/C (Volts/
Battery Cell). This applies to all Batteries - A- .

Note
WARNING
AG. Volkswagen A
Do not check or charge a Battery - A- when ksw the visual indicator
agen G do
es n
has no color or is bright yellow. dJump
y Vol starting must not be ot g
ua
b
used! se ran
ri tee
o h
ut or
There is a risk of explosionss aduring testing, charging or jump ac
starting.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
Procedure
h re
hole
spec
es, in part or in w
the ignition key.
t to the co
Check the battery type setting on the battery type switch.
Refer to
rrectness of i
page 32 . The battery type switch must be set to 2.4V/C
l purpos
(Volts/Battery Cell).
Connect the red charge terminal (+) to the positive terminal of
nform
ercia
the Battery - A- .
m
at
om
ion
c
in t
Note
or
his
ate
do
riv
On vehicles with a Start/Stop function and an installed Battery

p
cum
or
Monitoring Control Module - J367- , the black charge terminal (-)

f
en
ng
t.
must be connected to the body ground. The Start/Stop system
yi Co
op py
will malfunction when it is connected to the Battery - A- negative t. C rig
gh ht
terminal. yri
p by
co Vo
by lksw
cted agen
Prote AG.
Connect the black charge terminal (-) to the negative terminal
of the Battery - A- /negative connector.
Switch on the Battery Charger - VAS5095A- . Refer to
page 32 .
Charge current displays. Refer to
Fig. Battery Charger -VAS5095A- , page 32 -2- and -3- light
up yellow. The Battery - A- is partially charged (approximately
90 %) when only the yellow LED -3- is on.
If the green LED. Refer to
Fig. Battery Charger -VAS5095A- , page 32 -4- is also on,
then the Battery Charger - VAS5095A- has switched to mainte
nance charging. The Battery - A- is charged.
Switch off the Battery Charger - VAS5095A- . Refer to
page 32 .
Remove the charging clamps from the battery terminals.
Electrical Equipment General Information - Editionks01.2015
wage es n
ol ot g
yV ua
db ran
3.1.4 Severely Discharged Battery, Charging
e
ris tee
tho or
au
with Battery Charger - VAS5059A-
ss
ac
ce
le
un
pt
an
d
itte
WARNING
y li
erm
ab
ility
ot p
wit
is n
cautions. Refer to
h re
ole,
spec
t to the co
The Battery Charger - VAS5095A- automatically detects severely
discharged Batteries - A- and starts the charging process con
rrectne
servatively with a low charge current. The charge current is
automatically adjusted to the battery charge state.
s
For information in the chapter. Refer to
s o
cial p
f
inform
mer
The battery voltage must be at least 0.6 V!
atio
m
Severely discharged Batteries - A- in vehicles must be re

o
n
c
i
or
n
placed prior to delivery. Pre-existing damage cannot be ruled
thi
te
out.
sd
iva
o
pr
cum
r
fo
en
ng
WARNING
t.
yi Co
Cop py
ht. rig
rig ht
py by
o Vo
has no color or is bright yellow. Jump starting must not be by c lksw
cted agen
used! Prote AG.

starting.
Procedure
Charge the Battery - A- . Refer to
page 32 .
3.1.5 Battery Charger - VAS5059A- Support

Mode
General Information
The support mode provides the vehicle electrical system with
voltage when the Battery - A- is removed or disconnected.
For more information. Refer to the Battery Charger - VAS5095A-
Operating Instructions.
The support mode is used for the following situations:
Vehicle electrical system support mode with the Battery - A-
not installed
Maintaining the voltage when the battery is being replaced
Systems test without the Battery - A-

WARNING

cautions. Refer to
WARNING
kswage es n
Do not check or charge a Battery - A- when the visual indicator ol ot g
byV ua
has no color or is bright yellow. Jump starting must ir se not be
d ran
tee
used! autho
or
ac
ss
ce
e
nl
starting.
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
Procedure
hole
spec
es, in part or in w
t to the co
Caution
The polarity protection of the charger clamps is not active
rrectness of i
in the operation mode charging severely discharged bat
teries/Support mode. Connect the charger clamps to the
l purpos
battery terminals correctly according to polarity!

It can result in sparks due to short circuit.
nf
ercia
orm
This constitutes an explosion risk.
m
atio
om
Make sure the charging clamp connections are secure.
n in
or c
thi
te
sd
iva
o
r
rp
cu
Remove the Battery - A- . Refer to Electrical Equipment;
o
m
f
en
ng
Rep. Gr. 27 ; Battery; Battery, Removing and Installing .

t.
yi Co
Cop py
t. rig
gh ht
yri
Caution p by
co Vo
by lksw
cted agen
Prote AG.
Whenever the Battery - A- is removed, be careful to prevent
contact between the connected charge clamp on the positive
terminal and the body ground. Likewise prevent contact be
tween the battery terminals.
Clamp the red charging clamp (+) to the vehicle positive bat
tery terminal.
Note

will malfunction when it is connected to the Battery - A- negative
terminal.
Attach the black charging clamp (-) to the vehicle battery neg
ative terminal.
Check the setting for the support mode/standard opera-
tion switch. Refer to
page 32 . Support mode must be on.
Check correct polarity connection of charger clamps.

Switch on the Battery Charger - VAS5095A- . Refer to
page 32 .
The Battery Charger - VAS5095A- starts the support mode.
End the Battery Support Mode
Switch off the Battery Charger - VAS5095A- . Refer to
page 32 .
Disconnect the Battery Charger - VAS5095A- from the power.
3.1.6 Battery Charger - VAS5059A- Mainte

nance Charging
WARNING

cautions. Refer to
WARNING

used!
AG. Volkswagen
There is a risk of explosion during testing,
ksw charging or jump
agen AG do
es n
starting. y Vol ot g
ua
db r e an
ris tee
These Batteries - A- must be ureplaced.
tho or
a ac
ss
ce
le
un
pt
In maintenance charging, the Battery Charger - VAS5095A- pro

an
d
itte
y li
vides safe charging and preserves the charge of the Battery - A- .

rm
ab
pe
ility
Procedure
ot
wit
, is n
h re
Proceed as if charging the Battery - A- . Refer to

hole

spec
page 32 .
es, in part or in w
t to the co
If the Battery - A- is discharged by an electrical consumer during

maintenance charging, the Battery Charger - VAS5095A- auto
matically supplies the appropriate charge.
rrectness of i
Maintenance charging can be performed without time restrictions.

l purpos
The Battery - A- can be used constantly.

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

3.2 Battery Charger - VAS5900-

3.2.2 Battery Charger VAS5900 Device Description,
page 38
3.2.3 Battery, Charging with Battery Charger VAS5900 , page
38
3.2.4 Battery Charger VAS5900 Service Charge, page 40
Charger VAS5900 , page 43
3.2.6 Battery Charger VAS5900 Support Mode, page 44
3.2.7 Battery Charger VAS5900 Maintenance Charging, page
46
WARNING

cautions. Refer to
1.3 Warnings and Safety. VPrecautions,
olkswage
page 3 .
n AG n AG d
wage oes
Volks not
gu
by ara
ed nte
oris eo
au WARNING
th ra
ss c
ce
le

un
pt
an
d

itte
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used!
rm
ab
pe
ility

ot
wit
, is n
starting.
h re
hole
spec

es, in part or in w
t to the co
The effective charge current for the Battery Charger - VAS5900-

can be read directly on the Battery Charger - VAS5900- .
rrectness of i
Observe the Battery Charger - VAS5900- Operating Instructions.

l purpos
Battery Charger - VAS5900- device description. Refer to

3.2.2 Battery Charger VAS5900 Device Description, page
nform
ercia
38 .
m
a
com

ion in
3.2.3 Battery, Charging with Battery Charger VAS5900 ,

r
te o
thi
page 38 .
s
iva
do
r
rp
Service charge. Refer to

um
fo
en
3.2.4 Battery Charger VAS5900 Service Charge,

ng
t.
yi Co
page 40 . ht. Cop py
rig
rig ht
py by
co Vo
by lksw
cted agen
Prote
Charger VAS5900 , page 43 .
AG.

3.2.6 Battery Charger VAS5900 Support Mode,
page 44 .
Maintenance charging. Refer to
3.2.7 Battery Charger VAS5900 Maintenance Charging,
page 46 .
3.2.2 Battery Charger - VAS5900- Device De

scription
The Battery Charger - VAS5900- is designed to charge all 12 V
Battery Charger - VAS5900-
Control field overview

1- Display
2- -button Up
3- -button Down
4- START/STOP -button
AG. Volkswagen AG d
agen oes
5- INFO -button Volksw not
gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte

y li
erm
ab
- VAS5900-
ility
ot p
wit
, is n
h re
hole
Battery Charger - VAS5900- spec

es, in part or in w
t to the co
WARNING
rrectness of i

l purpos
cautions. Refer to
nform
mercia
at
om
WARNING
on
c
in t
or
his
te

a
do
riv

p
cum
or
used!
f
en
ng
t.
yi Co
op
There is a risk of explosion during testing, charging or jump C py
t. rig
starting.
gh ht
pyri by
Vo
o
by c lksw
These Batteries - A- must be replaced. cted agen
Prote AG.
Note

AG. Volkswagen AG d
Procedure agen oes
olksw not
byV gu
a
Turn offristhe ignition and all electrical consumersranand
ed
tee remove
the ignition
ut
ho key. or
a ac
ss
Connect the Battery Charger - VAS5900- to the power supply.
ce
le
un
The last selected mode is shown on the display. Refer to
pt
an
d

itte
y li
erm
38 .
ab
ility
ot p
Set the battery type with the INFO button.
wit
is n
h re
ole,
The symbol -1- for standard charge of wet batteries or the sym
spec
bol -2- for standard charge of Gel/Absorbent Glass Mat (AGM)

batteries is indicated in the display.
t to the co
Set the battery capacity (Ah) on the Battery - A- to be charged
with the corresponding button or button.
rrectne
the Battery - A- .
ss o
cial p
f inform
mer
Note
atio
om
n
c
i
or
n thi
te
sd
a

iv
o
pr

um
r
fo
en
ng
terminal.
t.
yi Co
Cop py
ht. rig
ht
rig by
opy Vo
by c lksw
cted agen
Prote AG.
The Battery Charger - VAS5900- recognizes the nominal voltage
of the connected Battery - A- (6 V/12 V/24 V) and begins the
charging process automatically.
The Battery Charger - VAS5900- begins the final charging when

the charge level is approximately 80 to 85 %. The fourth bar is
indicated on the display -1-. The Battery - A- is ready to be used.
With a charge status of 100 %, all bars are indicated on the display
-1-.
With the standard charge, parallel operation of electrical con
sumers during the charging process is possible. The charging
time is lengthened by this.
Depending on the battery type, the Battery Charger - VAS5900-
switches to maintenance charging after 1 to 7 hours. To reach a
100% charge level, the Battery - A- should remain connected to
the Battery Charger - VAS5900- .
Possible malfunctions and how they are handled
1- Displayed voltage does not match the nominal voltage:
Hold down the button or button until the charging process
begins.
2- Displayed battery voltage does not match the nominal volt
age - the charging process has w
already
agen
AG.begun:
Volkswagen AG
doe s no
ks
Vol t gu
Press the START/STOP button
ed
by two times. ara
ris nte
o eo
Hold down the button
aut or button until the charging process
h
ra
s c
begins again. s
ce
e
nl
pt
du
3- The Battery Charger - VAS5900- does not recognize the
an
itte
y li
Battery - A- , if the battery voltage is less than 2V:
erm
ab
ility
ot p
The display remains unchanged.
wit
, is n
h re
The selected battery type and Ampere hours (Ah) are displayed.
hole
spec
Battery - A- charging, ending
es, in part or in w
Press the START/STOP -button. t to the co

rrectness of i
Disconnect the Battery Charger - VAS5900- from the power.

l purpos
3.2.4 Battery Charger - VAS5900- Service

nf
ercia
Charge
rm
m
atio
m

o
n in
or c
thi
e

t
sd
iva
o
r
rp
cu
o
m
f
WARNING
en
ng
t.
yi Co
Cop py
ht. rig
Risk of injury. Follow all warning messages and safety pre rig ht
py by
cautions. Refer to co Vo
by lksw
cted agen
Prote AG.
Caution
Service charging is not permitted for VW vehicles, because

voltage surges can damage the on-board electronics.
The Battery - A- must always be disconnected from the vehicle
electrical system when using the service charge mode.

WARNING

used! en AG. V
olkswagen AG
g does
swa
There is a risk of explosion during
by
Vol testing, charging or jump
k not
gu
ara
starting. ris
ed
nte
tho eo
These Batteries - A- must
ss
au be replaced. ra
c
ce
e
nl
pt
du
an
itte
y li
erm
ab
Caution
ility
ot p
wit
, is n
Always set the mode that corresponds to the Battery - A- during
h re
hole
the charging process. Refer to the Battery Charger - VAS5900-
spec
es, in part or in w
t to the co
Service Charging is suitable for:
Wet batteries having a visual indicator which allows charg
rrectness of i
ing (visual indicator black or green).
l purpos
The Service charge (SERV) mode is only used with sulfated
nform
ercia
Batteries - A- . The Battery - A- with voltages greater than 14.4 V

is charged. A partial removal of the sulfation layer can result from
m
at
this. Check the visual indicator after charging, immediately before
om
ion
the Battery - A- is used. Refer to
c
in t
or
his
ate
page 10 .
do
priv
cum
for
en
ng
t.
yi Co
Note t. Cop py
rig
gh ht
yri by
cop Vo
by lksw
cted agen
Prote AG.
Procedure
the ignition key.
38 .

The symbol -1- for service charge of wet batteries or the symbol
-2- for service charge of Gel/Absorbent Glass Mat (AGM) bat
teries is indicated in the display.
the Battery - A- .
Note

agen
AG. Volkswagen AG d
Monitoring Control Module - J367- , the black charge Volksw terminal (-)
oes
not
by gu
d ara
ise
will malfunction when it is connected toththe
o Battery - A- negative
r nte
eo
terminal. sa
u ra
c
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
The Battery Charger - VAS5900- recognizes the nominal voltage
ot p
wit
is n
h re
ole,
spec
t to the co
the charge level is approximately 80 to 85% of the battery voltage.
The fourth bar is indicated on the display -1-. The Battery - A- is
now ready to be used.
rrectness
Note
o
cial p
f inform
A successful service charge depends on the degree of sulfation
mer
on the Battery - A- . atio

om
n
c
i
or

thi
te
sd
iva
o
r

p
cum
r
fo
en
ng

t.
yi Co
op
begins.
C py
t. rig
gh ht
yri by
2- Displayed battery voltage does not match the nominal volt cop Vo
by lksw
age - the charging process has already begun:
cted agen
Prote AG.
Press the START/STOP button two times.

begins.
3- The charger does not recognize a Battery - A- , when the
battery voltage is less than 2 V:
The set operating mode and Ampere-hours (Ah) are displayed.
Press the START/STOP -button.


with Battery Charger - VAS5900-
WARNING AG. Volkswagen AG d

agen oes
olksw not
byV gu
ara
d
Risk of injury. Follow all warning messages
orise and safety pre nte
cautions. Refer to
h eo
aut ra
1.3 Warnings and Safety Precautions,
ss page 3 . c
ce
e
nl
pt
du
an
itte
y li
erm
ab
WARNING
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
used!
t to the co
starting.
rrectness of i
l purpos
nf
ercia
Caution
orm
m
atio
m

o
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
Always set the mode that corresponds to the Battery - A-

t.
yi Co
op
during the charging process. Refer to the Battery Charger C py
ht. rig
- VAS5900- Operating Instructions. rig ht
py by
co Vo
by lksw
The Battery Charger - VAS5900- does not recognize the cted agen
Prote AG.
severely discharged Battery - A- . Refer to
Do not touch START/STOP button when battery cables are
incorrectly connected! The Battery Charger - VAS5900-
can become damaged.
The Battery Charger - VAS5900- will not automatically recognize

the Battery - A- for Batteries - A- with a voltage less than 2 V.
Note
For information. Refer to the chapter

Severely discharged batteries in vehicles must be replaced
prior to delivery. Pre-existing damage cannot be ruled out.
Procedure
the ignition key.

38 .
The symbol -1- for service charge of wet batteries or the symbol
the Battery - A- .
Note

terminal.

Press the START/STOP button for about 5 seconds. The menu
selection Charging severely discharged batteries/Support AG. Volkswagen AG d
agen
mode is activated. Volksw
oes
not
y gu
db ara
Press the corresponding -button or button to adjust risthe
e nte
ho eo
battery voltage(6 V/12 V/24 V). au
t ra
ss c
ce
le
un
pt
an
d
Note
itte
y li
erm
ab
ility
If no button is touched within five seconds, the Battery Charger -
ot p
wit
VAS5900- will return to the main menu (operating mode selec
is n
h re
tion).
ole,
spec
Select the battery voltage by pressing the START/STOP button.
t to the co
Then the inquiry about the correct polarity of the charging clamps
is made.
rrectne
ss
Confirm charging clamps are connected to correct poles via
o
cial p
START/STOP button.
inform
mer
The Battery Charger - VAS5900- starts to charge the severely

atio
m
discharged Battery - A- .
o
n
c
i
or
Battery - A- Charging, Ending

thi
te
sd
iva
o
r

p
cum
r
fo
en
ng

t.
yi Co
Cop py
. rig
ht ht
rig by
copy Vo
by lksw
cted agen
3.2.6 Battery Charger - VAS5900- Support
Prote AG.
Mode

General Information
For more information. Refer to the Battery Charger - VAS5900-
not installed
WARNING

cautions. Refer to
WARNING

used!
starting.
These Batteries - A- must be replaced. n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
o
Procedure auth or
ac
ss
ce
le
un
pt
Caution
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
It can result in sparks due to short circuit.
t to the co
rrectness of i

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Caution


the Battery - A- .
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terminal.

of the Battery - A- /negative connector. olksw AG. V agen AG
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Press the START/STOP button for about olks 5 seconds. The menu s not g
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Press the correspondings -button or button to adjust the
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START/STOP button.
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The Battery Charger - VAS5900- starts the Battery - A- support

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End the Battery Support Mode

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Remove the charging clamps from the battery terminals. pyri by
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Disconnect the Battery Charger - VAS5900- from the power. Prote AG.
3.2.7 Battery Charger - VAS5900- Mainte

nance Charging
maintenance charging, the Battery Charger - VAS5900- automat
ically supplies the appropriate charge.


The Battery - A- can be used constantly.
Note
Observe the maintenance notes of the battery manufacturer.
WARNING

cautions. Refer to
WARNING

used!
starting.
If the Battery - A- is fully charged, the Battery Charger - VAS5900-

starts maintenance charging.
Procedure
AG. Volkswagen AG d
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Proceed as if charging the Battery
Vol
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3.2.3 Battery, Charging d bywith Battery Charger VAS5900 ,guar
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With a charge status sof
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100 %, all bars are indicated on the display
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-1-.
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page 49
49
3.3.4 Battery Charger VAS5903 Refresh Charge, page 51
Charger VAS5903 , page 54
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3.3.6 Battery Charger VAS5903 Support Mode, page 55 Volkswa not
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cautions. Refer to
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WARNING
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Battery Charger - VAS5903- device description. Refer to gh ht
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49 .
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page 49 .
Refresh charge. Refer to
3.3.4 Battery Charger VAS5903 Refresh Charge,
page 51 .
3.3.6 Battery Charger VAS5903 Support Mode,
page 55 .
Maintenance charging. Refer to
page 57 .


scription
The Battery Charger - VAS5903- is designed to charge all 12 V
AG. Volkswagen AG d
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Control field overview
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1- Display
ab
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2- -button Up
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3- -button Down
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4- START/STOP -button
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5- INFO -button
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- VAS5903-
atio
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WARNING

used!
starting.
Note
Procedure
the ignition key.
The last selected operation mode is shown on the display.
Refer to
49 .
The symbol -1- for standard charge of wet batteries or the sym
bol -2- for standard charge of Gel/Absorbent Glass Mat (AGM)
batteries is indicated in the display.
the Battery - A- .
Note

terminal.
swage es n
Connect the black charge terminal (-) to the by V negative terminal
olk ot g
ua
of the Battery - A- /negative connector. ir se
d ran
tee
tho
or
The Battery Charger - VAS5903- recognizes
ss
au
the nominal voltage ac
ce
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un

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ility
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the charge level is approximately 80 to 85%. The fourth bar is

wit
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indicated on the display -1-. The Battery - A- is ready to be used.

h re
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spec
t to the co
rrectness o
cial p
f inform
mer
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With a charge status of 100%, all bars are indicated on the display
-1-.
With the battery type standard charge, parallel operation of
electrical consumers during the charging process is possible. The
charging time is lengthened by this.
Depending on the battery type, the Battery Charger - VAS5903-
switches to maintenance charging after 1 to 7 hours. To reach a
100% charge level, the Battery - A- should remain connected to
the Battery Charger - VAS5903- .
begins.
2- Displayed battery voltage
n AG. Vdoes
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rated voltage -
charging process wage
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Press theorisSTART/STOP
ed button two times. nte
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Holdssdown
a the button or button until the charging processc
begins again.
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The display remains unchanged. wit

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The selected battery type and Ampere hours (Ah) are displayed.
hole
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3.3.4 Battery Charger - VAS5903- Refresh

nform
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Charge
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cautions. Refer to
by lksw
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AG.
WARNING

used!
starting.
Caution
Refresh charging is not permitted for VW vehicles, because

voltage surges can damage the on-board electronics.
The Battery - A- must always be disconnected from the vehicle
electrical system when using the refresh charge mode.
Caution
wage e
Always set the mode that ycorresponds
Volks
to the Battery - A-s nduring
ot g
the charging process.risRefer to the Battery Charger - VAS5903-
b ua
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or
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Refresh charging is suitable for wet batteries, which must be
s
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filled with distilled water.

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Do not use the refresh charge mode on maintenance-free wet
erm
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batteries.
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The Refresh charging REFR operating mode is only used for
spec
Batteries - A- that are possibly faulty (sulfation). The Battery - A-
es, in part or in w
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is then charged to the maximum specific gravity of the electrolyte
and the plates are reactivated (removal of sulfation layer).
Note rrectness of i
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nform
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Procedure
m
at
om
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or
the ignition key.

his
ate
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p
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or

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Refer to
Co
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3.3.2 Battery Charger VAS5903 Device Description, page t. C rig
gh ht
49 . pyri by
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Prote AG.


The symbol -1- for refresh charge of wet batteries or the symbol
-2- for refresh charge of Gel/Absorbent Glass Mat (AGM) batter
ies is indicated in the display.
the Battery - A- .
Note

terminal.
wage e
Connect the black charge Vterminal
olks (-) to the negative terminal
s no
t gu
by
of the Battery - A- /negative
ised connector. ara
n r tee
tho
The Battery Charger au - VAS5900- recognizes the nominal voltage
or
ac
ss
ce
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un
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an
d
itte
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erm
ab
ility
ot p
the charge level is approximately 80 to 85 % of the battery voltage.
wit
is n
The fourth bar is indicated on the display -1-. The Battery - A- is
h re
now ready to be used.
ole,
spec
t to the co
Note
A successful refresh charging depends on the degree of sulfation

rrectne
on the Battery - A- .
ss o

cial p
f inform

mer
atio
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o
n
c
begins.
i
or
n thi
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sd
a
2- Displayed battery voltage does not match rated voltage -

iv
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pr
charging process has already begun:

um
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Press the START/STOP button two times.
Co
Cop py
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Vo
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begins.
c by lksw
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The set operating mode and Ampere-hours (Ah) are displayed.
AG. Volkswagen AG d
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with Battery Chargerri - VAS5903-
ed
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Special tools and workshop equipment
ss required c
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nl
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du
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itte
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ab
ility
WARNING
ot p
wit
, is n
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spec
cautions. Refer to
es, in part or in w
t to the co
rrectness of i
WARNING
l purpos

nform
ercia
used!
m
at
om
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starting.
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a
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Caution
t. rig
gh ht
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Always set the mode that corresponds to the Battery - A-
during the charging process. Refer to the Battery Charger
- VAS5903- Operating Instructions.
The Battery Charger - VAS5903- does not recognize the
severely discharged Battery - A- . Refer to
can become damaged.
The Battery Charger - VAS5903- will not automatically recognize

the Battery - A- for Batteries - A- with a voltage less than 2 V.
Note
For information. Refer to the chapter

The Battery - A- temperature must be at least 10 C (50 F).
Severely discharged batteries in vehicles must be replaced
prior to delivery. Pre-existing damage cannot be ruled out.
Procedure
the ignition key.

Refer to
49 . olks
wage es n
o V t gu
by ara
Set the battery type with the INFO
ris
ed button. nte
ho eo
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The symbol -1- for service charge
ss
a of wet batteries or the symbol ra
c
ce
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ot
wit
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the Battery - A- .
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es, in part or in w
t to the co
Note
rrectness of i
l purpos

terminal.
nform
mercia
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com
t
ion in
r
te o
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selection Charging severely discharged batteries/Support
um
fo
mode is activated.
en
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t.
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Press the corresponding -button or button to adjust the
. C rig
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battery voltage(6 V/12 V/24 V). py by
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Note

tion).

is made.
START/STOP button.
The Battery Charger - VAS5903- starts to charge the severely

discharged Battery - A- .
Battery - A- Charging, Ending
3.3.6 Battery Charger - VAS5903- Support

Mode
General Information
not installed
WARNING

cautions. Refer to
WARNING

used!
There is a risk of explosion during testing, charging or jump AG. Volkswagen AG d
agen
starting. Volksw
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not
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These Batteries - A- must be replaced. rise nte
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Procedure
nl
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du
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ab
Caution
ility
ot p
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, is n
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hole
spec
es, in part or in w
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It can result in sparks due to short circuit. rrectness of i
l purpos
Make sure the charging clamp connections are secure.

nform
ercia

can become damaged.
m
at
om
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e

at
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p
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The last selected operation mode is shown on the display. C py
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Refer to
gh ht
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49 .
agen
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Caution


the Battery - A- .
AG. Volkswagen AG d
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Note o lksw not
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On vehicles with a Start/Stop function and anauinstalled
tho
Battery eo
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Monitoring Control Module - J367- , the black
s charge terminal (-)
s c
ce
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un
pt
an
d
itte
terminal.
y li
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ab
ility
ot p
wit
is n
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ole,
spec
t to the co
selection Charging severely discharged batteries/Support
mode is activated.
Press the corresponding -button or button to adjust the
rrectne
battery voltage(6 V/12 V/24 V).
ss o
cial p
f
Note
inform
mer
atio
m

o
n
c
i
tion).
or
n thi
te
sd
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t.
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Co
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is made.
t. C rig
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Vo
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START/STOP button.
The Battery Charger - VAS5903- starts the Battery - A- support

mode.
End the battery support mode
3.3.7 Battery Charger - VAS5903- Mainte

nance Charging
maintenance charging, the Battery Charger - VAS5903- automat
ically supplies an appropriate charge.
ks wage es n
Vol ot g
by ua
The Battery - A- can be used constantly. ris
ed ran
tee
tho or
s au ac
s
Note
ce
le
un
pt
an
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itte
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Observe the maintenance notes of the battery manufacturer.
rm
ab
pe
ility
ot
wit
, is n
h re
WARNING
hole
spec
Risk of injury. Follow all warning messages and safety pre es, in part or in w
t to the co
cautions. Refer to
rrectness of i
l purpos
WARNING
nform
ercia

m
a
com
ti
used!
on in
r
te o
thi
s
iva
do
starting.
r
rp
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t.
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Cop py
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If the Battery - A- is fully charged, the Battery Charger - VAS5903- cop Vo
by lksw
starts maintenance charging. cted agen
Prote AG.
Procedure
Proceed as if charging the Battery - A- . Refer to
page 49 .
With a charge status of 100%, all bars are indicated on the display
-1-.


page 59
60
WARNING

cautions. Refer to
WARNING

used!
There is a risk of explosion during testing, charging or jumpn AG. Volkswagen AG do
starting. wage es n
olks ot
yV gu
db ara
These Batteries - A- must be replaced. rise nte
tho eo
s au ra
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nl
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du
an
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Battery Charger - VAS5906- device description. Refer to
y li
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ab
ility
ot p
59 .
wit
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spec
es, in part or in w
page 60 .
t to the co
scription rrectness of i
l purpos

The Battery Charger - VAS5906- was developed especially for
nform
ercia
charging the vehicle electrical system while the vehicle is on dis

play.
m
at
om
io
It supplies for automatic charging of 3 - 300 Ah for starter batter

n
c
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r
ies.
o
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ate
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The 14.4 V maximum charging voltage is not exceeded. All elec

p
cum
or
trical consumers will be supported up to 30 A by the support

f
en
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charging.
n
t.
yi Co
Cop py
After the battery - A- is completely charged, the Battery Charger
t. rig
gh ht
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- VAS5906- switches into the maintenance charging for long-term cop Vo
by lksw
operation. cted agen
Prote AG.
The Battery Charger - VAS5906- starts automatically and does

not need any adjustments. Only the charging terminals and the
network cable need to be connected.
Control Field Overview

1- 25% charge display
5- Ready-to-use display
6- Pushing the START/STOP and Setup buttons will stop and
start the charging process. Enter into the setup menu and
select characteristic line type (hold for 10 seconds)
7- Display malfunction

- VAS5906-
WARNING

cautions. Refer to
WARNING
Volkswa
Do not check or charge a Batteryksw
a-geA-
n Awhen
G.
thegvisual
en AG
dindicator
oes
has no color or is brightbyyellow.
Vol
Jump starting must not not
gbe
ua
used! ris
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te
tho eo
There is a risk of
ss
aexplosion
u
during testing, charging or jump ra
c
starting.
ce
e
nl
pt
du
an

itte
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ab
ility
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Procedure
, is n
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hole
spec
the ignition key.

es, in part or in w
t to the co
Place the Battery Charger - VAS5906- in the engine compart

ment or under the vehicle.
rrectness of i

l purpos
The Battery Charger - VAS5906- is in idle, the display comes on

when it is ready to be used.
nform
ercia
WARNING
m
at
om
ion
c
in t

or
his
e
cautions. Refer to
at
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p
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for
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t.
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Connect the red charge terminal (+) to the positive terminal of t. C rig
gh ht
the Battery - A- . pyri by
Vo
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by c lksw
cted agen
Prote AG.

Note

terminal.

The charging process starts after approximately two seconds.
LEDs show the battery charge level of the Battery - A- . When all
the lights are on, the Battery - A- is charged.
When the Battery - A- is completely charged, the Battery Charger
- VAS5906- automatically switches to maintenance charging.
Caution
Sparks can result if the charging terminals are removed too

early. End the charging process by pressing the START/STOP
button.

3.5 Battery Tester ChargerwaKit

gen A-G
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does
GRX3000VAS- d by V olks not
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3.5.1 General Information,utpage
ho 61 or
a ac
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3.5.2 Battery Tester Charger Kit GRX3000VAS Device De
ce
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nl
scription, page 62
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itte
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3.5.3 Battery, Charging with Battery Tester Charger Kit

erm
ab
GRX3000VAS , page 63
ility
ot p
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, is n
3.5.4 Battery Tester Charger Kit GRX3000VAS Troubleshoot

h re
ing, page 65
hole
spec
es, in part or in w

t to the co
WARNING
rrectness of i
l purpos

cautions. Refer to
nform
mercia
at
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c
in t
or
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ate
do
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AG. Volkswagen AG d
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Beetle 2012 , Golf 2015 , Golf Variant 2007 aut , Golf Variant 2010 ... ra
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Electrical Equipment General Information - Edition 01.2015 s
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ab
WARNING
ility
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is n
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spec
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starting.
rrectne
ss
Observe the Battery Tester Charger Kit - GRX3000VAS- Oper
o
cial p
f i
ating Instructions.
nform
mer
Battery Tester Charger Kit - GRX3000VAS- device descrip
atio
tion. Refer to om
n
c
i
3.5.2 Battery Tester Charger Kit GRX3000VAS Device or
n thi
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Description, page 62 .
t
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GRX3000VAS , page 63 . Cop py
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Battery Tester Charger Kit - GRX3000VAS- troubleshooting. p by
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Refer to
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3.5.4 Battery Tester Charger Kit GRX3000VAS Trouble
AG.
shooting, page 65 .
3.5.2 Battery Tester Charger Kit -

GRX3000VAS- Device Description
Only Volkswagen approved battery chargers may be used to
charge Batteries - A- in Volkswagen vehicles. Only the Battery
Tester Charger Kit - GRX3000VAS- battery charger is used in the
USA and Canada.
The Battery Tester Charger Kit - GRX3000VAS- battery charger
combines battery charging with checking the charge level and
testing the battery.
The charging and analysis procedures apply to all Batteries - A- ,
all battery installation locations (engine compartment or luggage
compartment) and all battery designated usage (for the starter or
for the second/convenience battery).
Always observe the following points:
Safety precautions
Midtronics Battery Tester - MCR340VKT- set-up guidelines
Display menu
Display button and LED
Procedure in the Midtronics Battery Tester - MCR340VKT-
Operating Instructions
For additional information. Refer to Self Study Program No.
234 ; Vehicle Batteries .
WARNING

cautions. Refer to

WARNING
Keep open flame and sparks away from the Batteries - A- and
do not smoke.
The Battery Tester Charger Kit - GRX3000VAS- must be
switched off when connecting or disconnect the cables.
Do not remove the plugs while charging.
Overcharging sulfated Batteries - A- can cause an explosion.
Precision tools may not be kept in areas where batteries are
charged. Chemical reactions can lead to corrosion.
WARNING
n AG. Volkswagen A
Do not check or chargeoalksBattery
wage - A- when theGvisual
does indicator
not
has no color or isd bright
by V yellow. Jump starting must gunot be
ara
used! orise nte
e h
ut or
There is a srisk
s a of explosion during testing, charging or jump ac
starting.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
3.5.3 Battery, Charging with Battery Tester h re

hole
Charger Kit - GRX3000VAS- spec

es, in part or in w
t to the co
Requirements
WARNING
rrectness of i
l purpos

used!
nf
ercia
orm

m
atio
m
starting.
o
n in
or c
thi

te
sd
iva
o
r
rp
cu
o
m
f
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ng
Output - setup (unit number/date/ time), performing. Refer to

t.
yi Co
op
the Battery Tester Charger Kit - GRX3000VAS- Operating In C py
t. rig
structions.
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General information, checking. Refer to cted agen
Prote AG.
3.5.2 Battery Tester Charger Kit GRX3000VAS Device
Description, page 62 .
Battery - A- , visually inspecting. Refer to
Close all the vehicle doors.
Note

For more information. Refer to the Battery Tester Charger Kit
- GRX3000VAS- Operating Instructions.
Procedure
the ignition key.
olkswagen AG
en AG. V
Connect the red charge terminal (+) to the positive
ksw terminal of
ag does
not
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the Battery - A- . ed
by gu
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terminal.
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t to the co
Connect the Battery Tester Charger Kit - GRX3000VAS- to the
rrectness of i
power supply.
l purpos
Switch the ON/OFF switch on the Battery Tester Charger Kit -

GRX3000VAS- to ON.
nform
ercia
Select charging mode (automatic or manual).

m
at
om
ion
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in t
or
his
ate
do
riv
Select the type of test (Warranty or other). Note any other ad

p
cum
or
ditional details (depending on the type of test).

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For more information. Refer to the Battery Tester Charger Kit
- GRX3000VAS- Operating Instructions.
Select the necessary menu points for the test type warranty.
The Battery Tester Charger Kit - GRX3000VAS- checks the Bat

tery - A- and starts the charging process. The display then show
one of 3 results with the exact charging time.
Result Measure
Battery - A- good The Battery - A- can be used
again.
Charging is required The test shows a low state
of charge.
The charging process be
gins and the exact duration
for the charging will be dis
played
The cold start performance
and the remaining charging
time are displayed and up
dated regularly.
Battery - A- , replacing Battery - A- defective. The

charging process is interrupted.
Replace the Battery - A- .
stalling .

Note
If other malfunction messages or text displays, other than the

ones already mentioned, appear in the display on the Battery
Tester Charger Kit - GRX3000VAS- battery charger, then refer to
chapter
3.5.4 Battery Tester Charger Kit GRX3000VAS Troubleshoot
ing, page 65 .
WARNING
If the Battery - A- starts to vent gas heavily, stop the charging

process. Press the Stop button on the front side.
After the charging and testing process is completed, the Battery

Tester Charger Kit - GRX3000VAS- will display battery good or
replace the battery and the total charging time.
Depending on the individual circumstance (Warranty Claim, Re
pair Order, Evaluation and File), there are 3 possible messages:
Produce a test code (possible only after automatic charging
and testing).
Print last test result (for Warranty)
Display the last test result.
Note
For more information. Refer ton Athe

. VBattery
olkswagenTester Charger Kit -
GRX3000VAS- Operating ge G
waInstructions.
AG do
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Battery - A- charging,
tho
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Removess the charging clamps from the battery terminals.
ce
le
un
pt
Disconnect the Battery Tester Charger Kit - GRX3000VAS- .

an
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itte
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erm
ab
3.5.4 Battery Tester Charger Kit -

ility
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GRX3000VAS- Troubleshooting
wit
is n
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ole,
Sometimes the display shows the malfunction or the messages

spec
based on the condition.

t to the co
The following is a list of the most frequent displayed messages

together with suggested solutions.
rrectne
Note
ss o
cial p
f i
For any messages not listed. Refer to the Battery Tester Charger
nform
Kit - GRX3000VAS- Operating Instructions.

mer
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Display Message Measure

Check the connection Make sure the Battery Test
er Charger Kit - AG. Volkswagen AG d
GRX3000VAS- charging lksw
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not
clamps are attached se d by V o gu
ara
curely to the battery termi
orise nte
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nals. au
th
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ce
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Make sure the battery pole
nl
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is tightened to the tightening
an
itte
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specification and is not cor
erm
ab
roded.
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Terminals connected? Battery Tester Charger Kit -
, is n
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GRX3000VAS- safety function.
hole
spec
Connect the charging
es, in part or in w
clamps to the Battery - A-
t to the co
before starting the charging
process.
System noises Switch off all electrical con
rrectness of i
sumers.
l purpos
Wait until all electrical equip

ment, which are monitored
nf
ercia
by the Vehicle Electrical
orm
System Control Module -
m
atio
m
J519- , are switched off.

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or c
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Remove the key.

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Disconnect any doubtful or
o
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standard production electri

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hicle electrical system.
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Wait a few minutes and repeat the charging process. Refer to
cted agen
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GRX3000VAS , page 63

3.6 Solar Battery Maintainer - VAS6102A-

3.6.1 Solar Battery Maintainer VAS6102A Device Descrip
tion, page 67
3.6.2 Solar Battery Maintainer VAS6102A Maintenance
Charging, page 67
3.6.1 Solar Battery Maintainer - VAS6102A-

Device Description
Solar Battery Maintainer - VAS6102A-
AG. Volkswagen AG d
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The Solar Battery Maintainer - VAS6102A- supports the vehicle Vol
ksw not
gu
d by
electrical system and prevents the Battery - A- from self-discharg ara
e nte
ing. ris
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au ra
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The Solar Battery Maintainer - VAS6102A- reachesss a maximum
ce
le
voltage of 14.3 V and a maximum charge current of 255 mA.
un
pt
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All chargeable lead- and lead gel batteries can be charged with
erm
ab
the Solar Battery Maintainer - VAS6102A- .
ility
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The Solar Battery Maintainer - VAS6102A- is connected to the
is n
h re
diagnostic connection in the vehicle.
ole,
spec
The Solar Battery Maintainer - VAS6102A- has a green LED in
t to the co
tegrated inside the frame which displays the function being per
formed. The brighter the LED, the higher the charging current.
It is not possible to overcharge the Battery - A- due to the inte
rrectne
grated electronics.
ss
The Solar Battery Maintainer - VAS6102A- is secured on the in
o
cial p
f i
terior rearview mirror -1-. The bottom rests on the instrument
nform
panel -2-.
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Note
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The Solar Battery Maintainer - VAS6102A- must not touch the
um
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fo
en
instrument panel completely. Only the bottom edge may be used
ng
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for support. If it touches completely, the color of the instrument Cop py
panel could change.
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3.6.2 Solar Battery Maintainer - VAS6102A-

Maintenance Charging
Procedure
Secure the Solar Battery Maintainer - VAS6102A- to the inte
rior rearview mirror -1-.
Lay the bottom on the instrument panel -2-.
Note
The Solar Battery Maintainer - VAS6102A- must not touch the

instrument panel completely. Only the bottom edge may be used
for support. If it touches completely, the color of the instrument
panel could change.
Pull the securing string together so that the Solar Battery

Maintainer - VAS6102A- is close to the glass.
Connect the connector for the Solar Battery Maintainer -
VAS6102A- to the vehicle diagnostic connection. Connecting
is the same as with Vehicle Diagnostic Tester . Refer to
Check the Solar Battery Maintainer - VAS6102A- functionality.
The green LED must come on.
3.7 Severely Discharged Batteries
WARNING

cautions. Refer to
olkswagen AG
en AG. V
A Battery - A- is designated as severely discharged if the restingksw
ag does
not
Vol
voltage is less than 11.6 V. db
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WARNING ss
a c ce
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used!
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starting.
hole
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es, in part or in w

t to the co
rrectness of i
Caution
l purpos
Severely discharged Batteries - A- freeze earlier.

nform
ercia
Batteries - A- that have frozen must no longer be used.

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ate
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Note
Batteries - A- that have not been used for a long time will dis
charge by themselves.
In severely discharged Batteries - A- , the electrolyte consists
almost completely of water,
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nbecause the
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Severely discharged
tho
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nte
e
all of the splate
au surfaces of the Batteries - A- harden. or
ac
s
The sulfation process may be reversed if a severely dis
ce
e
nl
pt
du
charged Battery - A- is recharged immediately.
an
itte
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erm
ab
If the Battery - A- is not recharged, the plates will continue to
ility
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harden, and the ability to accept a charge will decrease. This
wit
, is n
results in reduction of battery performance.
h re
hole
Severely discharged Batteries - A- in vehicles must be re
spec
placed prior to delivery. Pre-existing damage cannot be ruled
es, in part or in w
t to the co
out.
Procedure
rrectness of i
Check the Battery - A- resting voltage. Refer to
l purpos
3 Battery, Charging, page 31 .

Charge the Battery - A- :
nf
ercia
orm
Battery Charger - VAS5095A- . Refer to
m
atio
m

o
n in
c
Charger VAS5059A , page 34 .

or
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te
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a

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Charger VAS5903 , page 54 . by c lksw
cted agen
Prote AG.
page 60 .
Battery Tester Charger Kit - GRX3000VAS- . Refer to
GRX3000VAS , page 63 .
4 Cruise Control System

4.1 Cruise Control System Function, page 70
4.2 Cruise Control System, Activating and Deactivating, page
70
4.1 Cruise Control System Function

General Information
Cruise control system functions are controlled by the Engine Con
trol Module - J623- .
Cruise Control System, activating and deactivating. Refer to
4.2 Cruise Control System, Activating and Deactivating, page
70 .
DTC Recognition and Display
Malfunctions in relation to the cruise control system are sent via
the Engine Control Module - J623- .
Use Vehicle Diagnostic Tester in Guided Fault Finding mode.
4.2 Cruise Control System, Activating and

Deactivating
Procedure
Connect Vehicle Diagnostic Tester . Refer to
1 Vehicle Diagnosis, Testing andwaInformation
gen AG
. VolkswSystems,
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page 89 . olks not
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Select Guided Fault Findingtho
ris . e or
au ac
s
Use the GO TO button s to select the function/component se
ce
le
lection and the following menu options one after the other:
un
pt
an
d
itte
y li
Powertrain
rm
ab
pe
ility
Engine code
ot
wit
, is n
h re
01 - OBD-capable systems
hole
spec
Engine control module or diesel direct injection and pre-glow

es, in part or in w
t to the co
system
Functions
rrectness of i
Cruise Control System, Activating and Deactivating

l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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5 Special Tools
Analog/Digital Multimeter - FLU83III-
lkswage es n
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spec
t to the co
rrectness o
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Battery Tester with Printer - VAS5097A- cum

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5. Special Tools 71
AG. Volkswagen AG d
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h
Battery Charger - VAS5906- s aut ra
c
s
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nl
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itte
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erm
ab
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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ercia
orm
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or c
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Beetle
agen
AG. Vo2012
lkswage
n A,GGolf
does 2015 , Golf Variant 2007 , Golf Variant 2010 ...
ksw Electrical
gu Equipment General Information - Edition 01.2015
ol not
y V
edb ara
ris nte
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ut
92 Wiper/Washer Systems
a ra
ss c
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e
nl
pt
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1 Washer Fluid Hoses
erm
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ility
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1.1 Windshield and Rear Window Washer System,
wit
, is n
h re
page 73
hole
spec
1.2 Headlamp Washer System, page 74
es, in part or in w
t to the co
1.3 Washer Fluid Hoses, Servicing, page 74
1.1 Windshield and Rear Window Washer
rrectness of i
System
l purpos
Procedure
nform
ercia
Loosen the connection by pulling both halves of the coupling

apart (no fuse).
m
at
om
io
To secure the connection, push both halves of coupling to
n
c
in t
or
gether until felt and heard to engage.
his
ate
do
priv
cum
for
en
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t.
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rig ht
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Prote AG.
Disconnect by turning the locking ring -1- 90 -arrow- and re

moving the hose connection.
Reconnect by pushing both halves of coupling together and
rotating locking ring -1- in the direction of the -arrow- until it
engages.
Disconnect by lifting securing clip -1- approximately 1 mm

-arrow- and removing the hose connection.
To secure the connection, connect the hose connection and
press in securing clip -1- until it engages.
1. Washer Fluid Hoses 73

To loosen the connection, pull the securing clip -1- in the di

rection of -arrow- and disconnect the hose connection.
To secure connection, connect hose connection and press in
securing ring -1- until it engages.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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1.2 Headlamp Washer System
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itte
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Procedure
erm
ab
ility
ot p
To loosen connection, press securing clip -1- in the direction
wit
, is n
of -arrow- and disconnect the hose connection.
h re
hole
To secure the connection, hold the securing clip -1- in the di
spec
rection of the -arrow- and connect the hose connection. Check
es, in part or in w
t to the co
the securing clip for secure locking by attempting to pull it off
without depressing the clip.
rrectness of i
l purpos
nform
mercia
at
om
io
1.3 Washer Fluid Hoses, Servicing
n
c
in t
or
his
ate

do
priv
cum
or
1.3.2 Smooth Tube, Repairing, page 74

f
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1.3.3 Corrugated Tube, Repairing, page 75 C py
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A new repair concept has been developed for repairing washer
system hoses. Various individual hose connectors, adapters, Eth
ylene Propylene Diene Methylene (EPDM) rubber hoses and
shrink tubing will be offered as replacement parts.
Replacement parts are found in the Parts Catalog.
The replacement parts are available both for the repair of a
smooth tube as well as for the repair of a corrugated tube.
1.3.2 Smooth Tube, Repairing

Smooth tubes with a diameter of 5 x 1 mm or 6 x 1 mm can be
repaired with a EPDM repair hose section.
Procedure
Cut out the damaged sections of the smooth tube to be re
paired.
74 Rep. Gr.92 - Wiper/Washer Systems

Select the appropriate EPDM hose -2- and cable tie. Refer to
the Parts Catalog.
Cut a length of EPDM-hose -2-, so that the smooth tube ends
-1- and -3- can be pushed approximately 10 mm into the
EPDM-hose -2-.
Secure with cable ties as illustrated -1-.
1.3.3 Corrugated Tube, Repairing

Hot Air Blower - VAS5179-
Note wage
es n
olks ot g
byV ua
Area to be repaired must not be under stressrisof
ed stretching or ran
tee
bending. autho
or
ac
ss
If the damaged area is longer than 20 mm, a new section of
ce
le
un
corrugated hose must be inserted and the procedure descri

pt
an
d
bed in the following must be performed twice.

itte
y li
rm
ab
pe
ility
Procedure
ot
wit
, is n
h re
Trim and remove damaged sections of the corrugated tube.

hole
spec
es, in part or in w
Choose matching repair adapters -2- and -3- as well as ap

t to the co
propriate heat-shrink tubing from the Parts Catalog.

Warm the end of the corrugated tube -1- using the Hot Air
Blower - VAS5179- .
rrectness of i
Press the connecting piece -2- into the corrugated tube -2-
l purpos
-arrow A-.
Warm the end of the corrugated tube -4- using the Hot Air
nform
ercia
Blower - VAS5179- .
m
a
com
ti
Press the connecting piece -3- into the corrugated tube -4-
on in
-arrow B-.
r
te o
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s
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1. Washer Fluid Hoses 75

Trim the heat-shrink sleeve so that corrugated tube is covered

on both sides with a minimum of 20 mm -dimension x- of heat-
shrink sleeve.
Slide the heat-shrink tubing over the corrugated tube, attach
the connecting pieces together and secure the repair area with
heat-shrink tubing.
lkswage es n
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byV ua
d ran
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erm
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wit
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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Prote AG.

nBeetle
AG. Volk2012 AG, dGolf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
swagen
wage oes
y Volks Electrical
not
gu Equipment General Information - Edition 01.2015
d b ara
ir se nte
tho eo
2 Joint-Free Wiper Blade Characteris
au ra
ss c
ce
e
tics
nl
pt
du
an
itte
y li
2.1 Joint-Free Wiper Blade Characteristics, page 77
erm
ab
ility
ot p
2.1 Joint-Free Wiper Blade Characteristics
wit
, is n
h re
hole
Characteristics for Bosch and Federal Mogul
spec
es, in part or in w
Check the manufacturer when replacing the wiper blades. Always
t to the co
replace them with blades made by the same manufacturer.
The wiper blades can be identified by the wiper arm mount.
rrectness of i
Bosch Wiper Blades -1 and 2-:
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
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for
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Federal Mogul Wiper Blades -1-:
p by
co Vo
by lksw
cted agen
Prote AG.
2. Joint-Free Wiper Blade Characteristics 77

3 Special Tools
Hot Air Blower - VAS5179- or
lkswage es n
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h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
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c
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Prote AG.

AG. Volkswagen AG d
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olksw not
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94 Exterior Lights, Switches
d b ara
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or eo
h
aut ra
ss c
ce
1 HID Headlamp Usage and Safety
e
nl
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itte
Precautions
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ility
ot p
1.1 Safety Precautions, page 79
wit
, is n
h re
1.1 Safety Precautions
hole
spec
es, in part or in w
If Performing Assembly Work on HID Headlamps, Note the Fol
t to the co
lowing
Notes on hazardous high voltage/currents. Refer to
rrectness of i
page 79
l purpos
Notes on pressure, temperature and radiation/electric arc. Re
fer to page 80
nf
ercia
Assembly notes on HID headlamp bulbs. Refer to
orm
page 81
m
atio
om
Disposal regulations for HID headlamp bulbs. Refer to
n in
or c
page 81
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Protective eyewear
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WARNING
Prote AG.
Always disconnect the Battery - A- before working on any HID

headlamp components marked with the yellow high voltage
symbols. Refer to Electrical Equipment; Rep. Gr. 27 ; Bat
tery; Battery, Removing and Installing .
Then switch the low beams on and back off. This removes any
possible residual voltage.
The gas discharge lamp control module should not be operated
without the gas-discharge lamp.
Due to the high voltage (over 28000 V when igniting the lamp)
and temperatures, the HID headlamp bulb should only be op
erated inside the headlamp housing.
WARNING
Never change an HID headlamp bulb if you are not familiar

with the corresponding steps, safety precautions and the
tool.
Warnings for Dangerous High Voltage and Currents
WARNING
Light system control modules, connectors or components in

the bulb socket area conduct dangerous high voltage
The control module and igniter may be used only on the HID
headlamp bulb.
1. HID Headlamp Usage and Safety Precautions 79

WARNING
AG. Volkswagen AG d
agen
Turn off the ignition and all electrical consumers and re Volksw
oes
not
gu
move the ignition key. se
db
y ara
nte
i
or eo
When working on headlamp system, ensure all compo ut
h
ra
sa
nents are without voltage, including relieving residual volt
s c
ce
le
age after switching headlamps off.
un
pt
an
d
itte
Residual voltages are discharged by switching low beam
y li
rm
ab
on and off again after ignition key was removed.
pe
ility
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Make sure lamps cannot be switched on when working on
, is n
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headlamp system.
hole
spec
es, in part or in w
t to the co
Notes on Pressure, Temperature and Radiation/Glare
rrectness of i
WARNING
l purpos
HID Headlamp Bulb must only be operated in headlamp

housing (it offers protection against touching extremely
nform
ercia
hot lamp, absorption of UV radiation, prevention of glare,

protection against explosion).
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com
tio
The glass HID headlamp bulbs can become very hot - risk
n in
r
of burning!
te o
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do
Avoid looking directly into light beam, since UV radiation
r
rp
cum
of the HID lamp is approximately 2.5 times higher than that
fo
en
g
of standard Halogen lamps.

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Cop py
.
Avoid looking into light beam (risk of glare), it can have
t rig
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lasting negative effects on vision. cop Vo
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Prote AG.
WARNING
Avoid contact with burst bulbs.

H7 bulbs and HID bulbs are under pressure and can burst
when replaced - danger of injury!
When removing and installing HID bulbs, always wear
safety glasses and gloves.
80 Rep. Gr.94 - Exterior Lights, Switches

Assembly Instructions on HID Headlamp Bulbs
Caution
Before replacing a HID headlamp bulb, the corresponding

electrical equipment must always be switched off.
Turn off the ignition and all electrical consumers and re
move the ignition key.
Do not touch an HID headlamp bulb with bare hands, use
clean gloves. The remaining fingerprint would evaporate
due to the heat of the operated HID headlamp bulb and
condense on the reflector which would impair headlamp
luminosity.
An HID headlamp bulb must be replaced with an HID
headlamp bulb of the same version. Bulb identification can
be found on bulb socket or glass cone.
Harness connectors must engage correctly when installed
and must be checked for proper connection.
Disposal Regulations for HID Headlamp Bulbs
WARNING
HID lamps must be disposed of as hazardous waste, nev

er dispose of HID lamps via domestic waste.
HID lamps contain metallic mercury (Hg) and traces of
thallium, they must not be destroyed.
. Volkswagen AG
gen AG
These components must be returnedVofor lkswproper recycling
a does
not
in accordance with national legislation.
ed
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Dispose of only in the designated
auth containers at the re eo
ra
sponsible collection point. ss c
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1. HID Headlamp Usage and Safety Precautions 81

96 Interior Lights, Switches

1 Cigarette Lighter and Socket
1.1 Overview - Cigarette Lighter, 12 V Socket, page 82
1.2 Cigarette Lighter U1 , Removing and Installing,
page 83
1.3 Socket Illumination Bulb L42 , Removing and Installing,
page 86
1.4 Cigarette Lighter Illumination Bulb L28 , Removing and
Installing, page 86
1.1 Overview - Cigarette Lighter, 12 V Sock

et
Caution
Using force to remove Sockets -aU- genwithout

AG. VolksSocket Illumination
wagen AG
does
Bulb - L42- can result in damage
Volksw to the mounting sleevenot re
gu
tainers. se
d by ara
n i tee
or
Using the Cigaretteau Lighter Release Tool - T40148- , only the
th or
ac
Sockets - U- ( Cigarette
ss
Lighter - U1- ) with the Socket Illumi
ce
e
nation Bulb - L42- can be removed.

nl
pt
du
an
itte
The Cigarette Lighter Release Tool - T40148- cannot release

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erm
ab
the tabs on Sockets - U- without illumination.

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wit
Sockets - U- without a Socket Illumination Bulb - L42- usually

, is n
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get damaged when being removed.

hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
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82 Rep. Gr.96 - Interior Lights, Switches

olksw
AG. V agen AG
agen does
lksw not
1 - Cigaretted bLighter
yV
o
Socket gu
ara
with Trailingrise Cable nte
tho eo
s au
2 - Cigarette Lighter - U1-
ra
c
s
ce
e
Removing and instal

nl
pt
du
ling. Refer to
an
itte
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1.2 Cigarette Lighter
erm
ab
U1 , Removing and In
ility
ot p
stalling, page 83
wit
, is n
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3 - Socket - U-
hole
spec
Removing and instal
es, in part or in w
t to the co
ling. Refer to
1.2 Cigarette Lighter
U1 , Removing and In
rrectness of i
stalling, page 83
l purpos
4 - Cigarette Lighter Recepta

cle
nf
ercia
5 - Mounting Sleeve
orm
m
6 - Socket Illumination Bulb -
atio
m
L42-
o
n in
or c
12 V/1.2 W bulb
thi
te
sd
iva
Removing and instal o

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rp
cu
ling. Refer to
o
m
f
en
ng
1.3 Socket Illumina

t.
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op
tion Bulb L42 , Remov C py
t. rig
ing and Installing, page
gh ht
pyri by
86
o Vo
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cted agen
Prote AG.
7 - Bulb Holder
1.2 Cigarette Lighter - U1- , Removing and

Installing
Cigarette Lighter Release Tool - T40148-
Cigarette Lighter Release Tool - Thrust Piece - T40148/1-
Caution
Using force to remove Sockets - U- without Socket Illumination

Bulb - L42- can result in damage to the mounting sleeve re
tainers.
Using the Cigarette Lighter Release Tool - T40148- , only the
Sockets - U- ( Cigarette Lighter - U1- ) with the Socket Illumi
nation Bulb - L42- can be removed.
The Cigarette Lighter Release Tool - T40148- cannot release
the tabs on Sockets - U- without illumination.
Sockets - U- without a Socket Illumination Bulb - L42- usually
get damaged when being removed.
1. Cigarette Lighter and Socket 83

Note
The procedure for removing and installing is the same for all
Sockets - U- and is only described for the cigarette lighter socket.
Removing
Disconnect the Battery - A- . Refer to Electrical Equipment;
Rep. Gr. 27 ; Battery; Battery, Disconnecting and Connecting .
Remove the Cigarette Lighter - U1- from the Socket - U- .
Note
The illustration shows the Socket - U- removed.
Caution
The Socket - U- or mounting sleeve can be damaged.

Make sure the Cigarette Lighter Release Tool - T40148- is
seated properly or the mounting sleeve retaining tabs will not
release.
Slide the Cigarette Lighter Release Tool - T40148- -arrow- into

the Socket - U- so that the tabs -1- engage in the openings
-2-. wage
e
olks s no
yV t gu
edb ara
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tho eo
au ra
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e
nl
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ab
ility
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, is n
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hole
spec
es, in part or in w
Release the mounting sleeve retaining tabs by pulling on grip

t to the co
piece -3- in the direction of the -arrow-.

Remove the Socket - U- from the mounting sleeve using the
rrectness of i
Cigarette Lighter Release Tool - T40148- .

l purpos
Caution
nform
ercia
The wiring for the Socket - U- could get damaged.

m
at
om
Pay attention to the length of electrical wiring when removing

ion
c
the Socket - U- .
in t
or
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ate
do
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Beetle 2012 e,n Golf
AG. Vo2015
lkswag
en ,AGolf
G do
Variant 2007 , Golf Variant 2010 ...
ag
Volksw Electrical Equipment es n General Information - Edition 01.2015
ot
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Depending on installation tholocation, the
r
Thrust Piece - T40148/1- eo
-2- with knurled nut -1-
s aucan be used. ra
c
s
ce
le
un
pt
an
d
Caution
itte
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ab
pe
ility
Make sure not to damage any of the surrounding components
ot
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when using the Thrust Piece - T40148/1- .
, is n
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hole
spec
es, in part or in w
Release and disconnect the connector for the Socket - U- .
t to the co
Note
rrectness of i
l purpos
There are different versions of the Socket - U- and cigarette lighter

socket due to different installation locations and construction. The
differences are primarily In the length and type of electrical con
nform
ercia
nectors. For Sockets - A- and cigarette lighter sockets with a

trailing cable, additional work may be necessary to access the
m
a
com
ti
connector.
on in
r
te o
thi
s
iva
do
Release the Cigarette Lighter Release Tool - T40148- tabs by
r
rp
cum
fo
pressing the spindle -1- in the direction of the -arrow B-. Then
en
ng
t.
turn the Cigarette Lighter Release Tool - T40148- -2- slightly
yi Co
op
to the left direction of -arrow A- and release. Remove the Cig
C py
t. rig
gh
arette Lighter Release Tool - T40148- from the Socket - U- .
ht
pyri by
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by c lksw
cted agen
Prote AG.
Note
Make sure the tabs on the Cigarette Lighter Release Tool -

T40148- are not spread.
Caution
The Cigarette Lighter - U1- can be ejected from the Socket -

U- after the heating cycle is complete.
Inserting the Cigarette Lighter Release Tool - T40148- into the
Socket - U- spreads the socket retainer springs and reduces
their ability to retain the cigarette lighter insert.
After removing the Socket - U- , carefully press the retainer
springs slightly together again and check if the Cigarette Light
er - U1- remains in the socket when the heating cycle is
complete.
Carefully press the retainer springs for the Socket - U- together

-arrows-.
Make sure the Cigarette Lighter - U1- remains in the socket
and is not ejected into vehicle interior after the heating cycle
is complete.
Installing
Install in reverse order of removal.
Connect the Battery - A- . Refer to Electrical Equipment;

1.3 Socket Illumination Bulb - L42- , Remov

ing and Installing
The Socket Illumination Bulb - L42- is removed in the same man
ner as the Cigarette Lighter Illumination Bulb - L28- . Refer to
1.4 Cigarette Lighter Illumination Bulb L28 , Removing and
Installing, page 86 .
1.4 Cigarette Lighter Illumination Bulb -

L28- , Removing and Installing
The Cigarette Lighter Illumination Bulb - L28- has an LED rather
than a bulb on some vehicles. These LEDs are integrated with
the illumination housing and cannot be serviced or replaced sep
AG. Volkswagen AG d
arately. ksw
agen oes
n ol ot g
yV ua
There are various versions of adapter ed
b sleeves with a bulb: one ran
ris
version with replaceable bulbutandho one without a replaceable bulb. tee
or
In this case, the entire illumination
ss
a housing must be replaced. ac
ce
e
Removing
nl
pt
du
an
itte
y li
Remove the Cigarette Lighter - U1- . Refer to
erm
ab
1.2 Cigarette Lighter U1 , Removing and Installing,
ility
ot p
page 83 .
wit
, is n
h re
Press the tabs -1- in the direction of the -arrow- and remove
hole
spec
the mounting sleeve with the bulb holder.
es, in part or in w
t to the co
Unclip bulb holder from mounting sleeve.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
Disconnect the bulb holder near -A and B-.

do
priv
cum
or
Open the bulb holder component -B-.

f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
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co lksw
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Prote AG.

Remove the bulb in the direction of the -arrow-.

Installing
Install in reverse order of removal.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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f
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t.
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2 Special Tools
Cigarette Lighter Release Tool - T40148-
Cigarette Lighter Release Tool - Thrust Piece - T40148/1-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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aut ra
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nl
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spec
es, in part or in w
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rrectness of i
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nform
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c
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ate
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97 Wiring
1 Vehicle Diagnosis, Testing and Infor
mation Systems
1.1 Description of Vehicle Diagnosis, Testing and Information
Systems, page 89
1.2 Connect the Vehicle Diagnostic Tester , page 89
1.3 Vehicle Diagnostic Tester, Connecting, Golf MY 1998
through 2003, page 90
1.1 Description of Vehicle Diagnosis, Test

ing and Information Systems
WARNING
Using a Vehicle Diagnostic Tester during a road test can

result in injuries if the specified precautions are not fol
lowed.
If Vehicle Diagnostic Tester is deposited in the action area
of an airbag during a road test, there is the hazard of ex
treme to lethal injuries in the event the airbag deploys!
During road tests, have a second person sitting in the rear
seat operate the Vehicle Diagnostic Tester .
Note
All work instructions can be reached in the operating modes Gui

ded Fault Finding and Guided Functions.
gen AG
. Volkswagen AG
d
wa oes
olks not
yV gu
Additional information: rised b ara
nte
tho eo
Self Study Program
s au No. 202 ; Vehicle Diagnostic Tester ra
c
s
ce
e
Self Study Program No. 256 ; VAS5052

nl
pt
du
an
itte
Self Study Program No. 294 ; Online connection of

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ab
VAS5051
ility
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Follow the current operating instructions for Vehicle Diagnos

, is n
h re
tic Tester , which can be displayed after selecting buttons

hole
spec
Administration and Owner's Manual.

es, in part or in w
t to the co
Connect Vehicle Diagnostic Tester . Refer to

1.2 Connect the Vehicle Diagnostic Tester

rrectness of i
l purpos

nf
ercia
orm
m
atio
m
Note
o
n in
or c
thi
e
Follow the current operating instructions for Vehicle Diagnostic

t
sd
iva
Tester , which can be displayed after selecting buttons Admin

o
r
rp
cu
istration and Owner's Manual.

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1. Vehicle Diagnosis, Testing and Information Systems
Procedure
the ignition key.
On vehicles with automatic transmissions, move the selector n AG. Volkswagen AG do
lever to the P or N position. lkswage es n
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byV ua
On vehicles with manual transmissions, move the shift lever ir se
d ran
tee
to the neutral position. autho
or
ac
ss
With the ignition switched off, connect the Vehicle Diagnostic
ce
e
nl
Tester to the vehicle diagnostic connection-arrow-.
pt
du
an
itte
y li
Turn on the ignition.
erm
ab
ility
ot p
The method for connecting all Vehicle Diagnostic Tester can be
wit
, is n
derived from the sequence described above.
h re
hole
spec
Component location and connector assignment for the diagnostic
es, in part or in w
connection. Refer to Wiring diagrams, Troubleshooting & Com
t to the co
ponent locations.
rrectness of i
l purpos
1.3 Vehicle Diagnostic Tester, Connecting,
nform
Golf MY 1998 through 2003
mercia
at
om
ion
c
in t
r

o
his
ate
do
riv
Procedure
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for
en
ng
t.
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the ignition key. t. Cop py
rig
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On vehicles with automatic transmissions, move the selector pyri by
Vo
co
lever to the P or N position.
by lksw
cted agen
Prote AG.
On vehicles with manual transmissions, move the shift lever
to the neutral position.
Remove the trim panel -1- in the direction of the -arrow-.
With the ignition switched off, connect the Vehicle Diagnostic
Tester to the vehicle diagnostic connection.
Turn on the ignition.
Note
The method for connecting all other Vehicle Diagnostic Tester can
be derived from the sequence described above.
90 Rep. Gr.97 - Wiring

2 Connectors
2.1 Wiring Harnesses and Connectors, Repairing,
page 91
2.2 Vehicle Electrical System, General Repair Information,
page 96
2.3 Wiring Harnesses, Repairing, page 98
2.1 Wiring Harnesses and Connectors, Re

pairing
2.1.1 Wiring Harness Repair Set VAS1978 , page 91
2.1.2 Upgrade Kit For VAS1978 VAS1978/50 , page 92
2.1.3 Wiring Harness Repair Set VAS1978A , page 92
2.1.4 Release Tool Set VAS1978/35 , page 92
2.1.5 Crimping Pliers with Insert, page 93
. Volkswagen AG
2.1.6 Contact Release Tools, page gen AG
a93 does
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2.1.7 Single Wire Seal Assembly by Tools, page 94 ara
ed nte
oris eo
th
2.1.8 Wiring Harness auRepair Set - Wire Strippers VAS1978/3 ra
c
, page 94 ss
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le
un
pt
2.1.9 Wiring Harness Repair Set - Hot Air Blower
an
d
itte
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VAS1978/14A , page 95
rm
ab
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ility
2.1.10 Crimping Pliers - .35-2.5mm VAS1978/1A ,
ot
wit
, is n
page 95
h re
hole
spec
2.1.1 Wiring Harness Repair Set - VAS1978-
es, in part or in w
t to the co
The Wiring Harness Repair Set - VAS1978- makes optimal repair
quality possible in the realm of vehicle electronics. Using the
tools, repairs affecting harness connectors and for breaks in wir
rrectness of i
ing can be performed. For this purpose, complete repair wires with
terminals already crimped on are used and can be connected to
l purpos
vehicle-specific wiring harness by the use of crimp connections.

Crimping Pliers - VAS1978/1- with Crimping Pliers - Insert 2 -
nform
ercia
VAS1978/2- and three different crimp slots and a Wiring Harness

Repair Set - Hot Air Blower - VAS1978/14A- for shrinking the
m
crimp connections provide a trouble-free electrical connection.

com
tion in
r
Wiring Harness Repair Set - VAS1978-

te o
thi
s
iva
do
Additional information:
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rp
cum
fo
Refer to Wiring Harness Repair Set - VAS1978- Operating In

en
ng
t.
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structions. t. Cop py
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Prote AG.
2. Connectors 91
2.1.2 Upgrade Kit For VAS1978 -

VAS1978/50-
The Upgrade Kit For VAS1978 - VAS1978/50- is required in order
to bring the old Wiring Harness Repair Set - VAS1978- up to the
new standard of the Wiring Harness Repair Set - VAS1978A- .
The Upgrade Kit For VAS1978 - VAS1978/50- contains 4 assem
bly- and 10 release tools as well as the new Wiring Harness
Repair - Crimping Plier - Base Tool - VAS1978/1-2- for crimp
connectors with the Wiring Harness Repair - oCrimping
AG. V Head -
lkswagen AG
0.35-2.5 mm/2 - VAS1978/1-1-V,olWiring agenHarness Repair does
Set n-ot
ksw
Crimping Head - 4-6 mm/2 e-d VAS1978/2A- and the Wiring
by gu
ara
Harness Repair Set - Crimping
horis Head - JPT - VAS1978/9-1- . Fur nte
eo
thermore it contains new aut
stickers, a new set of user instructions, ra
c
ss
crimp connections for 0.35 mm2-wire cross sections and a roll of
ce
le
black felt adhesive tape.

un
pt
an
d
itte
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Upgrade Kit For VAS1978 - VAS1978/50-
rm
ab
pe
ility
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2.1.3 Wiring Harness Repair Set -
, is n
h re
hole
VAS1978A-
spec
es, in part or in w
t to the co
The new Wiring Harness Repair Set - VAS1978A- makes optimal
repair quality possible in the realm of vehicle electronics. Using
the new pliers, repairs affecting harness connectors and for
rrectness of i
breaks in wiring can be performed. For this purpose, complete
repair wires with terminals already crimped on are used and can
l purpos
be connected to vehicle-specific wiring harness by the use of the

4 different types of crimp connections. A new Wiring Harness Re
pair - Crimping Plier - Base Tool - VAS1978/1-2- with exchange
nform
ercia
able Wiring Harness Repair - Crimping Head - .35-2.5mm -

m
VAS1978/1-1- or Wiring Harness Repair Set - Crimping Head -

a
com
tio
4-6mm - VAS1978/2A- and a Wiring Harness Repair Set - Hot Air

n in
Blower - VAS1978/14A- for shrinking the crimp connectors pro

r
te o
thi
vide a trouble-free electrical connection.

s
iva
do
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rp
cum
Wiring Harness Repair Set - VAS1978 A-

fo
en
ng
t.
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Additional information:
Co
Cop py
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Refer to Wiring Harness Repair Set - VAS1978A- Operating yri
p by
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Instructions.
c by lksw
cted agen
Prote AG.
The Wiring Harness Repair Set - VAS1978A- was replaced by the
Wiring Harness Repair Set - VAS1978B- .
2.1.4 Release Tool Set - VAS1978/35-

The Release Tool Set - VAS1978/35- is used to release the var
ious primary and secondary locking mechanisms on VW-group
vehicles. The set consists of 26 different tools with which round
connector systems, flat terminals with one or two locks as well as
single wire seals can be professionally released and assembled.
Release Tool Set - VAS1978/35-
The allocation of the correct release tools to the respective locking
mechanisms can be found in the table in Release Tool Set -
VAS1978/35- Operating Instructions.

AG. Volkswagen AG d
agen oes
lksw not
2.1.5 Crimping Pliers with Insert
o
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ara
ed
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The Crimping Pliers - VAS1978/1- , withaut the Crimping Pliers - In
h
ra
sert 2 - VAS1978/2- , is a components of the Wiring Harness Repair
s c
ce
le
Set - VAS1978- / Wiring Harness Repair Set - VAS1978A- / Wiring
un
pt
Harness Repair Set - VAS1978B- and is used to crimp the crimp
an
d
itte
y li
connectors during the wiring harness repair.
erm
ab
ility
ot p
Color of crimp Color of crimping Wire cross-section
wit
is n
connectors slot
h re
ole,
spec
yellow yellow 0.35 mm2
t to the co
Red Red 0.5 mm2 through
1.0 mm2
Blue Blue 1.5 mm2 through
rrectne
2.5 mm2
s
yellow yellow 4.0 mm2 through
s o
6.0 mm2
cial p
f inform
mer
atio
m
Note
o
n
c
i
or
n thi
te
sd
The Wiring Harness Repair - Crimping Plier - Base Tool -
iva
o
r
VAS1978/1-2- can also be used together with the Wiring Har

p
cum
r
fo
ness Repair - Crimping Head - .35-2.5mm - VAS1978/1-1- or
en
ng
t.
yi
Wiring Harness Repair Set - Crimping Head - 4-6mm -
Co
op py
VAS1978/2A- to crimp the connections as an alternative.
. C rig
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rig by
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Always be sure to use the correct crimping slot for the crimp
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cted agen
connector used. Prote AG.
Do not crimp wire insulation.
2.1.6 Contact Release Tools

Various release tools are used to remove the different terminals
from the connector housing without damage.
A selection of release tools is a component of the Wiring Harness
Repair Set - VAS1978- / Wiring Harness Repair Set -
VAS1978A- / Wiring Harness Repair Set - VAS1978B- . The
Release Tool Set - VAS1978/35- contains the entire set of release
tools.
WARNING
Some tools are supplied with a tool safety clip, which is slid
over the tool points after using the tool, in order to protect other
workers from injuries and tool points from damage.
2. Connectors 93
2.1.7 Single Wire Seal Assembly Tools

Assembly tools serve the purpose of allowing the single wire seals
to be slid without damage into the connector housing up to stop,
this achieves a complete seal between a single wire and connec
tor housing.
Four assembly tools for single wire seals are components
agen
AGof the
. Volkswagen AG
does
Wiring Harness Repair Set - VAS1978- / WiringVoHarness
lksw Repair not
gu
y
Set - VAS1978A- / Wiring Harness Repair sSeted - VAS1978B- .
b ara
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ho
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un
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ility
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2.1.8 Wiring Harness Repair Set - Wire Strip
h re
hole
pers - VAS1978/3-
spec
es, in part or in w
t to the co
The Wiring Harness Repair Set - Wire Strippers - VAS1978/3- is
used for professional stripping and cutting of wires.
rrectness of i
The Wiring Harness Repair Set - Wire Strippers - VAS1978/3- are
a component of the Wiring Harness Repair Set - VAS1978- / Wir
l purpos
ing Harness Repair Set - VAS1978A- / Wiring Harness Repair Set

- VAS1978B- .
nform
ercia
The Wiring Harness Repair Set - Wire Strippers - VAS1978/3-

have an adjustable stop in its pliers-jaws which can be set to the
m
a
com
t
desired length of wire insulation to be removed.
ion in
r
te o
Stripping
thi
s
iva
do
Set the slideable stop in pliers-jaws to the desired length di
r
rp
cum
fo
mension to be stripped. en
ng
t.
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Cop py
Insert the wire end from the front up to the stop into the jaws
t. rig
gh ht
yri
of pliers and squeeze the Wiring Harness Repair Set - Wire
p by
o Vo
by c lksw
Strippers - VAS1978/3- together completely. Prote
cted AG.
agen
Reopen the Wiring Harness Repair Set - Wire Strippers -

VAS1978/3- and remove the stripped wire end.
Cut the wires using the side-cutter function on the top of the
Wiring Harness Repair Set - Wire Strippers - VAS1978/3- .

2.1.9 Wiring Harness Repair Set - Hot Air

Blower - VAS1978/14A-
Wiring Harness Repair Set - Hot Air Blower - VAS1978/14A-
Caution
When heat-shrinking crimp connections, be careful not to dam

age any other wiring, plastic parts or insulating material with
the hot nozzle of the Wiring Harness Repair Set - Hot Air Blow
er - VAS1978/14A- .
AG. Volkswagen A
Always follow theolkWiring
swa
gen Harness Repair Set
G do
es n- Hot Air Blower
- VAS1978/14A-
db
y V Operating Instructions! ot g
ua
r
e an
ris tee
utho or
a ac
The ss
ce
le
is used together with the Wiring Harness Repair - Blower - Shrink

un
pt
an
d
Element - VAS1978/15A- to heat-shrink the crimp connectors.

itte
y li
After crimping, the crimp connectors must be heat-shrunk using
rm
ab
pe
the Wiring Harness Repair Set - Hot Air Blower - VAS1978/14A-
ility
ot
to prevent moisture penetration.
wit
, is n
h re
hole
The Wiring Harness Repair Set - Hot Air Blower - VAS1978/14A-
spec
is a component of the Wiring Harness Repair Set - VAS1978- /
es, in part or in w
Wiring Harness Repair Set - VAS1978A- / Wiring Harness Repair
t to the co
Set - VAS1978B- .
rrectness of i
2.1.10 Crimping Pliers - .35-2.5mm -
l purpos
VAS1978/1A-
The Crimping Pliers - .35-2.5mm - VAS1978/1A- or the Wiring
nform
ercia
Harness Repair - Crimping Plier - Base Tool - VAS1978/1-2- to

gether with the Wiring Harness Repair - Crimping Head - .
m
a
com
ti
35-2.5mm - VAS1978/1-1- and the Wiring Harness Repair Set -

on in
Crimping Head - 4-6mm - VAS1978/2A- from the wiring harness

r
te o
thi
repair set is used to compress the crimp connectors.

s
iva
do
r
rp
Crimp connectors, press using the Crimping Pliers - .35-2.5mm -

um
fo
en
VAS1978/1A- .
ng
t.
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op py
The following crimping heads are available for the Wiring Harness
t. C rig
gh ht
Repair - Crimping Plier - Base Tool - VAS1978/1-2- :
pyri by
Vo
co lksw
by
cted agen
Wiring Harness Repair - Crimping Head - .35-2.5mm -
Prote AG.
VAS1978/1-1-
Wiring Harness Repair Set - Crimping Head - 4-6mm -
VAS1978/2 A-
Wiring Harness Repair Set - Crimping Head - JPT -
VAS1978/9-1-
In conjunction with Wiring Harness Repair Set - Crimping Head -
JPT - VAS1978/9-1- , crimping pliers are used to crimp terminals
onto individual wires when repairing wiring cross-sections up to
0.35 mm2 .
Changing Exchangeable Head
Completely open the Wiring Harness Repair - Crimping Plier
- Base Tool - VAS1978/1-2- .
2. Connectors 95
Disengage both locking pins -arrows- from the Wiring Harness

Repair - Crimping Plier - Base Tool - VAS1978/1-2- .
Insert the required exchangeable head into the Wiring Har

ness Repair - Crimping Plier - Base Tool - VAS1978/1-2- from
above -arrow-.
Lock the exchangeable head by pressing the pins -arrows- into

the Wiring Harness Repair - Crimping Plier - Base Tool -
VAS1978/1-2- .
AG. Volkswagen AG d
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2.2 Vehicle Electrical System, General Re

h re
hole
spec
pair Information
es, in part or in w
t to the co
Caution
rrectness of i
When disconnecting and connecting the Battery - A- , the pro

l purpos
cedure must be followed as described in the repair manual.

Refer to Electrical Equipment; Rep. Gr. 27 ; Battery; Battery,
Disconnecting and Connecting .
nform
mercia
at
om
ion
c
in t
r
WARNING
o
his
ate
do
priv
Some tools are supplied with a tool safety clip, which is slid
cum
for
over the tool points after using the tool, in order to protect other
en
ng
t.
yi
workers from injuries and tool points from damage.
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
When performing repairs, always heed any notes, cautions cted agen
Prote AG.
and warnings found in the applicable repair manual.

Observe the country-specific requirements.

Disconnect the Battery - A- before working on the electrical
system. Refer to Electrical Equipment; Rep. Gr. 27 ; Bat
tery; Battery, Disconnecting and Connecting . By disconnect
ing the Battery - a- (current disruption), the electrical system
is guaranteed to be safe to work on. Disconnecting the positive
battery cable is only required when removing the Battery - A- .
Before beginning repair work, always eliminate any cause of
damage (sharp body edges, faulty electrical components, cor
rosion).
Further information, for example, installing and removing the
individual components, can be found in the appropriate repair
manual.
Soldering is not permissible for repairs to the vehicle electrical
system. Volkswa AG. gen AG
agen does
Wiring harness and connector repairs olto
kswvehicle electrical sys not
yV gu
tem may only be performed using ed the Wiring Harness Repair
b ara
nte
Set - VAS1978- / Wiring Harness ris Repair Set - VAS1978A- /
tho eo
Wiring Harness Repair Set
ss
au- VAS1978B- . ra
c
ce
le
Wiring harness repairs are only to be done using yellow wires.

un
pt
an
d
itte
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Wiring harness repairs may not be performed again in the
rm
ab
wrapping of the vehicle-specific wiring harness and are to be
pe
ility
marked with yellow adhesive tape.
ot
wit
, is n
h re
These yellow wires and every location on wiring harness wrap
hole
spec
ped in yellow insulating tape indicates a previous repair.
es, in part or in w
t to the co
Crimp connections must never be repaired. Route a wire par
allel to the faulty wire.
After crimping, the crimp connectors must be heat-shrunk us
rrectness of i
ing the Wiring Harness Repair Set - Hot Air Blower -
l purpos
VAS1978/14A- to prevent moisture penetration.

Always observe the supplementary notes also for repairing nform
ercia
wiring harnesses on airbag-system and belt tensioners, fiber

optic cables, CAN-Bus wires, antenna wires and wires with
m
cross-sections up to 0.35 mm 2. Refer to

com
tion in
2.3.4 Wires with Cross Section up to 0.35 mm 2, Repairing,

r
te o
thi
page 101 .
s
iva
do
r
A function test must be performed after every repair. If nec

rp
cum
fo
essary, check DTC memory, erase and/or bring systems into

en
ng
t.
yi
basic setting.
Co
Cop py
t. rig
gh
If possible, do not loosen ground (GND) straps from body
ht
pyri by
Vo
o
(danger of corrosion).
c by lksw
cted agen
Prote AG.
Not all wire cross-sections in the vehicle are contained in the
Wiring Harness Repair Set - VAS1978B- and its previous ver
sions. If the required wire cross-section is not present, the next
greater cross-section must be used.
Shielded harnesses may not be repaired. If faulty, the entire
harness must be replaced.
Heat-resistant wires have been installed in the vehicle at var
ious locations, mainly in the engine compartment. Heat-resist
ant wires can be recognized by their somewhat duller and
softer insulation. Only heat-resistant wires may be used to re
pair these wires.
2. Connectors 97
AG. Volkswagen AG d
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Beetle 2012 , Golf 2015 , Golf Variant 2007 Vol , Golf Variant 2010 ...ot gu
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by
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d ara
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2.3 Wiring Harnesses, Repairing ss
ce
le
un
pt
2.3.1 Wiring Harnesses, Repair Information, page 98
an
d
itte
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rm
ab
2.3.2 Airbag and Belt Tensioner Wire Repair Information,
pe
ility
page 98
ot
wit
, is n
h re
2.3.3 CAN Bus Lines Repair Information, page 100
hole
spec
2.3.4 Wires with Cross Section up to 0.35 mm 2, Repairing,
es, in part or in w
t to the co
page 101
2.3.5 Wire Break with Single Repair Point, page 103
rrectness of i
2.3.6 Wire Break with Dual Repair Point, page 105
l purpos
2.3.1 Wiring Harnesses, Repair Information

Observe general notes for repairs on the vehicle electrical
nform
ercia
system. Refer to
m
a
2.2 Vehicle Electrical System, General Repair Information,
com
tio
page 96 .
n in
r
te o
thi
Not all wire cross-sections in the vehicle are contained in the
s
iva
do
Wiring Harness Repair Set - VAS1978- / Wiring Harness Re
r
rp
cum
pair Set - VAS1978A- . If the required wire cross-section is not
fo
en
ng
present, the next greater cross-section must be used.

t.
yi Co
Cop py
t. rig
Wiring harness and connector repairs to vehicle electrical sys yri
gh by
ht
tem must only be performed using the Wiring Harness Repair cop Vo
by lksw
Set - VAS1978- / Wiring Harness Repair Set - VAS1978A- .
cted agen
Prote AG.
Soldering is not permissible for repairs to the vehicle electrical

system.
Wiring harness repairs are only to be done using yellow wires.
Wiring harness repairs may not be performed again in the
wrapping of the vehicle-specific wiring harness and are to be
marked with yellow adhesive tape.
These yellow wires and every location on wiring harness wrap
ped in yellow insulating tape indicates a previous repair.
Crimp connections must never be repaired. Route a wire par
allel to the faulty wire.
After crimping, the crimp connectors must be heat-shrunk us
ing the Wiring Harness Repair Set - Hot Air Blower -
VAS1978/14A- to prevent moisture penetration.
Shielded harnesses may not be repaired. If faulty, the entire
harness must be replaced.
Heat-resistant wires have been installed in the vehicle at var
ious locations, mainly in the engine compartment. Heat-resist
ant wires can be recognized by their somewhat duller and
softer insulation. Only heat-resistant wires may be used to re
pair these wires.
Always observe also the supplementary notes for repairing
wiring harnesses on airbag- and seat belt tensioner systems,
fiber optic cables, CAN bus lines, antenna wires and wires with
cross-sections up to 0.35 mm 2.
2.3.2 Airbag and Belt Tensioner Wire Repair

Information
In addition to the general repairs on wiring harnesses, the follow
ing methods and instructions must be observed for repairs on
wiring harnesses for airbag systems and belt tensioners:

WARNING
The airbag system and belt tensioner can fail.

Faulty repairs performed on airbag and seat belt tensioner
system can lead to malfunction in passenger protection.
When performing repairs on airbag and seat belt tensioner
wiring harness, use only terminals, connectors and wires
designated for it. Refer to the Parts Catalog.
AG. Volkswagen AG d
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erm
ab
ility
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, is n
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
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te
sd
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en
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Cop py
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cted agen
Prote AG.
2. Connectors 99
. Volkswage
Electrical Equipment General Informationsw- aEdition
gen AG 01.2015n AG doe
s
k not
Vol gu
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Wires from the airbag and seat belt tensioner
ris
e wiring harness nte
utho Harness Repair Set -
may only be repaired using the Wiring eo
ra
a
VAS1978- / Wiring Harness Repairss Set - VAS1978A- / Wiring c
Harness Repair Set - VAS1978B- .
ce
e
nl
pt
du
an
itte
Pay attention to stickers on vehicle designating high voltage
y li
erm
ab
components. When performing repairs, residual voltage must
ility
ot p
be discharged. Refer to Rep. Gr. 00 ; Safety Precautions;
wit
Pyrotechnic Components Safety Precautions . , is n
h re
hole
A maximum of 2 repairs may be performed when repairing
spec
es, in part or in w
wires of airbag- and seat belt tensioner system. Repairs in
t to the co
crease the electrical resistance in the wire and may trigger
malfunctions in the system On Board Diagnostic (OBD).
When repairing airbag or safety belt tensioner wiring, crimp
rrectness of i
connectors must be shrunk to prevent corrosion.
l purpos
Wiring harness repairs may only be performed using yellow

wires.
nf
ercia
o
Do not wrap the repair point again into the vehicle-specific
rm
m
atio
wiring harness and mark the repair point very visibly with yel
om
low insulating tape.
n in
or c
thi
e
Repairs in the area of the airbag or seat belt tensioner should

t
sd
iva
be performed a maximum of 30 cm from the next connector
o
r
rp
cu
housing. Together with the identification via yellow insulating
o
m
f
en
ng
tape, this procedure makes it possible to obtain a quick over

t.
yi Co
op
view of previously performed repairs.
C py
t. rig
gh ht
yri by
Wires to the deploying units (airbags) have a wire-twisting with cop Vo
by lksw
a length of lay of 20 mm 5 mm in series production. This
cted agen
Prote AG.
length of lay is guaranteed via the norm part numbers for wire
pairs in series production and must be observed strictly for the
repair lengths of twisted wires.
During repair work, wires to deploying units (airbags) must
have the same length. When twisting together wires -1- and
-2-, length of lay of A = 20 mm 5 mm must be strictly ob
served.
While doing this, no section of the wire also in area of crimp
connectors -arrow-, may be greater than B = 100 mm without
twisting of the wires.
2.3.3 CAN Bus Lines Repair Information

Unshielded two-strand wiring -1- and -2- with a cross section
of 0.35 mm2 and/or 0.5 mm2 can be used as CAN bus wiring.
The color coding of CAN bus lines can be found in the following
table:
Powertrain CAN high wire Orange/black
Comfort CAN high wire Orange/green
Infotainment CAN high wire Orange/violet
CAN low wire (all) Orange/brown

Repairs on CAN bus lines can be performed using repair wire

with matching cross section, and also using twisted wires
green/yellow and white/yellow from the Parts Catalog.
When repairing CAN bus lines, both wires must be same
length. When twisting together wires -1- and -2-, the lay length
of A = 20 mm must be observed.
While doing this, no section of the wire also in area of crimp
connectors -arrow-, may be greater than B = 50 mm without
twisting of the wires.
Wrap repair points with yellow adhesive tape to mark a per
formed repair.
2.3.4 Wires with Cross Section up to 0.35 mm

2
, Repairing
When repairing wires with a cross-section up to 0.35 mm2, new
contacts must always be crimped on using the Crimping Pliers -
JPT - VAS1978/9A- or the Wiring Harness Repair - Crimping Plier AG. Volkswagen AG d
- Base Tool - VAS1978/1-2- with the Wiring Harness Repair agen
ksw Set
oes
ol not
- Crimping Head - JPT - VAS1978/9-1- installed. Due d by Vto the low gu
ara
current strengths of these wires in the micro- tohomilli- range, con
rise nte
eo
tacts crimped on incorrectly lead to continuityautresistances and ra
c
cause malfunctions or failure of the respective
ss
system. The most
ce
e
frequent applications of these contacts are:

nl
pt
du
an
itte
y li
Heated Oxygen Sensor
erm
ab
ility
ot p
RPM sensor
wit
, is n
h re
Mass Airflow Sensor
hole
spec
By using the Crimping Pliers - JPT - VAS1978/9A- or the Wiring
es, in part or in w
Harness Repair - Crimping Plier - Base Tool - VAS1978/1-2- with
t to the co
the Wiring Harness Repair Set - Crimping Head - JPT -
VAS1978/9-1- installed, the correct connection between crimp
contact, wire and single wire seal is guaranteed. The tool is to be
rrectness of i
used only for the purpose described.
l purpos
Note
nf
ercia
orm
m
Contacts in a normal and a gold-plated version are crimped onto atio

m
repair wires. The same version of the contact that was installed
o
n in
or c
at the factory must always be used for repairs.

thi
te
sd
iva
o
r
rp
cu
Crimping A New Contact with Single Wire Seal

o
m
f
en
ng
t.
yi
Insert the Wiring Harness Repair Set - Crimping Head - JPT -
Co
op py
VAS1978/9-1- into the Wiring Harness Repair - Crimping Plier
. C rig
ht ht
rig
- Base Tool - VAS1978/1-2- . Refer to py by
co Vo
2.1.10 Crimping Pliers - .35-2.5mm VAS1978/1A ,
by lksw
cted agen
Prote
page 95 .
AG.
2. Connectors 101
. Volkswagen AG
a gen AG does
Place the single wire seal onto the repair wire.
Vol
ksw not
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th
Note ss
au ra
c
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un
pt
When doing this, the smaller diameter of single wire seal must be
an
d
itte
facing in the direction of the contact to be crimped on.
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Open the Wiring Harness Repair - Crimping Plier - Base Tool
rrectness of i
- VAS1978/1-2- (green body) and insert the repair wire end
into the stripping slot of the Wiring Harness Repair - Crimping
l purpos
Plier - Base Tool - VAS1978/1-2- .
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
Close the Wiring Harness Repair - Crimping Plier - Base Tool yri
p by
o Vo
- VAS1978/1-2- completely.
c by lksw
cted agen
Prote AG.
Reopen the Wiring Harness Repair - Crimping Plier - Base
Tool - VAS1978/1-2- and remove the stripped wire end.
Slide single wire seal in direction of stripped wire end until it

rests flush with the wire insulation.

Insert the new crimp contact into the Wiring Harness Repair -
Crimping Plier - Base Tool - VAS1978/1-2- mount.
Insert the stripped wire end with positioned single wire seal
into crimp contact until it makes contact on Wire-Stop.
Crimp the contact, wire and single wire seal by completely
closing the Wiring Harness Repair - Crimping Plier - Base Tool
- VAS1978/1-2- .
Reopen the Wiring Harness Repair - Crimping Plier - Base
Tool - VAS1978/1-2- and remove the finished crimped-on con
tact.
A correctly performed crimp is distinguished by a clean compres

sion of wire and single wire seal in the contact and has an
impression on the rear side which identifies that the crimp was
performed by a professional using the correct tool.
AG. Volkswagen AG d
agen oes
olksw not
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erm
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ility
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2.3.5 Wire Break with Single Repair Point wit

, is n
h re
Repair Point with Single Crimp Connection

hole
spec
es, in part or in w
Free up the wire to be repaired approximately 20 cm on both

t to the co
sides of the repair point.

If required, remove wiring harness wrapping using a folding
rrectness of i
knife.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
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by lksw
cted agen
Prote AG.
2. Connectors 103
Cut out the damaged section of wire using the Wiring Harness
Repair Set - Wire Strippers - VAS1978/3- .
Note
If, by cutting out the damaged wire section, both ends of the ve
hicle-specific single wire are too short for a repair using a single
crimp connector, insert a repair wire section of matching length
with two crimp connectors. Refer to
2.3.6 Wire Break with Dual Repair Point, page 105 . agen
AG. Volkswagen AG d
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d by ua
ran
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ris tee
utho or
sa ac
Strip the wire ends 6 to 7 mm using the WiringsHarness Repair
Set - Wire Strippers - VAS1978/3- .
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Slide the crimp connector onto both stripped wire ends of the
vehicle-specific single wire and crimp them using the Crimping
nf
ercia
Pliers - .35-2.5mm - VAS1978/1A- .
orm
m
atio
om
n in
c
Note
or
thi
te
sd
iva
Always be sure to use the correct crimping slot for the crimping
o
r
rp
cu
o
connection used.
m
f
en
ng
t.
yi Co
Do not crimp wire insulation. Cop py
t. rig
gh ht
pyri by
Vo
o
c by lksw
cted agen
Prote AG.

Place the Wiring Harness Repair - Blower - Shrink Element -
VAS1978/15A- on the Wiring Harness Repair Set - Hot Air
Blower - VAS1978/14A- .
Heat the crimp connector using the Wiring Harness Repair Set
- Hot Air Blower - VAS1978/14A- lengthwise from the center
outward until it is sealed completely and the adhesive comes
out at the ends.
Caution

er - VAS1978/14A- .
Always follow the Wiring Harness Repair Set - Hot Air Blower
- VAS1978/14A- Operating Instructions!

Note
Make sure that crimp connections do not lie directly next to

each other when several wires need to be repaired. Arrange
the crimp connectors at a slight offset so that the circumfer
ence of the wiring harness does not become too large.
In the event the repair point was previous taped, this point
must be taped anew with yellow insulating tape after repairs.
Secure the repaired wiring harness with a cable tie to prevent
flapping noises while driving.
2.3.6 Wire Break with Dual Repair Point

Repair Point with Intermediate Wire Section
Free up the wire to be repaired at two places (approximately
20 cm on both sides of the respective repair point).
Remove wiring harness wrapping using a folding knife.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
Place the yellow repair wire next to the damaged wiring har
itte
y li
erm
ness and cut the repair wire to the required length using the
ab
Wiring Harness Repair Set - Wire Strippers - VAS1978/3- . ility
ot p
wit
, is n
Cut damaged wire section from the vehicle-specific single h re

hole
wire.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
Strip the wire ends 6 to 7 mm using the Wiring Harness Repair

rm
m
Set - Wire Strippers - VAS1978/3- .

atio
om
n in
c
Slide crimp connection onto vehicle-specific single wire at one

or
thi
e
side and onto repair wire at the other side.

t
sd
iva
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m
f
en
ng
t.
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Cop py
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pyri by
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cted agen
Prote AG.
2. Connectors 105
Crimp the crimp connector at both wire ends using the Crimp
ing Pliers - .35-2.5mm - VAS1978/1A- .
Repeat this procedure at the other repair wire end.
AG. Volkswagen AG d
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Note y Volksw not
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Always beusure
tho to use the correct crimping slot for the crimping eo
ra
connection
ss a
used. c
ce
le
Do not crimp wire insulation.

un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
Place the Wiring Harness Repair - Blower - Shrink Element -
es, in part or in w
VAS1978/15A- on the Wiring Harness Repair Set - Hot Air
t to the co
Blower - VAS1978/14A- .
Heat the crimp connector using the Wiring Harness Repair Set
rrectness of i
- Hot Air Blower - VAS1978/14A- lengthwise from the center
l purpos
outward until it is sealed completely and the adhesive comes

out at the ends.
nform
ercia
Caution
m
a
com
tion in

r
te o
thi

s
iva
do
r
rp
cum
er - VAS1978/14A- .
fo
en
ng
t.
yi
Always follow the Wiring Harness Repair Set - Hot Air Blower
Co
Cop py
- VAS1978/14A- Operating Instructions!
t. rig
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pyri by
Vo
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by
cted agen
Prote AG.
Note


3 Connector Housings, Releasing and

Disassembling
3.1 Connector Housings, Releasing and Disassembling, page
107
3.2 Connector Housings and Connectors, Repairing,
page 112
3.1 Connector Housings, Releasing and

Disassembling
3.1.1 Information on Releasing and Disassembling Connector
Housings, page 107
3.1.2 Secondary Lock, page 107
3.1.3 Primary Lock, page 108
3.1.4 Round Connector Systems, page 109
3.1.5 Flat Connector Systems, page 109
3.1.6 Special Connector Systems, page 111
3.1.1 Information on Releasing and Disas

sembling Connector Housings
system. wage
es n
lks ot g
Vo
Always use the release tools intended for the releasing ed proc
by ua
ran
ess. Under no circumstances may terminals be pulled horis force tee
fully out of connector housings. aut or
ac
ss
Damaged connector housings must be replaced. New con
ce
e
nl
pt
du
nector housings may be ordered via the replacement parts
an
itte
y li
distributor.
erm
ab
ility
ot p
Small screwdrivers may be used as an aid to release the sec
wit
, is n
ondary locks.
h re
hole
The chamber/connector assignment is partially stamped on
spec
es, in part or in w
the secondary lock or the rear side of the connector housing.
t to the co
Detailed information on component locations of harness con
nectors. Refer to Wiring diagrams, Troubleshooting & Com
ponent locations.
The allocation of the correct release tools to the respective locking rrectness of i
l purpos
mechanisms can be found in the table in the Release Tool Set -

VAS1978/35- Operating Instructions.
nform
ercia
3.1.2 Secondary Lock

m
at
om
ion
The secondary lock is a housing securing mechanism (second

c
in t
or
locking mechanism) that secures all wires in one connector hous

his
ate
ing. If a secondary lock is installed at a connector housing, it must

do
priv
always be opened or removed using specified tool before releas

um
for
ing and pulling out individual crimp contacts.

en
ng
t.
yi Co
op py
Secondary lock is distinguished by a different color from the rest t. C rig
gh ht
of the connector housing. It simplifies recognizing the secondary yri
p by
o Vo
lock and clarifies its function.
c by lksw
cted agen
Prote AG.
3. Connector Housings, Releasing and Disassembling 107

The shapes of the connector housings depicted here are only a

selection which, as an example, should make clear the various
functions of the secondary lock.
Example 1
Housing securing mechanism is released by removing a comb
-arrow-.
Example 2
Housing securing mechanism is released by opening a flap
-arrow-.
Example 3
Housing securing mechanism can be released by disengaging a
slider -arrow-.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
3.1.3 Primary Lock

ot p
wit
is n
h re
The primary lock is the locking mechanism of an individual crimp

ole,
spec
contact in the connector housing.

t to the co
If necessary, housing securing mechanisms (secondary locks)

must be released or removed using specified tool before releasing
the contacts. Refer to 3.1.2 Secondary Lock, page 107 .
rrectne
The shapes of the primary locks depicted in the following are only
a selection which, as an example, should make clear the various
s
functions of the primary lock.

s o
cial p
f in
Round connector systems. Refer to

form
mer
3.1.4 Round Connector Systems, page 109 .

atio
m
Flat connector systems. Refer to

o
n
c
i
or
3.1.5 Flat Connector Systems, page 109 .

thi
te
sd
va
Special connector systems. Refer to

i
o
pr
cum
r
3.1.6 Special Connector Systems, page 111 .

fo
en
ng
t.
yi Co
The allocation of the correct release tools for the respective locks Cop py
can be found in the table in the Release Tool Set - VAS1978/35-
t. rig
gh ht
yri
p by
o Vo
by c lksw
cted agen
Prote AG.

3.1.4 Round Connector Systems

Equipped housing securing mechanisms (secondary locks) must
be released or removed using specified tool before releasing the
contacts. Refer to 3.1.2 Secondary Lock, page 107 .
Guide the release tool which fits the connector housing into
release channel on the connector housing.
Grasp the contact at the wire and gently push it into the con
nector housing -arrow-.
Note
By pushing the contact in the direction of the connector housing,

contact retaining tabs are lifted off the housing shoulder and can
be released using the release tool.
At the same time, push the release tool in the direction of the
connector housing and pull the released contact out of the
connector housing.
After removing the contact, release tool can be pulled out of the
connector housing again.
3.1.5 Flat Connector Systems

n AG. Volkswagen AG
Equipped housing securing mechanisms olks
w(secondary
age locks) must
does
not
be released or removed using specified
d by V tool before releasing the gu
ara
contacts. Refer to 3.1.2 Secondary
orise
Lock, page 107 . nte
e
h
ut or
Flat Connector System with
ss One Retaining Tab
a ac
ce
le
un
pt
an
d

itte
y li
rm
ab
pe
ility
ot

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

the contact retaining tab is lifted off the housing shoulder and can
rrectness of i

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

connector housing -arrow-.
Flat Connector System with Two Retaining Tabs
nector housing-arrow-.
Note

Asymmetrical
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li

rm
ab
pe
ility
ot
wit
, is n

h re
hole
spec
es, in part or in w
Note
t to the co

rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
110
Prote AG.
Rep. Gr.97 - Wiring
3.1.6 Special Connector Systems

Equipped housing securing mechanisms (secondary locks) must
be released or removed using n Aspecified
G. Volkswagtool before releasing the
en AG
wage
contacts. Refer to 3.1.2
olks Secondary Lock, page no107 .
does
t V gu
d by ara
Fasten Contacts
or
ise nte
h eo
ut ra
Guide the
ss release tool which fits the connector
a housing into c
the release channel on the connector housing -arrow-.
ce
e
nl
pt
du
an
itte
y li
nector housing.
erm
ab
ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w

t to the co
rrectness of i
l purpos
nf
ercia

orm
m
atio
m

o
n in
or c
thi
e
GT 150/280 Contacts
t
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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cted agen
Prote AG.
Guide the release tool which fits the connector housing under
the retaining tab into connector housing.
Insert the tool all the way -arrow- into the connector housing.

Contact is ejected from the connector housing.

After ejecting the contact, release tool can be pulled out of the
Contacts without Retaining Tabs
Insert release tool under retaining tab of the connector hous

ing.
Push release tool through until it stops by gently lifting
-arrow-.
Contact is ejected from the connector housing.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
3.2 Connector Housings and Connectors,

es, in part or in w
Repairing
t to the co
3.2.1 Connector Housings and Connectors, Repair Informa

tion, page 112
rrectness of i
3.2.2 Contacts in Connector Housing, Repairing, page 113

l purpos
3.2.3 Single Wire Seals, Installing, page 114

nf
ercia
3.2.4 Connector Housing with Insulation Displacement Con

rm
m
nections, Repairing, page 116

atio
om
n in
c
3.2.1 Connector Housings and Connectors,

or
thi
te
sd
Repair Information
iva
o
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rp
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f

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ng
t.
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system.
Co
Cop py
ht. rig
Allocation of crimp contacts with correct fit to connector hous
rig ht
py by
o Vo
ing is performed according to the part number stamped in on by c lksw
cted agen
the connector housing. Part numbers of connector housing are Prote AG.
listed in conjunction with the respective crimp contacts with

correct fit in plate 198 (electrical connecting elements) in the
Parts Catalog.

Damaged connector housings must be replaced.

New connector housings may be ordered via the replacement
parts distributor.
3.2.2 Contacts in Connector Housing, Repair

ing
Procedure
First open or release the secondary lock of the connector
housing.
Release the contact (primary lock) using the appropriate re
lease tool.
Pull contact at single wire out of the connector housing.
Take the yellow repair wire with the correct contact out of the
Wiring Harness Repair Set - VAS1978- / Wiring Harness Re
pair Set - VAS1978A- / WiringlksHarness
wage Repair Set - es n
VAS1978B- . db
yV
o ot g
ua
e ran
ris tee
Free up repair pointuthof
o vehicle-specific wiring harness (ap
or
proximately 20 cmss ato both sides of repair point). ac
ce
le
Remove wiring harness wrapping using a folding knife.

un
pt
an
d
itte
y li
rm
ab
pe
ility
Insert new contact of repair wire into connector housing until
ot
wit
it engages.
, is n
h re
hole
Slide a single wire seal onto the repair wire.
spec
es, in part or in w
t to the co
Note
rrectness of i
When doing this, the small diameter of the single seal must point
toward the connector housing.
l purpos
Slide the single wire seal into the connector housing using the
nform
ercia
correct assembly tool. Refer to

3.2.3 Single Wire Seals, Installing, page 114 .
m
a
com
tion in
r
Shorten the repair wire and the vehicle-specific wiring harness

te o
thi
s
single wire using the Wiring Harness Repair Set - Wire Strip
iva
do
r
pers - VAS1978/3- .
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Strip the ends of the repair wire and the vehicle-specific single
wire 6 to 7 mm using the Wiring Harness Repair Set - Wire
Strippers - VAS1978/3- .
Crimp the stripped ends of the repair wire and single wire of
vehicle-specific wiring harness using the Crimping Pliers - .
35-2.5mm - VAS1978/1A- and a crimp connector as described
in chapter Open circuit with single repair point.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
Note
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
ss o
cial p
f
3.2.3 Single Wire Seals, Installing
inform
mer
atio
om
n
Note
c
i
or
n thi
te
sd
a
Single wire seals prevent the penetration of water and dirt into
iv
o
pr
the connector housing. They are installed in the engine com

um
r
fo
en
ng
partment and must be reinstalled after a repair.

t.
yi Co
op py
Single wire seal is crimped on at the factory together with con
t. C rig
gh ht
yri
tact on the wire, this is not the case for repair wires. Single wire p by
co Vo
seal must be slid onto wire first before crimping the repair wire.
by lksw
cted agen
Prote AG.
Single wire seals must always fit with the repair wire cross-
section. Outer circumference of single wire seal is aligned
according to chamber circumference of the connector hous
ing. Perform assembly using only the assembly tool with cor
rect fit.
Assembling Single Wire Seal

Release the contact lock using the appropriate release tool
-A- and then pull wire with single wire seal toward the rear
-arrow- out of the connector housing.

Cut off the old contact with single wire seal from the vehicle-
specific wiring harness.
Slide repair wire with the new contact into the corresponding
chamber of connector housing until it engages -arrow-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
ho
Put single wire seals -A-
au onto the free end of the repair wire.
t or
ac
s ce
le
un
pt
an
d
Note
itte
y li
rm
ab
pe
ility
When doing this, the small diameter of the single wire seal must
ot
wit
, is n
point toward the connector housing.

h re
hole
spec
Slide single wire seal -A- on the repair wire up to the connector
es, in part or in w
t to the co
housing -arrows-.
rrectness of i
l purpos
Slide single wire seal -A- all the way into the connector housing
using the corresponding assembly tool -B-.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Shorten the repair wire and the vehicle-specific wiring harness

single wire as needed using the Wiring Harness Repair Set -
Wire Strippers - VAS1978/3- .
Crimp the stripped ends of the repair wire and single wire of
vehicle-specific wiring harness using the Crimping Pliers - .
35-2.5mm - VAS1978/1A- and a crimp connector as described
in chapter Open circuit with single repair point.
lkswage es n
o ot g
byV ua
d ran
3.2.4 Connector Housing with Insulation Dis
utho
ir se tee
or
placement Connections, Repairing
ss
a ac
ce
le
un
pt
an
d
itte
y li
Note
rm
ab
pe
ility
ot
wit
For technical reasons, the connector housing for the wire ter
, is n
h re
minals can be supplied only with the contacts pushed in.
hole
spec
These contacts can be removed at every other connector
es, in part or in w
t to the co
housing in the event they are not required.
Repair wires which have already been equipped with corre
sponding contacts crimped on are available. Refer to the Parts rrectness of i
Catalog.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

4 Contact Surfaces, Cleaning

4.1 Contact Surface Cleaning Set VAS6410 , page 117
4.1 Contact Surface Cleaning Set - agen

AG. Volkswagen AG d
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VAS6410- d by Volksw not
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4.1.1 Using Contact Surface Cleaning Set VAS6410 uth,
o eo
ra
page 117 ss a c
ce
e
nl
4.1.2 Wiring Eyelets, Repairing, page 117
pt
du
an
itte
y li
4.1.3 Threaded Connections, Repairing, page 119
erm
ab
ility
ot p
4.1.4 Battery Clamps and Battery Terminals, Cleaning,
wit
, is n
page 120
h re
hole
spec
4.1.5 Protecting, page 121
es, in part or in w
t to the co
4.1.1 Using Contact Surface Cleaning Set -
VAS6410-
rrectness of i
The Contact Surface Cleaning Set - VAS6410- makes optimal
l purpos
repair quality possible in the realm of vehicle electronics. Using

the tools, service work can be performed in the area of the contact
sensor on the threaded connection wiring harnesses in the high
nf
ercia
current circuit (starter and charging current). The Contact Surface
orm
Cleaning Set - VAS6410- is adapted to the vehicle structural
m
atio
m
measurements and ensures correct servicing and a comfortable

o
n in
c
procedure.
or
thi
te
sd
iva
o
r
rp
cu
Note
o
m
f
en
ng
t.
yi Co
op
The illustrations of the service work only serve as examples.
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
Contact Surface Cleaning Set - VAS6410- Prote
cted AG.
agen
4.1.2 Wiring Eyelets, Repairing

Torque Wrench 1331 5-50Nm - VAG1331-
Note
Do not use rust remover, contact spray or grease because the

lack of friction will cause the torque to be exceeded when in
stalling and this will lead to the threaded connection breaking.
The gray sanding pads are for slight contamination and suit
able for "soft surfaces". The red sanding pads are for heavy
contamination and suitable for "hard surfaces".
4. Contact Surfaces, Cleaning 117

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ar
Beetle 2012 ris , Golf 2015 , Golf Variant 2007 , aGolf
ed
nte Variant 2010 ...
o eo
Electrical aEquipment
ut
h
General Information - Edition 01.2015 ra
ss c
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nl
pt
du
an
WARNING itte
y li
erm
ab
ility
ot p
wit
cautions. Refer to
, is n
h re
hole
spec
es, in part or in w
t to the co
Procedure
rrectness of i
l purpos
Loosen the cap nut and remove the wiring eyelet from the
threaded connection.
nform
ercia
Check the wiring eyelet for corrosion and dirt.

m
at
Select the corresponding adapter and the corresponding
om
io
sanding pad.
n
c
in t
or
his
ate
do
priv
c
Note
um
for
en
ng
t.
yi Co
The sanding block can be used instead. Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Caution
Prote AG.
Make sure the tin layer is not worn down too much and the
copper is not visible. A galvanic element can form from this,
destroying the metal and causing incorrect repairs.
Note
Due to the different thicknesses of the tin layer, the cleaning proc
ess must be performed in several steps and a visual inspection
of the wiring eyelet between steps is necessary.
Insert the adapter in the wiring eyelet and sand off the corro
sion and contamination with circular motions.
Check the wiring eyelet and sand it again.

Remove the burr on the wiring eyelet with the deburrer. . Volkswagen AG
gen AG does
swa
Install the wiring eyelet to the specified tightening specifica
y Volk not
gu
tion. Refer to Electrical Equipment; Rep. Gr. 97ris;eCompo
db ara
nte
nent Location Overview - Relay Carriers, Fuse Panels ut
ho and E- eo
ra
Boxes or Electrical Equipment; Rep. Gr. 27 ss a; Overview - c
Battery .
ce
le
un
pt
an
d
Protect the connection with the corresponding protection ma
itte
y li
terial. Refer to 4.1.5 Protecting, page 121 .
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
WARNING
t to the co
cautions. Refer to
rrectne
ss o
cial p
f inform
4.1.3 Threaded Connections, Repairing
mer
atio
m

o
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
Note
t.
yi Co
Cop py
t. rig
gh
ht
pyri by
Vo
lack of friction will cause the torque to be exceeded when in
o
by c lksw
cted agen
stalling and this will lead to the threaded connection breaking. Prote AG.
The gray sanding pads are for slight contamination and suit
able for "soft surfaces". The red sanding pads are for heavy
contamination and suitable for "hard surfaces".
WARNING

cautions. Refer to
Procedure

Loosen the cap nut and remove the wiring eyelet from the
threaded connection.
Check the threaded connection for corrosion and dirt.
Select the corresponding adapter and the corresponding
sanding pad for the threaded connection.
Caution
Make sure the tin layer is not worn down too much and the
copper is not visible. A galvanic element Acan
G. Voform
lkswagfrom
en AGthis,
destroying the metal and causing oincorrect
lksw
agen repairs. does
no
yV t gu
db ara
rise nte
tho eo
au ra
c
ss
Note
ce
le
un
pt
an
d
itte
y li
Due to the different thicknesses of the tin layer, the cleaning proc
erm
ab
ess must be performed in several steps and a visual inspection
ility
ot p
of the wiring eyelet between steps is necessary.
wit
is n
h re
ole,
spec
Insert the adapter in the threaded connection and sand off the
t to the co
corrosion and contamination with circular motions.
Check the threaded connection and sand it again.
rrectne
Fasten the connection and the anti-twist mechanism to the
specified tightening specification. Refer to Electrical Equip
ment; Rep. Gr. 97 ; Component Location Overview - Relay
ss o
Carriers, Fuse Panels and E-Boxes or Electrical Equipment;
cial p
Rep. Gr. 27 ; Overview - Battery . f inform

mer
Protect the threaded connection with the corresponding pro

atio
m
tection material. Refer to 4.1.5 Protecting, page 121 .

o
n
c
i
or
n thi

te
sd
a

iv
o
pr
cum
r
fo
en
ng
t.
yi
WARNING
Co
Cop py
ht. rig
rig ht
by
Risk of injury. Follow all warning messages and safety pre copy Vo
by lksw
cautions. Refer to cted agen
Prote AG.
4.1.4 Battery Clamps and Battery Terminals,

Cleaning
Note

lack of friction will cause the torque to be exceeded when instal
ling and this will lead to the threaded connection breaking.

WARNING

cautions. Refer to
Procedure
Check the battery terminal and battery pole for corrosion and
dirt.
The battery terminal clamp is cleaned with the battery terminal
cleaner wire brush using circular motions.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
The battery terminal is cleaned with the bottom side of the termi
pe
ility
nal cleaner using circular motions.

ot
wit
, is n
h re
hole
WARNING
spec
es, in part or in w
t to the co

cautions. Refer to
rrectness of i
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4.1.5 Protecting
com
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Caution
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Missing protection leads to the electrical system damage.

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Note
All threaded connections must be tightened to the tightening

specification.
When applying protection, use the accompanying hose on the
protection container.
Protection wax is used in the cool area.
Cavity protection wax is used in the warm area.
The protection material draws itself into the affected places by
capillary action.

Procedure
Hold the injector under the wiring eyelet and spray all around wage
es n
s
the pins. yV
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Hold the injector above the wiring eyelet and spray all around
the pins and wiring eyelet.
rrectness o
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5 Antenna Wires, Repairing

5.1 General Information, page 123
5.2 Overview - Antenna Wiring, page 123
5.3 New Antenna Wire, Installing, page 123
5.1 General Information

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A new repair concept has been developed olks
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wires. Instead of a complete antenna d b wire, connecting wires of ua
ran
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different lengths and various thadapter
or leads are now available as tee
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General Information
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If a repair is necessary, antenna wires may not be repaired,
rm
ab
but rather are to be replaced with genuine replacement parts,
pe
ility
such as connecting wires and adapter leads.
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Replacement parts are found in the Parts Catalog.
hole
spec
These genuine replacement parts are suitable for all antenna
es, in part or in w
t to the co
wires and wire cross sections, that require replacement.
Connector housing for antenna wires can be obtained as a
replacement part only in one color, but can be used for all an
rrectness of i
tenna connector colors.
l purpos
The replacement of individual antenna connectors during re

pair work is not intended.
nform
ercia
The wires are appropriate for use on all VW vehicles with

m
equipped antenna wiring cross-sections.
a
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All adapter leads and connecting wires are suitable for various
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transmission and reception signals. thi

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This repair concept can also be used for testing or as an after-

um
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market solution.
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5.2 Overview - Antenna Wiring
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Overview of Antenna Wiring Prote
cted AG.
agen
Example: antenna wire from the Radio - R- to the Antenna - R11-

faulty. The following wires are required for repair:
1- Adapter cable for connecting to the Radio - R- , length ap
proximately 30 cm
2- Connecting wire, available in various lengths.
3- Adapter cable for connecting to the Antenna - R11- , length
approximately 30 cm
5.3 New Antenna Wire, Installing

Note that, depending on the vehicle equipment, the entire length
of an antenna wire may be separated into partial lengths by the
Antenna Selection Control Module - J515- , Traffic Monitoring
Control Module - J559- or Antenna Amplifier - R24- . Only the
defective sections need to be replaced.
Procedure
Separate the connectors of the faulty antenna wiring from their
components.
Determine the path of the faulty antenna wire in the vehicle
and measure the total length of antenna wire to be replaced.
5. Antenna Wires, Repairing 123

The entire length of the antenna wire consists of the length of the
required adapter leads -1 and 3- as well as the connecting wire
-2-.
Subtract 60 cm from the total length of antenna wire meas
ured, to receive the length of connecting wire -2- required.
Obtain the required adapter cables -1 and 3- as well as the
calculated length of connecting line -2- as original replacement
part according to the Parts Catalog.
Cut the connectors off of the faulty antenna wiring.
Leave the rest of the defective antenna wire in the vehicle.
Connect the adapter leads -1 and 3- to devices in the vehicle.
Route and secure connecting wire -2- in the immediate vicinity
of the series-installed wire routing.
Note
AG. Volkswagen AG d
Antenna wires must not be kinked or excessively bent! The bend
olks
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ing radius must not be less than 50 mm. db
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Connect the connecting wire with the adapter leads.
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Perform a functionality test.

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6 Fiber-Optic Cable
6.1 Fiber-Optic Cables, Repairing, page 125
6.2 Fiber-Optic Cable, Assembling, page 125
6.3 Fiber-Optic Cable, Disconnecting from Wiring Harness
Connector, page 130
6.1 Fiber-Optic Cables, Repairing

It is very difficult to find the exact location of the problem. Replace
the damaged fiber-optic cable and lay a new wire parallel to the
defective fiber-optic cable.
Note
Select the damaged fiber-optic cable components with the

Guided Fault Finding or Guided Functions from the Vehicle
Diagnostic Tester menu options.
A fiber-optic cable that needs repair is represented by a yel
low color.
Procedure:
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Choose Guided FaultyFinding
Vol
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Vehicle DiagnosticiseTester .
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Assemble the afiber-optic
ut cable. Refer to or
ac
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6.2 Fiber-Optic Cable, Assembling, page 125 .
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Do not bend the fiber-optic cable too much. The bending radius
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must be no less than 25 mm.

h re
hole
spec
Fiber optic cables must not be routed over sharp edges.

es, in part or in w
t to the co
The fiber-optic cable must not be dirty or touched with bare

fingers.
rrectness of i
Fiber optic cables may not be heated.

l purpos
It is not permitted to twist together 2 fiber optic cables or one

fiber optic cable with a copper wire.
nform
ercia
Protect the connector and the connection box from dust. Place
the cap on the trunk.
m
at
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ion
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6.2 Fiber-Optic Cable, Assembling

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Fiber-Optic Conductor Repair Set - VAS6223A- t. Cop py
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Hose Cutting Pliers - VAS6228- p by
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Vehicle Diagnostic Tester Prote AG.
6. Fiber-Optic Cable 125

Caution
Do not bend the fiber-optic cable too much. The bending radius
must be no less than 25 mm.
Fiber optic cables must not be routed over sharp edges.
The fiber-optic cable must not be dirty or touched with bare
fingers.
Fiber optic cables may not be heated.
It is not permitted to twist together 2 fiber optic cables or one
fiber optic cable with a copper wire.
Protect the connector and the connection box from dust. Place
the cap on the trunk.
AG. Volkswagen AG d
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Mount the Tool Head for therise Fiber-Optic Repair Set - Pliers -
d b ara
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VAS6223/1- . utho eo
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Remove the locating
s pin in the direction of the -arrow-.
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Position the tool head in the direction of the -arrow-.

nform
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Push the locking pin back.

m
at
Fiber Optic Cable, Cutting to Length

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Open the Fiber-Optic Repair Set - Pliers and lay the fiber-optic
cable -1- in direction of the -arrow- in the mount.
Establish length of fiber optic cable required.
Close the Fiber-Optic Repair Set - Pliers - VAS6223/1- to cut
the fiber-optic cable to length.
Stripping

Open the Fiber-Optic Repair Set - Pliers - VAS6223/1- .

Position the wire stripper lever in the lower position in direction
of the -arrow-.
Insert fiber-optic cable into the stripping station.
The end of the fiber-optic cable must be flush with the rear side
of the cutting pliers.
AG. Volkswagen AG d
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Close the Fiber-Optic Repair Set - Pliers - VAS6223/1- until it s
ce
le
stops and keep closed.
un
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Turn the wire stripper lever in the direction of the -arrow-.
rm
ab
pe
ility
Remove the fiber-optic cable.
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Precision Cutting (production of optical end face)
hole
spec
es, in part or in w
t to the co
rrectness of i
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Push the fiber-optic cable -1- into the cutting station.
nform
ercia
Insulation must make contact with cutting point stop.

m
a
Close the Fiber-Optic Repair Set - Pliers - VAS6223/1- and
com
tion in
remove the wire.
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Visually inspect the wire -1- to make sure that it was cut cor
rectly and that there are no burrs on the front surface.
Note
Fiber-optic cable is only to be placed on an absolutely clean

surface or held in hand.
Use the cap if there is a risk of the fiber-optic cable surface
becoming dirty.
Attaching Brass Pin Contact to Fiber-Optic Cable.

Position the tool head in the direction of the -arrow-.
Slide the safeguard on the Fiber-Optic Repair Set - Pliers -

VAS6223/1- in direction of the -arrow- so that the word
Stift (pin) is legible.
AG. Volkswagen AG d
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Insert a brass pin contact -1- in the mount. s
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Close the securing lever on the Fiber-Optic Repair Set - Pliers

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- VAS6223/1- in the direction of the -arrow-.

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rrectness of i
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Insert the fiber-optic cable into the brass pin contact -arrow-
all the way up to the threaded stop and then close the Fiber-
nform
ercia
Optic Repair Set - Pliers - VAS6223/1- .

m
at
om
Open the fiber-optic cable pliers and remove the fiber-optic

on
c
in t
cable along with the brass contact pin.

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Do not excessively bend or kink the fiber-optic cables (mini C py
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Make sure the brass pin contact
ss -2- is secured properly on the
a ac
fiber-optic cable -1-.
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4 crimped points must be visible on the brass connecting pin.
itte
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The brass pin contact must not be able to be removed by hand
ility
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from fiber-optic cable.
wit
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The front surface of the fiber-optic cable is 0.01 to 0.1 mm
spec
behind the brass pin contact (visual check).
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Note
rrectne
Connector couplings are available for connecting the fiber-op
tic cables. Refer to Parts Catalog.
ss o
cial p
f
To install the new fiber optic cable in wiring harness connector.
inform
Refer to
mer
6.3 Fiber-Optic Cable, Disconnecting from Wiring Harness
atio
m
Connector, page 130 .

o
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c
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Corrugated Tube, Install on Fiber Optic Cable.
sd
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Cut the corrugated tube to the fitting length using Hose Cutting
t.
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Pliers - VAS6228- . t. Cop py
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The corrugated tube must be cut on the wave peak -arrow-, p by
o Vo
by c
not in the wave trough.
lksw
cted agen
Prote AG.
Use the Hose Cutting Pliers - VAS6228- or a sharp knife for
cutting.
The corrugated tube must not be cut using a side cutter under
any circumstances.
The corrugated tube must audibly engage in the fiber-optic
cable housing when installing.
Guide the fiber-optic cable into the Fiber-Optic Repair Set -

Tube Tool - VAS6223/10- .
Position corrugated tube assembly pliers on slot on the tube.
Position crimping pliers for fiber-optic cable at slot of corruga
ted tube. The fiber optic cable is then routed in the corrugated
tube.

6.3 Fiber-Optic Cable, Disconnecting from

Wiring Harness Connector
Removing agen
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Unplug connector for fiber optic cable efromd b appropriate control
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Release the locking mechanism s in the fiber-optic cable con
s c
nector -1- by pushing on it.
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itte
Release the secondary lock -2- with a small screwdriver.
y li
rm
ab
pe
Remove the fiber-optic cable.
ility
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wit
, is n
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hole
Caution
spec
es, in part or in w
t to the co
Install the cap on the trunk, in order to protect the fiber-
optic cable from dust and dirt.
Use a new housing since it is likely that the secondary lock
rrectness of i
was damaged during the removal of the fiber-optic cable.
l purpos
Note the arrows on the base module for allocation IN and

OUT.
nform
mercia
a
com
t
Installing
ion in
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Install in the reverse order of removal. Note the following:
thi
s
iva
do
Install the fiber-optic cable according to the markings.
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Push the corrugated tube into the connector housing until it
Prote AG.
audibly engages.
Seal open fiber-optic cable connector -2- with Fiber-Optic Re
pair Set - Connector Protective Caps - VAS6223/9- -item 1-.
The protective cap prevents contamination of or mechanical
damage to front surface of fiber optic cable which would impair
signal transmission.

AG. Volkswagen AG d
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Beetle
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7 Heated Oxygen Sensor, Replacing
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7.1 Heated Oxygen Sensor, Replacing, 4-Pin Universal Oxy
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7.2 Heated Oxygen Sensor, Replacing, 6-Pin Universal Oxy
spec
gen Sensor, page 131
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7.3 Oxygen Sensor Unit Protective Pipes, page 132
7.1 Heated Oxygen Sensor, Replacing, 4-
rrectne
Pin Universal Oxygen Sensor
ss
Use the faulty sensor as a guide for installing all of the accompa
o
cial p
f
nying attachments, cable ties or marking bands.
inform
mer
Do not repair the heated oxygen sensor wires. Repairing may re
atio
m
sult in malfunctions.
o
n
c
i
or
n
Procedure
thi
te
sd
iva
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r
Remove the faulty heated oxygen sensor.

p
cum
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fo
en
ng
Lay both of the heated oxygen sensors next to each other so

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the sensor housings are the same level. C py
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Tie the excess length of the sensor (approximately 50 to 250

mm) back so it is the same length as the faulty sensor and
secure it with cable ties -1-.
Check if the heated oxygen sensor connector housing is com
patible with the vehicle electrical system side.
Replace the vehicle electrical system connector with the pro
vided heated oxygen sensor connector housing. Refer to
3.2 Connector Housings and Connectors, Repairing, page
112 .
Note
Only replace the connector housing on older vehicles. The

connector housing is correct on new vehicles.
Check the pin assignment. The individual pins in the new con
nector housing are marked with colors.
The packaging for the new heated oxygen sensor contains
additional information.
Install the new heated oxygen sensor in the vehicle.
7.2 Heated Oxygen Sensor, Replacing, 6-

Pin Universal Oxygen Sensor
Use the faulty sensor as a guide for installing all of the accompa
nying attachments, cable ties or marking bands.
7. Heated Oxygen Sensor, Replacing 131

Do not repair the heated oxygen sensor wires. Repairing may re

sult in malfunctions.
Procedure
Remove the old heated oxygen sensor.
Lay both of the heated oxygen sensors next to each other so
the sensor housings are the same level.
Tie the excess length of the sensor (approximately 50 to 250

mm) back so it is the same length as the faulty sensor and
secure it with cable ties -1-.
Install the new heated oxygen sensor in the vehicle.
7.3 Oxygen Sensor Unit Protective Pipes

AG. Volkswagen AG d
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In addition to using the part number, the protective pipeautcan also
ho eo
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be used for identification. ss c
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Version D1: 6 Openings, 3.5 mm Each

itte
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Only used with the 4-pin oxygen sensor

ility
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es, in part or in w
t to the co
Version D2: 6 Openings, 2 mm Each

Used with 4-pin and 6-pin universal oxygen sensors.
rrectness of i
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132
agen
Prote AG.
Rep. Gr.97 - Wiring
Version D4: 12 Openings,1.4 mm Each

Used with 4-pin and 6-pin universal oxygen sensors.
gen AG
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7. Heated Oxygen Sensor, Replacing 133

8 Special Tools
AG. Volkswagen AG d
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Wiring aut
Harness Repair Set - VAS1978- ra
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Wiring Harness Repair Set - VAS1978A-

nform
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at
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ion
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Release Tool Set - VAS1978/35-
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Upgrade Kit For VAS1978 - VAS1978/50-
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Fiber-Optic Conductor Repair Set - VAS6223A-
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Hose Cutting Pliers - VAS6228-
8. Special Tools 135

Contact Surface Cleaning Set - VAS6410-
Edition K0059070121 C 04/02/2015- TMP
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9 Revision History
Re Dat Job Type Feedback # Notes Editor
vi e
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wage es n
6 04/ Correction y Volks Added miss ot Tom
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5 1/2 Factory Up N/A Jim

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4 11/ Correction N/A Deleted Yam
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3 08/ Factory Up N/A Tom
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9. Revision History 137

AG. Volkswagen AG d
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Cautions & Warnings
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Please read these WARNINGS and CAUTIONS before proceeding with maintenance
h re
ole,
and repair work. You must answer that you have read and you understand these
spec
WARNINGS and CAUTIONS before you will be allowed to view this information.
t to the co
= If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this manual, we
rrectne
suggest you leave such repairs to an authorized Volkswagen retailer or other qualified shop. We especially urge
you to consult an authorized Volkswagen retailer before beginning repairs on any vehicle that may still be covered
ss
wholly or in part by any of the extensive warranties issued by Volkswagen.
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= Disconnect the battery negative terminal (ground strap) whenever you work on the fuel system or the electrical
mer
system. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.
atio
om
n
c
i
or
n
= Volkswagen is constantly improving its vehicles and sometimes these changes, both in parts and specifications,
thi
te
sd
a
are made applicable to earlier models. Therefore, part numbers listed in this manual are for reference only. Always
iv
o
pr
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check with your authorized Volkswagen retailer parts department for the latest information.
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= Any time the battery has been disconnected on an automatic transmission vehicle, it will be necessary to C py
ht. rig
rig ht
reestablish Transmission Control Module (TCM) basic settings using the VAG 1551 Scan Tool (ST). copy by
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Prote AG.
= Never work under a lifted vehicle unless it is solidly supported on stands designed for the purpose. Do not support
a vehicle on cinder blocks, hollow tiles or other props that may crumble under continuous load. Never work under a
vehicle that is supported solely by a jack. Never work under the vehicle while the engine is running.
= For vehicles equipped with an anti-theft radio, be sure of the correct radio activation code before disconnecting the
battery or removing the radio. If the wrong code is entered when the power is restored, the radio may lock up and
become inoperable, even if the correct code is used in a later attempt.
= If you are going to work under a vehicle on the ground, make sure that the ground is level. Block the wheels to
keep the vehicle from rolling. Disconnect the battery negative terminal (ground strap) to prevent others from
starting the vehicle while you are under it.
= Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to yourself and
others if you are tired, upset or have taken medicine or any other substances that may impair you or keep you from
being fully alert.
= Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.
= Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid. Wear
goggles, gloves and other protective clothing whenever the job requires working with harmful substances.
= Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near
machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery, severe
injury could result.
= Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used
only once and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts,
washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners with
new parts where indicated, and any other time it is deemed necessary by inspection.
Page 1 of 3
2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0
Cautions & Warnings
= Illuminate the work area adequately but safely. Use a portable safety light for working inside or under the vehicle.
Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled
fuel or oil.
= Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not create dust by
grinding, sanding, or by cleaning with compressed air. Avoid breathing asbestos fibers and asbestos dust.
Breathing asbestos can cause serious diseases such as asbestosis or cancer, and may result in death.
= Finger rings should be removed so that they cannot cause electrical shorts, get caught in running machinery, or be
crushed by heavy parts.
= Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the
instructions thoroughly; do not attempt shortcuts. Use tools that are appropriate to the work and use only
replacement parts meeting Volkswagen specifications. Makeshift tools, parts and procedures will not make good
repairs.
.
n AGin gen AG Volkswa
= Catch draining fuel, oil or brake fluid
age suitable containers.
does Do not use empty food or beverage containers that
olksw not
might mislead someone by into drinking from them. Store flammable
V gu
ara fluids away from fire hazards. Wipe up spills at
d
ise the oily rags, which can ignite and burn
once, but do not store ntspontaneously.
or h
e eo
ut ra
ssa c
= Use pneumatic and
electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten
ce
e
nl
pt
fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque
du
an
itte
listed.
y li
erm
ab
ility
ot p
= Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping hydrogen gas is wit
, is n
ignited, it will ignite gas trapped in the cells and cause the battery to explode. h re
hole
spec
es, in part or in w
= Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of
t to the co
the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local ordinances that
govern the disposal of wastes.
rrectness of i
= The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C system should be
l purpos
serviced only by trained automotive service technicians using approved refrigerant recovery/recycling equipment,
trained in related safety precautions, and familiar with regulations governing the discharging and disposal of
automotive chemical refrigerants.
nform
mercia
at
= Before doing any electrical welding on vehicles equipped with anti-lock brakes (ABS), disconnect the battery
om
ion
c
negative terminal (ground strap) and the ABS control module connector.
in t
or
his
ate
do
riv
= Do not expose any part of the A/C system to high temperatures such as open flame. Excessive heat will increase
p
cum
or
system pressure and may cause the system to burst.

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= When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the Transmission
t. C rig
gh ht
yri
Control Module (TCM), the ABS control module, and the trip computer. In cases where one or more of these
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components is not separately fused, disconnect the control module connector(s). Prote
cted AG.
agen
= Some of the vehicles covered by this manual are equipped with a supplemental restraint system (SRS), that
automatically deploys an airbag in the event of a frontal impact. The airbag is operated by an explosive device.
Handled improperly or without adequate safeguards, it can be accidentally activated and cause serious personal
injury. To guard against personal injury or airbag system failure, only trained Volkswagen Service technicians
should test, disassemble or service the airbag system.
Page 2 of 3
Version 1.0
Cautions & Warnings
= Do not quick-charge the battery (for boost starting) for longer than one minute, and do not exceed 16.5 volts at the
battery with the boosting cables attached. Wait at least one minute before boosting the battery a second time.
= Never use a test light to conduct electrical tests of the airbag system. The system must only be tested by trained
Volkswagen Service technicians using the VAG 1551 Scan Tool (ST) or an approved equivalent. The airbag unit
must never be electrically tested while it is not installed in the vehicle.
= Some aerosol tire inflators are highly flammable. wage

n Be Volkswagen A
AG. extremely cautious
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es n
when repairing a tire that may have been
ks
inflated using an aerosol tire inflator. Keep
y Vo sparks, open flame or other
l osources
t gu of ignition away from the tire repair
d b four times before breaking the bead
area. Inflate and deflate the tire atrileast
ara
se nfrom
tee the rim. Completely remove the
tire from the rim before attempting
utho any repair. or
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= When driving or riding in an airbag-equipped vehicle, never hold test equipment in your hands or lap while the
un
pt
an
d
itte
vehicle is in motion. Objects between you and the airbag can increase the risk of injury in an accident.
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ot
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I have read and I understand these Cautions and Warnings.
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es, in part or in w
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Page 3 of 3
Version 1.0

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New Beetle RSI 2001 ,

Electrical Equipment General Information

Service Department. Technical Information

All rights reserved.

Copyright 2015 Volkswagen AG, Wolfsburg D3E802072D0

1.1 Battery Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.3 Warnings and Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.2 Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.6 Midtronics Battery Tester MCR340VKT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.7 Battery Test with Vehicle Diagnostic Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

94 - Exterior Lights, Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

96 - Interior Lights, Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

1.1 Description of Vehicle Diagnosis, Testing and Information Systems . . . . . . . . . . . . . . . . . . 89

27 Battery, Starter, Generator, Cruise Control

1.1.1 Battery with Visual Indicator, Stand

Maintenance-free Battery - A- with fluid electrolyte (wet battery)

distilled water. Perform only a visual inspection. Note the chap

2 Battery, Checking, page 7 .

Do not check or charge a Battery - A- when the visual indicator

These Batteries - A- must be replaced.

This Battery - A- has a color display (visual indicator). The colors

AGM is the English abbreviation for absorbent glass mat.

These Batteries - A- cannot have a visual indicator due to the fixed

Do not check or charge a Battery - A- when the visual indicator

The Battery - A- is installed in certain Stop/Start vehicles due to

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

EFB batteries are being installed in smaller gasoline engines with

Visual indicator, checking. Refer to

1.2 Battery General Information

Refer to Self Study Program No. 234 ; Battery .

In order to prevent damage to the Battery - A- or vehicle, ob

1.3 Warnings and Safety Precautions

1.3.1 Dangers When Working with Batteries, page 3

1.3.2 Battery Safety Label, page 5

1.3.3 Working on Airbag System, page 5

1.3.1 Dangers When Working with Batteries

Recognizing and Preventing Risks

Batteries - A- present risks. Read the warnings on the Battery -

A- label, in the Owner's Manual and in ELSA to prevent these

Personnel instructed in protection, such as a trainee or an

and jump starting may not be used. There is a risk of ex

Only perform Battery - A- procedures in suitable and well- f inform

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

1.3.2 Battery Safety Label

tools should not be rested on the Battery - A- .

Battery - A- charging produces a highly explosive gas mix

Catalog and in the Owner's Manual.

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

working on the Battery - A- . The Battery - A- must not be

When working on the airbag system (pyrotechnic components,

Never use force to attach the battery terminals by hand.

Do not apply grease to battery posts.

Terminal clamp tightening specification. Refer to Electrical

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

2.1 Different Types of Batteries, Checking

2.1.3 EFB Battery, Checking, page 8

2.1.1 Battery with Color Display, Visual Indi

Perform the Tests in the Following Sequence:

1. Visual inspection. Refer to

2. Color display test

Three colors. Refer to

2.3.1 3-Color Visual Indicator, Checking, through 03/2008,