Electrical System, General Information

Service
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Workshop Manual
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Electrical System, General Information
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Edition 09.2012
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Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
27 - Starter, current supply, CCS
90 - Gauges, instruments
92 - Windscreen wash/wipe system
94 - Lights, bulbs, switches - exterior
96 - Lights, bulbs, switches - interior
97 - Wiring
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Technical information should always be available to the foremen and mechanics, 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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safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
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All rights reserved.
No reproduction without prior agreement from publisher.
Copyright 2012 Volkswagen AG, Wolfsburg D4B8025555B

Amarok 2011 , Caddy 2004 , Caddy 2011 , Crafter 2006 , Transpo ...
Electrical System, General Information - Edition 09.2012
Contents
27 - Starter, current supply, CCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Fundamentals for batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Warning notices and safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Types of batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Battery terminal connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Checking battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Checking the various types of batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Checking colour indicator in battery cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4 Battery tester with printer VAS 6161 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.5 Current draw test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.6 Checking quiescent current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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3 Charging battery . . . . . . . . . .k.sw. a.g.en. A. G . . . . . . . . .n.A.G.d.o.es. n. . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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3.1 Totally discharged batteries d b . . . . . . . . . . . . . . . . . . . . . . . . .ua.ra. . . . . . . . . . . . . . . . . . . . . .
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3.2 Battery charger VASth5095 or eo 19
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3.3 Battery charger VAS ss a 5900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a.c . . . . . . . . . . . . . . . . . 24
3.4 Battery charger VAS 5903 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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3.5 Battery charger VAS 5906 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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3.6 Solar panel VAS 6102A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
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4 Cruise control system (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
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4.1 General description - cruise control system (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
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4.2 Activating and deactivating cruise control system (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . . 51
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90 - Gauges, instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
92 - Windscreen wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
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1 Washer fluid line hose couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.1 Hose couplings - windscreen and rear window washer system . . . . . . . . . . . . . . . . . . . . . . ss o 53
1.2 Hose couplings - windscreen and rear window washer system, Crafter . . . . . . . . . . . . . . 54
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1.3 Hose couplings - headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

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2 Hose repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
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2.1 General description - hose repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

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2.2 Repairing smooth pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

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2.3 Repairing corrugated pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

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94 - Lights, bulbs, switches - exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
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96 - Lights, bulbs, switches - interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
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1 12 V socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1.1 Removing and installing 12 V socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1.2 Removing and installing socket illumination bulb L42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2 Cigarette lighter U1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.1 General description - cigarette lighter U1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.2 Assembly overview - cigarette lighter U1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.3 Removing and installing cigarette lighter socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.4 Removing and installing cigarette lighter illumination bulb L28 . . . . . . . . . . . . . . . . . . . . . . 69
97 - Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1 Vehicle diagnostic, testing and information systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.1 General description - vehicle diagnosis, testing and information system . . . . . . . . . . . . . . 71
Contents i
1.2 Connecting vehicle diagnostic tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

2 Wiring harness and connector repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.1 Wiring harness repair set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.2 Tool descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2.3 General notes concerning repairs to vehicle electrical system . . . . . . . . . . . . . . . . . . . . . . 79
2.4 Repairs to electrical wiring harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2.5 Repairs to fibre optic cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.6 Repairing connector housings and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2.7 Releasing and dismantling connector housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3 Contact surface cleaning set VAS 6410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.1 General description - contact surface cleaning set VAS 6410 . . . . . . . . . . . . . . . . . . . . . . 109
3.2 Repairing ring terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.3 Repairing threaded electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.4 Cleaning battery terminal clamp and battery terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3.5 Preserving threaded electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
4 Renewing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4.1 General notes - renewing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4.2 Types of protective tube on uniform Lambda probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4.3 Renewing LSF Lambda probe (4-pin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4.4 Renewing LSU Lambda probe (6-pin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
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ii Contents
27 Starter, current supply, CCS

1 Battery
(VRL005192; Edition 09.2012)
1.1 Fundamentals for batteries, page 1
1.2 Warning notices and safety regulations, page 1
1.3 Types of batteries, page 3
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serviced and maintained according to the specifications in this
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Apart from supplying energy for starting the engine, the battery
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For additional information, refer to Self-study programme No.
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1.2 Warning notices and safety regulations

1.2.1 Dangers when handling vehicle batteries, page 1
1.2.2 Safety markings on battery, page 2
1.2.1 Dangers when handling vehicle batter

ies
Recognition and avoidance of dangers
Batteries can be dangerous. These dangers can be avoided when
the warnings on the battery, in the operating manual and in ELSA
are observed.
1. Battery 1
WARNING
Untrained personnel e.g. apprentices, trainees etc. may

only work on batteries when supervised by a vehicle me
chanic/foreman or vehicle electrician/foreman.
Acid is highly corrosive. There is a considerable danger of
acid burns if personnel do not handle batteries correctly.
Therefore suitable measures must be taken to ensure that
equipment/solutions etc. are available to neutralize acid
burns. A suitable solution is: e.g. a soap solution.
If electrolyte leaks from a battery it may cause skin burns
or acid corrosion and rusting on the vehicle. This may
damage safety relevant components on the vehicle.
The gas which forms when charging and the gas which
may escape through vent valves is explosive. In extreme
cases a battery may explode if the battery is not handled
correctly.
Batteries whose magic eye shows light yellow must be re
placed. They must not be checked or charged and do not
slave/jump start. Danger of explosion when checking and
charging or slave/jump starting.
It is prohibited to cause sparks through grinding, welding,
cutting operations and use naked lights in the vicinity of
batteries. Smoking is also prohibited. Sparks generated
by electrostatic charging must also be avoided. Always
touch the vehicle body before touching the battery.
Only work on batteries in well ventilated and suitable
rooms.
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1. - Fires, sparks, naked flames ands smoking are prohibited when
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when working with cables and electrical units. Avoid short circuits.
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Therefore never lay a tool on a battery.

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2. - Wear eye protection before commencing work on battery.

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3. - Keep children away from acid and batteries.

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4. - Disposal: old batteries are classed as hazardous waste. They

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may only be disposed of through a suitable collection centre and

only in accordance with respective legislation.
5. - Never dispose of old batteries in household waste system!
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6. - There is a danger of an explosion when working with batteries.

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A highly explosive gas is produced when batteries are charged.

7. - Always follow instructions given on battery in ELSA Elec
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trical System, General Information; Rep. gr. 27 ; Battery; Warning

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notices and safety regulations and in the operating manual.

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8. - Battery acid is very caustic; therefore wear eye protection and

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gloves when working with batteries. Do not tilt battery. Acid can
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2 Rep. gr.27 - Starter, current supply, CCS

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1.3.1 Battery with standard colour indicator, page 3
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1.3.2 Battery with enhanced colour indicator, page 3
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1.3.3 Absorbent glass mat battery, page 4
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1.3.1 Battery with standard colour indicator
This is a maintenance-free battery with liquid electrolyte (wet bat
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No stickers may be removed and do not replenish with distilled

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Only perform visual inspections on batteries.
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Observe the notes given in the chapters concerning battery
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It is not permissible to test or charge batteries whose colour

indicator is light yellow. Do not slave/jump start the vehicle!
Danger of explosion when checking and charging or slave/
jump starting.
These batteries must be renewed.
This battery is equipped with a colour indicator. The colour indi

cator provides information about the electrolyte level and the
charge state of the battery. Checking the colour indicator
page 8
1.3.2 Battery with enhanced colour indica

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

water.
Only perform visual inspections on batteries.
Observe the notes given in the chapters concerning battery
tests page 6 .
1. Battery 3
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The battery is used for particular requirements in certain vehicles
equipped with a start/stop system. The battery can be identified
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by the lettering EFB on the battery cover. EFB stands for en
hanced flooded battery.
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An EFB battery may only be replaced with another EFB bat
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The EFB battery has a colour indicator to enable the electrolyte
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EFB batteries have been used in the smaller petrol engines with yri
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1.3.3 Absorbent glass mat battery

This is a maintenance-free battery with a contained electrolyte
without colour indicator.
Lead-acid battery where the electrolyte is contained within a mi
croscopic glass mat (AGM). The battery is sealed and fitted with
valves.
AGM is the abbreviation for absorbent glass mat.
Due to containment of the electrolyte, this type of battery cannot
have a colour indicator. Absorbent glass mat batteries are iden
tified by the abbreviation AGM on the battery.
Note
Always replace an absorbent glass mat battery with another ab

sorbent glass mat battery.

1.4 Battery terminal connection

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To prevent damage to the battery
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The battery clamps should only be fitted by hand and with
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Battery terminals should not be coated with grease.
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The battery clamps should be fitted in such a way that the
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battery terminal is either flush with the clamp or protruding
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Once the battery clamps have been tightened to the speci
fied torque, the threaded connections should not be tight
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1. Battery 5
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2.2 Visual check, page 7
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2.4 Battery tester with printer VAS 6161 , page 11
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2.5 Current draw test, page 16
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2.6 Checking quiescent current, page 17
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2.1 Checking the various types of batteries
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2.1.1 Checking a battery with colour indicator, page 6
2.1.2 Absorbent glass mat battery, page 7
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2.1.1 Checking a battery with colour indicator

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Caution
AG.

Note
Observe the chapter "Battery" in the Maintenance ; Booklet for

the respective vehicle!
Perform the checks in the following sequence:

1. Visual check page 7
2. Colour indicator check: 3 colour page 8 or 2 colour
page 9
WARNING

jump starting.
3. Battery test with battery tester with printer -VAS 6161-

page 11 .
4. Depending on the result of the battery test, perform current
draw test page 16 .

2.1.2 Absorbent glass mat battery
WARNING

Caution
AG. Volkswagen AG d
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To prevent damage to the dbattery
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Observe the chapter "Battery" in the Maintenance ; Booklet for
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the respective vehicle!
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Perform the checks in the following sequence:
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1. Visual check page 7
2. Battery load test with battery tester with printer -VAS 6161-
rrectne
page 11
3. Depending on the result of the battery test, perform current
ss o
draw test page 16 .
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2.2 Visual check
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Before taking extensive measurements, visually check the con

dition of the exterior, the connections and whether the battery is
firmly seated!
Note
Observe the chapter Battery in the Maintenance ; Booklet for

the respective vehicle.
2. Checking battery 7
Caution
The battery will be damaged if the battery is not secured

correctly.
Vibrations shorten the life of the battery, there is a danger
of an explosion, the cell plates may be damaged and the
clamping bracket may damage the battery housing.
Check battery is securely seated, if necessary tighten se
curing bolt to specified torque.
Performing this test establishes:

If battery housing is damaged Electrolyte can leak out if the
housing is damaged. If battery acid leaks out, serious damage
to the vehicle could be caused. Treat components affected by
leaked battery acid immediately with acid neutraliser or a soap
solution.
Check whether the battery terminals (battery wire connec
tions) are damaged. The necessary contact on the battery
clamps cannot be guaranteed if the battery terminals are dam
aged. When connecting battery terminal clamps, adhere to
tightening torque specified in the workshop manual Electrical
system for the respective vehicle. If the battery clamps are
not correctly seated and tightened, the wiring may burn. Which
will cause malfunctions in the electrical system. Safe operation
of the vehicle is no longer guaranteed.
2.3 Checking colour indicator in battery cov

er
2.3.1 Checking colour indicator, 3-colour , page 8
2.3.2 Checking colour indicator, 2-colour , page 9
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General information about colour indicator:

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Applies for all batteries with 1J0, 7N0 and 3B0 indexes in
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original equipment and for all replacement batteries 191 915 105
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AB and from 000 915 105 AX index.

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The colour indicator provides information about the electrolyte

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level and the charge state of the battery.

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Before carrying out visual check, tap the inspection window lightly
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and carefully using the handle of a screwdriver. The air bubbles,

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which can influence the display, will dissipate when doing this.
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Note
Air bubbles can form under the sight glass, particularly when
a battery has been recharged, i.e. also when the battery has
been charged during normal vehicle operation. These falsify
the reading of the colour indicator.
Since the colour indicator is only located in one battery cell,
the indicator also only applies to this battery cell. Determining
the exact condition of the battery is only possible by means of
a battery test page 11 .
The colour indicator can be located at various positions on the
battery.
Three different colour displays are possible:

Green, battery is charged sufficiently.
Black, battery partly discharged, charge state < 65 % or
completely discharged
Colourless or light yellow, battery must be renewed.
WARNING

jump starting.
2.3.2 Checking colour indicator,

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Volkswagen AG
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General information about colour indicator:

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The general introduction of the 2-colour indicator took place

gradually in 2009. The 2-colour indicator does not include the
colour green to indicate the charge state.
nform
ercia
The colour indicator provides information on the electrolyte level

m
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of the battery.
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The battery charge can no longer be ascertained by means of the

his
ate
colour indicator; the battery has to be checked for this

do
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page 11
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Before carrying out visual check, tap magic eye lightly and care
Co
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fully using handle of a screwdriver. The air bubbles, which can
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influence the display, will dissipate when doing this. The colour py by
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display of the magic eye will therefore be more accurate.
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Note
Air bubbles can form under the sight glass, particularly when
a battery has been recharged, i.e. also when the battery has
been charged during normal vehicle operation. These falsify
the reading of the colour indicator.
Since the colour indicator is only located in one battery cell,
the indicator also only applies to this battery cell. Determining
the exact condition of the battery is only possible by means of
a battery test page 11 .
The colour indicator can be located at various positions on the
battery.
AG. Volkswagen AG d
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Black, electrolyte level is OK. orise nte
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Light yellow, electrolyte level too low The battery
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WARNING
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2.4 Battery tester with printer -VAS 6161-
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2.4.1 General description - battery tester with
aut printer VAS 6161
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, page 11 ss c
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2.4.2 Device description - battery tester with printer VAS 6161
an
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, page 12
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2.4.3 Perform battery test with battery tester with printer VAS
ot
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6161 ., page 12
, is n
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2.4.4 Perform guarantee test, page 13
spec
es, in part or in w
2.4.5 Performing maintenance test, page 14
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2.4.6 Perform service test, page 14
rrectness of i
2.4.7 Comments concerning test print out, page 15
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2.4.8 Assessing test results, page 15
2.4.1 General description - battery tester with
nform
ercia
printer -VAS 6161-

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WARNING
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It is not necessary to remove or disconnect battery when using co Vo
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battery tester with printer -VAS 6161- . cted agen
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The battery tester with printer -VAS 6161- does not load the bat
tery any more. It works on the principle of dynamic conductance
acquisition.
Every battery type is stored in the tester.
Data can be stored on an SD card.
The battery tester with printer -VAS 6161- can be updated via an
interface or an SD card, so that battery data from Volkswagen are
always up to date.
The integrated temperature sensor improves measurement qual
ity.
A 2D scanner is available as an option to read data directly from
the battery's 2D code.
Note
Observe the operating manual Operating manual of the battery

tester with printer -VAS 6161- .
2.4.2 Device description - battery tester with

printer -VAS 6161-
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1 - Integrated printer ksw
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2 - Operating lever for paper compartment ised ara
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3 - Paper slot s aut ra
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4 - LCD screen with main menu
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5 - Control panel with On/Off button
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6 - Connection for battery test cable
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7 - Memory card slot
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8 - Infrared temperature sensor
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9 - Data transmitter for PC
rrectness of i
2.4.3 Perform battery test with battery tester
l purpos
with printer -VAS 6161- .
nform
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WARNING
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Special tools and workshop equipment required C py
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Battery tester with printer -VAS 6161-
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Performing battery test:
WARNING

jump starting.
Switch off ignition and all electrical loads, and pull out ignition
key.
On batteries equipped with an inspection glass, check colour
indicator page 6 .

Switch on battery tester with printer -VAS 6161- .

Connect red terminal clamp + of tester to positive terminal of
battery.
Connect black terminal clamp - of tester to negative terminal
of battery.
Note
Make sure test terminals make good contact!
Select one of the following functions:

Warranty test for batteries during the warranty period
page 13 .
Maintenance test (only on new vehicles before registration, in
stationary and stock maintenance programme page 14 )
Service test for batteries no longer covered under warranty
and third-party batteries page 14
AG. Volkswagen AG d
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The test is completed
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The result of the test is printed out by the printer.

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The tester requires no cooling phase before it is ready for the
erm
next measurement. ab
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2.4.4 Perform guarantee test
hole
spec
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WARNING

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jump starting.
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Select Guarantee test in the menu.

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Select In vehicle or Outside vehicle.

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Select On battery terminal or On jump-start point.

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Scan in 2D code of battery or manually select battery type and ht. rig
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Measure temperature. Hold temperature sensor about 5 cm Prote AG.
above one battery terminal until temperature stabilises.
Start test.
Print out test log if necessary.
2.4.5 Performing maintenance test
WARNING

jump starting.
Select Maintenance test in the menu.

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

test printout by hand.
Scan in vehicle identification number.

Scan in 2D code of battery or select type and make manually
in menu.
olkswagen AG
en AG. V
Measure temperature. Hold temperature sensor about ksw 5 cm
ag does
not
Vol
above terminal connection until temperature stabilises.
db
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Start test. autho eo
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2.4.6 Perform service test an

itte
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WARNING
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jump starting.
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Select Service test in the menu.

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Select battery type Normal, AGM, 2*6V or Gel.

or c
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Select CCA, JIS, DIN, SAE, IEC or EN norm.

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Select battery value.

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Measure temperature. Hold temperature sensor about 5 cm Cop py
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above one battery terminal until temperature stabilises. opyri
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Start test.
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2.4.7 Comments concerning test print out

1- Check type.
2- Battery test result
3- Measured voltage
4- Measured cold start value of battery.
5- Nominal cold start value of battery selected on tester.
6- Measured temperature of battery.
7- Fitting location of battery
8- Position of battery terminal clamp selected on tester.
9- Selected battery technology.
Note
The test printout is required for warranty claims.

AG. Volkswagen AG d
agen oes
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2.4.8 Assessing test results
d
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Evaluating battery test results for guarantees and service tests
s c
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Battery test results Measures
an
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Battery OK No measures on battery
ility
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Battery OK - recharge. Charge battery page 18 . In
wit
, is n
case of discharging, look for
h re
hole
fault
spec
es, in part or in w
Perform current draw test Perform current draw test
t to the co
page 16 . Fully charge bat
tery page 18 and repeat
test.
rrectness of i
Renew battery. Disconnect battery and repeat
l purpos
test. The result Renew battery

may be caused by a weak cable
contact.
nform
ercia
Battery cell defective - renew. Renew battery.

m
at
om
Check connection. Connect cable directly to bat

ion
c
tery and not to jump start termi

in t
or
his
nal.
ate
do
priv
Evaluating battery test results for maintenance test

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Battery test results Measures Cop py
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Battery OK No measure pyri by
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Charge battery immediately. Charge battery fully
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page 18 .
Mark as defective. Mark as defective.
Check tester connection. Disconnect battery and repeat
test. The result Check tester
connection may be caused by
a weak cable contact.
Check connection. Connect cable directly to bat
tery and not to jump start termi
nal.
Noises Wait until measured value ap
pears on display.
2.5 Current draw test
WARNING
It is not permissible to test or charge batteries whose magic

eye shows light yellow. Do not slave/jump start the vehicle!
jump starting.
Note
Make sure to set the correct charging mode on the charger so

that the current draw test is not falsified.
Battery charger -VAS 5095 A- , page 19
Battery charger -VAS 5900- , page 24
Battery charger -VAS 5903- , page 35
To quickly ascertain the state of discharged batteries, the battery

current draw test whilst charging helps to determine whether the
battery must be replaced or fully recharged. wage
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For battery tester with printer -VAS 6161- , the current draw test
le
un
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must always be performed when the test result Perform current
an
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draw test appears on the display.
erm
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ility
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The current draw test should always be carried out if
is n
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The result of the test with battery tester with printer -VAS
spec
5097A- gave the following results:

t to the co
1 - Starting capability sufficient
2 - Starting capability poor
rrectne
3 - Starting capability very poor

ss
4 - Cannot be tested charge battery and repeat test.

o
cial p
f in
- and when the tester will not switch on (no LED, no printout)
form
mer
or
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n
c
The result of the test with battery tester with printer -VAS 6161-
i
or
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gave the following result:

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1 - Perform current draw test.

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Performing a current draw test whilst charging a battery will quick
Co
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ly establish whether a partly or fully discharged battery t. C rig
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page 18 can be recharged to return it to a serviceable condi p by
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Test requirements:
When charging battery, battery temperature must be at least
+10 .
The charger must be capable of outputting a charge current of
at least 30 A, as for example with VAS 5095A, VAS 5900, VAS
5903

The battery's current draw must be measured with a current

pick-up clamp, e.g. VAS 5051B/7, when charging with battery
charger -VAS 5095A- . Battery charger -VAS 5900- and bat
tery charger -VAS 5903- display the current draw on the unit.
Battery charger -VAS 5900- performs the current draw test
automatically with menu guidance.
Connect battery to battery charger and start charging proce
dure.
Measure charge current of battery after 5 minutes.
Test result:
If the current draw A is higher than 10 % of the nominal capacity
(e.g. > 6.1 A for a 61 Ah battery), fully charge battery and test
again.
Battery is fully charged if charge current is more than 10 % of
rated capacity.
After 2 hours of battery resting time, perform a battery test
page 12 .
Renew battery if the charge current, in amperes, lies below 10%
of the rated capacity 5 minutes after the start of charging (i. e. for
a 50 Ah battery < 5A). In the event of warranty and goodwill ges
tures, fill out the battery test sheet.
2.6 Checking quiescent current AG. Volkswagen AG d

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Note orise nte
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Observe TPI 2026882 when carrying out the quiescent current s
ce
e
test.
nl
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, is n
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nf
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3 Charging battery ksw

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3.1 Totally discharged batteries, page 18 ed b ara
nte
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3.2 Battery charger VAS 5095 A , page 19 aut ra
c
ss
3.3 Battery charger VAS 5900 , page 24
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3.6 Solar panel VAS 6102A , page 50
h re
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spec
3.1 Totally discharged batteries
t to the co
WARNING
rrectne
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mer
Caution
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A battery is completely discharged if the open-circuit voltage is Cop py
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WARNING
AG.

jump starting.
Caution
Totally discharged batteries freeze prematurely.

Frozen batteries should no longer be used.

Note
Totally discharged batteries in vehicles before registration

must be exchanged prior to delivery. Preliminary damage can
not be excluded. agen AG. Volkswagen AG do
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Batteries that
d b have not been used for a long period
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ar of time
discharge
or themselves, e.g. those fitted in stored vehicles.
ise an
tee
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ut or
In totally
ss
a
discharged batteries, the electrolyte is comprised
ac
al
most entirely of water because the acid content is so low.
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Exhaustively discharged batteries sulphate, i.e. the entire
itte
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plate surfaces of the battery harden.
ab
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If a battery is recharged shortly after it has totally lost its
wit
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charge, the sulphation will mostly dissipate.
h re
hole
spec
If these batteries are not recharged, the plates continue to
es, in part or in w
harden and the ability to recharge is reduced. The result of
t to the co
which is a reduction in the battery output.
rrectness of i
Check no-load voltage of battery page 18 .
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3.2 Battery charger -VAS 5095 A-

3.2.1 General description - battery charger VAS 5095 A , page
nform
ercia
19
m
at
om
3.2.2 Charging battery with battery charger VAS 5095 A , page

ion
c
20
in t
or
his
ate
3.2.3 Charging exhaustively discharged battery with battery

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charger VAS 5095 A , page 21

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3.2.4 Charging battery in support mode with battery charger
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VAS 5095 A , page 22
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3.2.5 Charging battery in maintenance mode with battery
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charger VAS 5095 A , page 24
agen
Prote AG.
3.2.1 General description - battery charger -

VAS 5095 A-
This chapter describes the basic functions of the battery charger
-VAS 5095 A- . For additional information refer to operating
instructions for battery charger -VAS 5095 A- .
Note
The effective charge current can not be read on these units.

The charge current must be read externally using a pick-up
clamp.
Observe operating manual Operating manual of the battery
charger -VAS 5095 A- .
The battery charger -VAS 5095- is suitable for charging all 12V
batteries supplied by Volkswagen.
3. Charging battery 19
The battery charger charges without peaks in amperage or volt

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

VAS 5095 A-
WARNING

AG. Volkswagen AG d
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Special tools and workshopris equipment required
ed
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Battery charger s-VAS
s a 5095 A- ra
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itte
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ab
ility
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Caution
nf
ercia
orm
m
Always set battery type 2.4 V/C (volts/battery cell) when charg
atio
m
ing! This applies for all batteries.

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The battery must have a temperature of at least 10 C. rig ht
py by
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WARNING

jump starting.
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Switch off ignition and all electrical loads, and pull out ignitionVol
ks ot g
key. d by ua
ran
ise r tee
ho
Check battery type setting on battery type change-over
sa
ut switch or
ac
page 19 . Must be set to 2.4 V/C (volts/batteryscell).
ce
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nl
pt
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Connect red terminal clamp + of charger to positive terminal
an
itte
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of battery. erm
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ility
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Note
h re
hole
spec
In vehicles with start/stop system and battery monitor control unit
es, in part or in w
t to the co
-J367- installed, black charger terminal clamp - must be con
nected to body earth. Connecting it to the negative terminal of the
battery will cause start/stop system to malfunction.
rrectness of i
Connect black terminal clamp - of charger to negative termi
l purpos
nal of battery.
Switch on charger page 19 .
nf
ercia
orm
The charge current indicators page 20 -2- and -3- light up yel
m
atio
m
low. When only the light emitting diode (LED) -3- lights up yellow,
o
n in
c
battery is partially discharged (approx. 90 %).

or
thi
te
sd
a
If the LED lights up green page 20 -4- the charger has switched
iv
o
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rp
cu
to "maintaining charge". The battery is fully charged.
o
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ng
t.
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Switch off charger page 19 .
Co
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Remove charger terminals from battery clamps.
ht
pyri by
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cted
3.2.3 Charging exhaustively discharged bat
agen
Prote AG.
tery with battery charger -VAS 5095 A-
WARNING

The charger unit automatically recognises totally discharged bat

teries and initiates a gentle charging procedure with a low charg
ing current. The charge current is automatically adapted to suit
the charge condition of the battery.
Note
Follow instructions in chapter

3.1 Totally discharged batteries, page 18 . AG. Volkswagen AG d
agen oes
lksw not
Totally discharged batteries in vehicles before registration by
Vo gu
ara
must be exchanged prior to delivery. Preliminary damage is can
ed
r nte
o
not be excluded. aut
h eo
ra
ss c
The battery voltage must be at least 0.6 V.
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nl
pt
du
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ab
WARNING
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
jump starting.
rrectness of i
l purpos
Charge battery page 20 .
nform
ercia
3.2.4 Charging battery in support mode with

m
battery charger -VAS 5095 A-
at
om
ion
c
in t
r
General notes:
o
his
ate
do
riv
The support mode provides the onboard supply with power when
p
cum
or
the battery is removed or disconnected.

f
en
ng
t.
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For further information, refer to VAS 5095A operating manual . t. Cop py
rig
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The support mode is suitable in the following situations: p by
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cted agen
Support mode of onboard supplies without installed battery Prote AG.
Power conservation when renewing the battery

Ancillaries test without battery
WARNING

WARNING

jump starting.
key.

Caution
The terminal polarity protection in operating mode charg

ing totally discharged batteries/support mode is not ac
tive. Connect battery charger terminal clamps correctly to
battery terminals.
It can cause sparks through a short-circuit.
Danger of explosion
Ensure charger terminals are fitted securely.
Do not press START / STOP button if charger unit cables
are connected incorrectly. The charger unit may be dam
aged.
Remove battery Electrical system; Rep. gr. 27 ; Removing

and installing battery .
Caution lkswage es n
o ot g
byV ua
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ir se tee
When the battery is removed,
utho ensure there is no contact be or
tween the positive terminal
ss
a clamp of charger and the body ac
earth.
ce
le
un
pt
an
d
Also ensure there is no contact between individual battery ter

itte
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minal clamps.
erm
ab
ility
ot p
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spec
clamp of vehicle battery.
t to the co
Note
rrectne

ss

o
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inform
mer
atio

om
nal clamp of vehicle battery.

n
c
i
or
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Check battery type setting on normal mode/support mode

t
sd
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change-over switch page 19 . It must be switched on support

i
o
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mode.
fo
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ng
t.
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Check that connections of charger terminals have correct po Cop py
. rig
larity.
t
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co
Switch on charger.
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cted agen
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The battery charger starts with support mode.
End battery support mode:
Switch off charger.
Disconnect black terminal clamp - of charger from negative
terminal clamp of vehicle battery.
Disconnect red terminal clamp + of charger from positive
Pull out mains plug of charger.
3.2.5 Charging battery in maintenance mode

with battery charger -VAS 5095 A-
WARNING

WARNING

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

that the battery is charged correctly and is maintained in fully
charged condition.
Procedure same as for charging battery page 20 .
AG. Volkswagen AG d
agen oes
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Note rised ara
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ho eo
aut ra
When a battery is being charged in maintenance modes and a
s c
electrical consumer draws current from the battery, the battery
ce
le
un
pt
charger -VAS 5095 A- automatically compensates the charge.
an
d
itte
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rm
ab
The maintenance mode can be continued for an unlimited pe
pe
ility
riod.
ot
wit
, is n
h re
The battery is always ready for use.
hole
spec
es, in part or in w
3.3 Battery charger -VAS 5900-
t to the co
3.3.1 General description - battery charger VAS 5900 ,
page 24
rrectness of i
3.3.2 Charging battery with battery charger VAS 5900 , page
l purpos
25
3.3.3 Charging battery in service mode with battery charger
nform
ercia
VAS 5900 , page 27

m
a
com
ti
3.3.4 Charging exhaustively discharged batteries batteries

on in
with battery charger VAS 5900 , page 30

r
te o
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s
iva

do
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rp
VAS 5900 , page 32

um
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ng
t.
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Co
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charger VAS 5900 , page 34 t. C rig
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VAS 5900-
WARNING


AG. Volkswagen AG d
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WARNING rise
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It is not s a test or charge batteries whose magic
permissible sto c
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nl
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an
Danger of explosion when checking and charging or slave/ itte
y li
erm
ab
jump starting.
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
-VAS 5900- . For additional information refer to operating in
structions for battery charger -VAS 5900- .
rrectness of i
Note
l purpos
The effective charge current can be read directly on this bat
nf
ercia
tery charger.
orm
m
atio
om
n in
charger -VAS 5900- .
or c
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Battery charger -VAS 5900- t. Cop py
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1 - Display p by
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2 - Adjustment button Up Prote AG.
3 - Adjustment button Down

4 - START / STOP
5 - INFO

VAS 5900-
WARNING

WARNING

jump starting.
Special tools and workshop equipment required
Battery charger -VAS 5900-
Note
The battery must have a temperature of at least 10 C.
key.
Plug in mains plug of charger. The last selected type of battery
will appear on display.
Set battery to respective operating mode with INFO .
In the display the symbol -1- for standard charge for wet batter
ies or symbol -2- for standard charge for gel/absorbent glass
mat batteries will appear.
AG. V olkswagen AG
Set capacity (Ah) of battery to be charged, using correspond
agen does
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ing button Up or Down . by
Vol not
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Connect red terminal clamp + of charger uto
thopositive terminal
r eo
of battery. ss
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c
ce
e
nl
pt
du
an
itte
Note
y li
erm
ab
ility
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wit
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-J367- installed, black terminal clamp must be connected to body

h re
earth. Connecting it to the negative terminal of the battery will

hole
spec
cause start/stop system to malfunction.

es, in part or in w
t to the co

nal of battery.
rrectness of i
The charger unit recognises the voltage required for the connec
l purpos
ted battery (6 V, 12 V or 24 V) and initiates the charging sequence.

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

ercia
switches to the final charge mode. The fourth bar appears in

m
at
display -1-. The battery is ready for use.

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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Prote AG.

At a charge condition of 100 % all bars appear in display.
AG. Volkswagen AG d
Note agen oes
olksw not
y V gu
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In thethor case of battery type standard charge, the eparallel
or op
eration
s au
of electrical consumers while charging is possible.
ac The
charging period will be longer.
s
ce
le
un
pt
The battery charger will switch to maintenance mode after
an
d
itte
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about 1-7 hours, depending on type of battery. To achieve a
rm
ab
100% charge, the battery should remain connected to the
pe
ility
ot
charger during this period.
wit
, is n
h re
hole
spec
Possible faults and fault rectification:
es, in part or in w
t to the co
1- Displayed battery voltage is not as per nominal voltage:
Press and hold Up or Down button until charging se
quence starts.
rrectness of i
2- Displayed battery voltage is not as per nominal voltage
l purpos
charging sequence has already started:
nform
Press START / STOP twice.
mercia

a
com
quence starts again. tion in

r
te o
thi
3- Battery charger does not detect a battery, when battery volt

s
iva
do
age is less than 2 V:

r
rp
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fo
en
g
Display remains unchanged.

n
t.
yi Co
op py
The battery type and ampere hours (Ah) as set is displayed.
t. C rig
gh ht
pyri by
Vo
o
Ending battery charging sequence:
c by lksw
cted agen
Prote AG.
Press START / STOP .
terminal of battery.
3.3.3 Charging battery in service mode with

battery charger -VAS 5900-
WARNING

Caution
The operating mode service charge is not permitted on VW

vehicles as the voltage peaks will damage the onboard elec
tronics.
If service charge operating mode is used nevertheless, the
battery must be disconnected from the onboard supply.
Amarok 2011 , Caddy 2004 , Caddy 2011 , Crafter olksw2006 , Transpo ...
agen AG
en AG. V
Electrical System, General Information - Edition
olkswag09.2012 does
no
yV t gu
db ara
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tho eo
WARNING s au ra
c
s
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
jump starting.
wit
is n
h re
These batteries must be renewed. ole,
spec
t to the co
Caution
rrectne
When charging always set the battery charger to the correct
type of battery operating instructions for battery charger -
ss
VAS 5900- !
o
cial p
f inform
The service mode is suitable for:
mer
atio
Wet batteries where the magic eye allows charging (magic
om
n
eye black or green)
c
i
or
n thi
te
sd
iva
o
pr
cum
r
The operating mode service charge (SERV) is only used on

fo
en
ng
sulphated batteries. The battery is charged at a voltage of

t.
yi Co
op
> 14.4 V. This can result in a partial reduction of the sulphated C py
t. rig
layer. After charging, always check the colour of the magic eye
gh ht
pyri by
before using the battery page 8 .
co Vo
by lksw
cted agen
Prote AG.
Note
key.
Plug in mains plug of charger. The last selected operating
mode will appear on display page 24 .


In the display, the symbol -1- for Service charge for wet batteries
or symbol -2- for Service charge for gel/absorbent glass mat bat
teries will appear.
ing button Up or Down .
of battery.
Note


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

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

the sulphation of the battery.

n AG. Volkswagen AG
1- Displayedolbattery
ksw
age voltage is not asdoper
es n nominal voltage:
o
V t gu
by a
Pressrisand
ed hold Up or Down button until
ran charging se
tee
o
quence
au
th starts. or
a
ss c
ce
le
un
pt
charging sequence has already started:

an
d
itte
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erm
ab
ility
ot p

wit
is n
quence starts.
h re
ole,
spec

t to the co

rrectne
The operating mode and ampere hours (Ah) as set are displayed.
ss o

cial p
f inform
mer

atio
om
n
c
i
or

thi
e
t
sd
iva
o
pr
cum

r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
29
AG.
3. Charging battery
lkswage es n
o ot g
byV ua
d ran
ir se tee
o
Amarok 2011 , Caddy 2004 , Caddy 2011
auth , Crafter 2006 , Transpo ... or
ac
Electrical System, General Information - Edition 09.2012 ss
ce
e
nl
pt
du
an
3.3.4 Charging exhaustively discharged bat
itte
y li
erm
ab
teries batteries with battery charger -
ility
ot p
wit
VAS 5900-
, is n
h re
hole
spec
es, in part or in w
WARNING
t to the co
rrectness of i
l purpos
WARNING
nf
ercia
orm
m
atio
m

o
n in
or c
thi
e

t
sd
iva
jump starting.
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
Caution
cted agen
Prote AG.

battery terminals.
When charging always set the battery charger to the cor
rect type of battery operating instructions for battery
charger -VAS 5900- !
Totally discharged battery is not recognised by battery
charger page 18 .
aged.
Batteries with a voltage of less than 2 volts will not be recognised

automatically by battery charger -VAS 5900- .

Note

3.1 Totally discharged batteries, page 18 .
Totally discharged batteries in vehicles before registration
must be exchanged prior to delivery. Preliminary damage can
not be excluded.
key.
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
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Use INFO to set battery to respective operating mode.

teries will appear.
olkswagen AG
en AG. V
Set capacity (Ah) of battery to be charged using kcorresponding
swa
g does
not
Vol
button Up or Down . ed
by gu
ara
is nte
or eo
Connect red terminal clamp + of charger
au
th to positive terminal ra
of battery. ss c
ce
e
nl
pt
du
an
itte
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Note
erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
nal of battery.
rrectness of i
Press START / STOP for approx. 5 seconds. The menu
l purpos
charging totally discharged batteries/support mode will be

activated.
nform
ercia
Press Up or Down button to set appropriate battery

m
at
voltage (6 V, 12 V or 24 V).
om
ion
c
in t
or
his
ate
Note
do
priv
cum
for
en
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If a button is not pressed within 5 seconds, the charger will return

n
t.
yi Co
to the main menu (select operating mode). Cop py
t. rig
gh ht
pyri by
Vo
o
Confirm selected battery voltage with START / STOP .
c by lksw
cted agen
Prote AG.
Then follows the enquiry for "is charger cable terminal polarity
correct".
Check that connections of charger terminals have correct po
larity.
Confirm that connections of charger terminal clamps have
correct polarity with START / STOP .
Charger will start charging sequence for totally discharged bat
tery.

General notes:
For further information, refer to VAS 5900 operating manual .

The support mode is suitable in the following situations:

Support mode of onboard supplies without
wage
n AG. Voinstalled battery
lkswagen AG
doe
ks s no
Vol t gu
Power conservation when
ed renewing the battery
by ara
is nte
or
Ancillaries test without
au battery
th eo
ra
ss c
ce
le
un
pt
WARNING
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
WARNING
rrectness of i
l purpos

jump starting.
nform
ercia

m
a
com
tion in
r
te o
thi
key.
s
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r
rp
cum
fo
Caution
en
ng
t.
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Cop py
t. rig
The terminal polarity protection in operating mode charg gh ht
yri by
ing totally discharged batteries/support mode is not ac cop Vo
by lksw
cted agen
Prote AG.
battery terminals.
Danger of explosion
Ensure charger terminals are fitted securely.
aged.
Remove battery Electrical system; Rep. gr. 27 ; Battery;

Removing and installing battery .
Caution
When the battery is removed, ensure there is no contact be

tween the positive terminal clamp of charger and the body
earth.
minal clamps.

Note


nal clamp of vehicle battery.
activated.
Note

to the main menu (select operating mode).

correct".
larity.
The battery charger starts with support mode.
gen AG
. Volkswagen AG
d
a oes
ksw not
End battery support mode: Vol gu
d by ara
e nte
ris
Press START / STOP . utho eo
ra
a c
ss
ce
e
nl

pt
du
an
itte
y li

erm
ab

ility
ot p
wit
, is n

h re
hole
spec

es, in part or in w
t to the co
with battery charger -VAS 5900-

rrectness of i
Note
l purpos
When a battery is being charged in the maintenance mode and

an electrical consumer draws current from the battery, the
nform
ercia
battery charger -VAS 5900- automatically compensates the

charge.
m
at
om
ion

c
in t
or
riod.
his
ate
do
riv

p
cum
for
en
ng
Observe battery manufacturer's maintenance instructions.

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

WARNING

WARNING

jump starting.
When the battery is fully charged the battery charger -VAS 5900-
switches to maintenance mode.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
3.4 Battery charger -VAS 5903-

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

page 35
rrectness of i

36
l purpos
3.4.3 Charging battery in refresh charge mode with battery

charger VAS 5903 , page 38
nform
ercia
3.4.4 Charging totally discharged battery with battery charger

m
VAS 5903 , page 41

com
tion in
r

te o
thi
VAS 5903 , page 43

s
iva
do
r
rp
cum

fo
en
g
charger VAS 5903 , page 45

n
t.
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Cop py

t. rig
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pyri by
Vo
o
VAS 5903-
by c lksw
cted agen
Prote AG.
WARNING

WARNING

Danger of explosion when checking and charging
agen
Aor slave/
G. Volkswagen AG
does
jump starting. Volksw not
g y ua
db ran
These batteries must be renewed. rise tee
tho or
s au ac
s
ce
e
nl
pt
du
an
-VAS 5903- . For additional information refer to operating in
itte
y li
structions for battery charger -VAS 5903- .
erm
ab
ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
t to the co
charger -VAS 5903- .
rrectness of i
l purpos
nf
ercia
1 - Display
orm
m
2 - Adjustment button Up
atio
om
n in
c
3 - Adjustment button Down

or
thi
te
sd
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4 - START / STOP
o
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m
f
5 - INFO
en
ng
t.
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Cop py
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gh ht
pyri by

co Vo
by lksw
cted agen
Prote AG.
VAS 5903-
WARNING

WARNING

jump starting.

Note

wage
e ks s no
Vol t gu
d by ara
Switch off ignition and all electrical loads,
ris
e and pull out ignition nte
key. utho eo
ra
a c
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
In the display the symbol -1- for standard charge for wet batter
wit
, is n
ies or symbol -2- for standard charge for gel/absorbent glass
h re
hole
mat batteries will appear.
spec
es, in part or in w
t to the co
rrectness of i
of battery.
l purpos
Note
nform
ercia

m
a
com
ti

on in

r
te o
thi

s
iva
do
r
rp
cum
fo

en
ng
t.
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nal of battery.
Co
Cop py
t. rig
gh
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
At a charge condition of approx. 80 - 85 % the battery charger

switches to the final charge mode. The fourth bar appears in
display -1-. The battery is ready for use.
Note
In the case of battery type standard charge, the parallel opn AG. Volkswagen AG doe
wage
eration of electrical consumers while charging is possible.
Vol
ks The s no
t gu
by
charging period will be longer. ise
d ara
nte
r
tho eo
The battery charger will switch to maintenance
sa
u mode after ra
c
about 1-7 hours, depending on type of battery.
s To achieve a
ce
e
100% charge, the battery should remain connected to the
nl
pt
du
an
charger during this period.
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
quence starts.
charging sequence already started:
rrectness of i
l purpos
nf
quence starts again.
ercia
orm
m
atio
m

o
n in
or c
thi
te
sd
iva
o
r
rp
cu
The battery type and ampere hours (Ah) as set is displayed.
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
Disconnect black terminal clamp - of charger from negative cted agen
Prote AG.
3.4.3 Charging battery in refresh charge

mode with battery charger -VAS 5903-
WARNING

WARNING

jump starting.

Caution
The operating mode refresh charge is not permitted on VW

vehicles as the voltage peaks will damage the onboard elec
tronics.
If the operating mode refresh charge is used nevertheless,
the battery must be disconnected from the onboard supply.
Caution
. Volkswagen AG
gen AG does
swa
When charging always set the battery chargerbyto Volthe correct
k not
gu
type of battery operating instructions forrisebattery charger -
d ara
nte
VAS 5903- ! ut
ho eo
ra
sa c
The refresh charge mode is suitable sfor:
ce
le
un
pt
Wet batteries, where distilled water can be replenished.
an
d
itte
y li
rm
ab
Do not use the operating mode refresh charge for mainte
pe
ility
nance-free wet batteries.
ot
wit
, is n
h re
hole
spec
The refresh charge (refr) operating mode is only used on sus
es, in part or in w
t to the co
pect defective batteries (e.g. sulphation). The battery will be
charged to maximum specific gravity and the plates will be reac
tivated (dissipation of sulphur layer).
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
key.

In the display the symbol -1- for refresh charge for wet batteries
or symbol -2- for refresh charge for gel/absorbent glass mat bat
teries will appear.
of battery.
Note


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

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

AG. Volkswagen AG d
the sulphation of the battery. Volksw
oes
not
gu
d by ara
ise nte
r
Possible faults and fault rectification: ut
ho eo
ra
s a c
s
ce
le
un
pt
an
d

itte
y li
quence starts.
rm
ab
pe
ility
ot
wit
, is n
charging sequence already started:
h re
hole
spec
es, in part or in w
t to the co
quence starts. rrectness of i

l purpos

nform
ercia
The operating mode and ampere hours (Ah) as set are displayed.
m

com
tion in

r
te o
thi
s
iva
do

r
rp
cum
fo
en
ng
t.
yi Co
Disconnect red terminal clamp + of charger from positive Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

3.4.4 Charging totally discharged battery with

WARNING

WARNING

jump starting.
Caution

battery terminals.
olkswagen AG
en AG. V
When charging always olks set the battery charger
wag does
nto
ot gthe cor
rect type of battery
ed by V operating instructions for battery
ua
ran
charger -VAS
thoris 5903- ! tee
or
au ac
Totallyssdischarged battery is not recognised by battery
charger page 18 .
ce
e
nl
pt
du
an
itte

y li
erm
ab

ility
ot p
aged.
wit
, is n
h re
hole
spec
Batteries with a voltage of less than 2 volts will not be recognised

es, in part or in w
automatically by battery charger -VAS 5903- .

t to the co

rrectness of i

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

3.1 Totally discharged batteries, page 18 .
Totally discharged batteries in vehicles before registration en AG. V
olkswagen AG
must be exchanged prior to delivery. Preliminary damage can olks
wag does
not
not be excluded. ed
byV gu
ara
is nte
or
The battery must have a temperature of at least 10 C. auth eo
ra
ss c
ce
le
un
pt
an
d
key.
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


teries will appear.
of battery.
Note
. Volkswagen AG
gen AG
In vehicles with start/stopksw system and battery emonitor control unit
a o s d
not
Vol
-J367- installed,ed bblack
y terminal clamp must be connected
gu
ara to body
earth. Connecting
ho
ris it to the negative terminal of the battery
nte
e o will
cause start/stop
sa
ut
system to malfunction. ra
c
s
ce
e
nl
pt
du
an
itte
nal of battery.
y li
erm
ab
ility
ot p
wit
, is n
h re
activated.
hole
spec
es, in part or in w
t to the co
rrectness of i
Note
l purpos

nf
ercia
orm

m
atio
om
n in
c
or
thi
correct".
te
sd
iva
o
r
rp
cu

o
m
f
larity.
en
ng
t.
yi Co
op py
t. C rig
gh ht
correct polarity with START / STOP . yri
p by
co Vo
by lksw
cted agen
Charger will start charging sequence for totally discharged batProte AG.
tery.

General notes:
The support mode is suitable in the following situations:

Support mode of onboard supplies without installed battery
Power conservation when renewing the battery
Ancillaries test without battery
WARNING

WARNING
. Volkswagen AG
gen AG
It is not permissible to test or charge batteries whose ksmagic
wa does
not
Vol
eye shows light yellow. Do not slave/jump start the
ed vehicle!
by gu
ara
is nte
or
Danger of explosion when checking and charging
au
th or slave/ eo
ra
jump starting. ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
key.
h re
hole
spec
es, in part or in w
Caution
t to the co
rrectness of i
battery terminals.
l purpos
nform
ercia
Danger of explosion
m
a
com
t
Ensure charger terminals are fitted securely. ion in
r
te o

thi
s
iva

do
r
rp
aged.
um
fo
en
ng
t.
yi Co
Cop py
t. rig
Remove battery Electrical system; Rep. gr. 27 ; Battery;
gh ht
pyri by
Removing and installing battery .
co Vo
by lksw
cted agen
Prote AG.
Caution
When the battery is removed, ensure there is no contact be

tween the positive terminal clamp of charger and the body
earth.
minal clamps.


Note

earth. Connecting it to the negative terminal
n AG. Vof
olkthe
swabattery
gen AG will
olks
wage does
not
yV gu
db ara
ise nte
Connect black terminal tho clamp
r
- of charger to negative termi eo
nal clamp of vehicle
s aubattery. ra
c
s
ce
le

un
pt
an
d

itte
y li
rm
activated.
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
l purpos
nform
ercia
correct".
m
a
com
tio
n in
r
te o
larity.
thi
s
iva
Confirm that connections of charger terminal clamps have do

r
rp
cum
fo

en
ng
t.
yi Co
op
The battery charger starts with support mode. C py
t. rig
gh ht
yri by
End battery support mode: cop Vo
by lksw
cted agen
Prote
AG.


with battery charger -VAS 5903-
Note
When a battery is being charged in the maintenance mode and

an electrical consumer draws current from the battery, the
battery charger -VAS 5903- automatically compensates the
charge.
riod.
Observe battery manufacturer's maintenance instructions.
WARNING

WARNING

jump starting.
When the battery is fully charged the battery charger -VAS 5903-
switches to maintenance mode.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
ksw
Amarok 2011 , Caddy 2004 , Caddy by
V 2011 , Crafter 2006 , oTranspo
ol n t
gu ...
d ara
ElectricaloSystem,
ris
e General Information - Edition 09.2012 nte
th eo
s au ra
c
3.5 Battery charger -VAS 5906- s
ce
le
un
pt
an
d
itte
y li
page 47
erm
ab
ility
ot p
wit
is n
47
h re
ole,
spec
t to the co
VAS 5906-
Battery charger - VAS 5906-
rrectne
WARNING
ss o
cial p
f i
nform
mer
atio
om
n
c
i
or
n thi
te
sd
a
WARNING
iv
o
pr
cum
r
fo
en
ng

t.
yi Co
eye shows light yellow. Do not slave/jump start the vehicle! Cop py
t. rig
gh ht
yri
Danger of explosion when checking and charging or slave/ p by
o Vo
by c
jump starting.
lksw
cted agen
Prote AG.
Battery charger -VAS 5906- has been specially developed for

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

VAS 5906-
WARNING

WARNING

jump starting.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Overview of operating panel:

1- Charge condition display 25 %.
5- Display ready
6- Start/stop and Setup buttons for interrupting and resuming
charging process. Entry to Setup menu and selection of
characteristic type (press for 10 s).
7- Malfunction display.
Place charger in engine compartment or under vehicle.
Connect mains cable to charger and plug it into mains.
Charger is in no-load operation - ready for use light is on.
AG. Volkswagen AG d
agen oes
WARNING olksw not
byV gu
ara
ed
ris nte
Danger of injury! Comply with the ut warning notices and safety
ho eo
ra
regulations page 1 ! ss a c
ce
e
nl
pt
du
an
itte
y li
Switch off ignition.
erm
ab
ility
ot p
Connect red charging cable to positive terminal + on battery.
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
rrectness of i
l purpos
Connect black charging cable to negative terminal - on bat

nf
ercia
tery.
orm
m
Charging starts after about 2 seconds.

atio
om
n in
c
Number of LEDs lit indicates charge condition of battery. Battery

or
thi
e
has been charged up once all lights are lit.

t
sd
iva
o
r
rp
cu
When battery is fully charged, battery charger -VAS 5906- auto

o
m
f
matically switches over to trickle charging.

en
ng
t.
yi Co
Cop py
ht. rig
ht
Caution
rig by
copy Vo
by lksw
cted agen
Prote
Danger of sparking if charging terminals are removed too soon.
AG.
Terminate charging by pressing the start/stop button.
Press start/stop button to terminate charging.

Disconnect black charging cable from negative terminal - on
battery.
Disconnect red charging cable from positive terminal + on
battery.
3.6 Solar panel -VAS 6102A-

3.6.1 Charging battery in maintenance mode with solar panel
VAS 6102A , page 50

with solar panel -VAS 6102A-
Solar panel VAS 6102A
General description:
Solar panel -VAS 6102A- supports onboard supply and prevents
spontaneous battery discharging. n AG. Volkswagen A ge G do
swa es n
Solar panel -VAS 6102A- achieves max.by
Vol voltage of 14.3 V and a
k ot g
ua
charge current of max. 255 mA. rised ran
tee
tho or
Solar panel -VAS 6102A- may ss
au be used for charging all recharge ac
able lead or lead gel batteries.
ce
le
un
pt
an
Solar panel -VAS 6102A- is connected to diagnostic connection
d
itte
y li
in vehicle.
rm
ab
pe
ility
A green LED is integrated in the frame to indicate its function. The
ot
wit
, is n
brighter the LED, the higher the charging current.
h re
hole
spec
Integrated electronics prevent battery overcharging.
es, in part or in w
t to the co
Secure solar panel -VAS 6102A- on interior mirror -1-.
Place underside on dash panel -2-.
rrectness of i
l purpos
Note
nform
ercia
Solar panel -VAS 6102A- may not lie fully on dash panel. It is only
allowed to be positioned with the bottom edge for support. Placing
m
a
com
ti
it fully on the surface can result in discolouration of the dash panel.

on in
r
te o
thi
s
Pull attachment string tight so that solar panel -VAS 6102A- is

iva
do
r
positioned close to windscreen.

rp
cum
fo
en
ng
Connect solar panel -VAS 6102A- to diagnostic connection of

t.
yi Co
op
vehicle. Connect in same way as vehicle diagnosis tester
C py
ht. rig
page 71 . rig ht
py by
co Vo
by lksw
Check function of solar panel -VAS 6102A- . Green LED indi
cted agen
Prote AG.
cates that solar panel -VAS 6102A- is operative.

4 Cruise control system (CCS)

4.1 General description - cruise control system (CCS),
page 51
4.2 Activating and deactivating cruise control system (CCS),
page 51
4.1 General description - cruise control sys

tem (CCS)
The functions of the cruise control system are controlled by the
engine control unit.
The cruise control system can be activated and deactivated
page 51 .
Fault detection and fault display:
Faults on the CCS are output via the engine control unit.
For fault finding, use vehicle diagnosis, testing and information
system -VAS 5051B- or vehicle diagnosis and service information
system -VAS 5052 A- in Guided fault finding mode.
4.2 Activating and deactivating cruise con

trol system (CCS)
Connecting vehicle diagnostic tester page 71
Select Guided fault finding in vehicle diagnosis tester .
Using GoTo button, select Functions/component and then
the following menu options in succession:
olks
wage es n
o
yV t gu
Drive db ara
rise nte
tho eo
Engine code ss
au ra
c
ce
le
01 - On Board Diagnostic capable systems

un
pt
an
d
itte
y li
Engine management/diesel direct injection and glow plug sys

erm
ab
tem
ility
ot p
wit
Functions
is n
h re
ole,
Activating and deactivating cruise control system (CCS)

spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
4. Cruise control system (CCS) 51

90 Gauges, instruments
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
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
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
52
AG.
Rep. gr.90 - Gauges, instruments
92 Windscreen
gen AG
wash/wipe
. Volkswagen AG
d
system
a oes
ksw not
Vol gu
by
1 Washer fluid line hose couplings
ris
ed ara
nte
tho eo
au r
The following
ss hose coupling types are used to connect the ahosesc
to pumps and spray jets and/or as points of separation:
ce
e
nl
pt
du
an
1.1 Hose couplings - windscreen and rear window washer
itte
y li
erm
system, page 53
ab
ility
ot p
1.2 Hose couplings - windscreen and rear window washer
wit
, is n
system, Crafter, page 54
h re
hole
spec
1.3 Hose couplings - headlight washer system, page 55
es, in part or in w
t to the co
1.1 Hose couplings - windscreen and rear
window washer system
rrectness of i
Pull the two coupling sections apart (no securing device) to
l purpos
loosen the connection.

To secure the connection, push the two coupling sections to
nf
ercia
gether, until you hear and feel them engage.
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
To loosen the connection, rotate the lock ring -1- through 90
Prote AG.
-arrow- and pull off the hose connection.
To secure the connection, push on the hose connection and
rotate the lock ring -1- -arrow- until it engages.
To loosen the connection, pull up the lock ring -1- by approx

imately 1 mm -arrow- and pull off the hose connection.
To secure connection, attach hose connection and press in
clip -1- until it engages.
1. Washer fluid line hose couplings 53

To loosen the connection, pull up the lock ring -1- -arrow- and
pull off the hose connection.
To secure connection, attach hose connection and press in
clip -1- until it engages.
1.2 Hose couplings - windscreen and rear

window washer system, Crafter
Hot air blower -VAS 1978/14A- or
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
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
Hot air blower -V.A.G 1416-
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
On Crafter vehicles, the connections of washer fluid hoses on ht. rig
rig ht
pumps and washer jets of the windscreen and rear window wash
py by
co Vo
by lksw
er system are not equipped with hose couplings. The washer fluid Prote
cted AG.
agen
hoses are pushed directly onto hose connections of the corre
sponding components.
It can be helpful to heat the hose ends with hot air blower in order
to ease the procedure of releasing or securing washer fluid hoses.
54 Rep. gr.92 - Windscreen wash/wipe system

Caution
Please note that the hose ends of the washer fluid lines may
only be heated slightly (test temperature by hand).
When heating the hose ends, take care not to damage any
other wiring, plastic parts or insulating material with the hot
nozzle of the hot air blower.
Observe the operating instructions for the hot air blower!
1.3 Hose couplings - headlight washer sys

tem
olkswagen AG
en AG. V
To loosen the connection, push othe
lkswlock ring -1- -arrow- and
ag does
not
pull off the hose connection.
ed
byV gu
ara
is nte
or
To secure the connection,
ut
h push and hold the lock ring eo
ra
s a hose connection. Check proper en
-arrow- and push onsthe c
gagement of securing clips by attempting to pull them off
ce
e
nl
pt
du
without pressing them.
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
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Washer fluid line hose couplings 55

lkswage es n
o ot g
byV ua
d ran
ir se tee
o
Amarok 2011 , Caddy 2004 , Caddy 2011 au , Crafter 2006 , Transpo ...
th or
ac
ss
ce
le
un
pt
an
d
itte
y li
2 Hose repair
erm
ab
ility
ot p
wit
2.1 General description - hose repair, page 56
is n
h re
ole,
2.2 Repairing smooth pipe, page 56
spec
2.3 Repairing corrugated pipe, page 56
t to the co
2.1 General description - hose repair
rrectne
A new repair concept has been developed for repair work on wash
system hoses. Various connectors, special EPDM hoses (ethyl
s
ene-propylene terpolymer) and heat-shrink hose are available as
s o
spare parts.
cial p
f inform
Refer to the electronic parts catalogue (ETKA) for spare
parts. mer
atio
om
n
c
Replacement parts are available for repair of both smooth and
i
or
n thi
e
corrugated pipes.
t
sd
iva
o
pr
c
2.2 Repairing smooth pipe
um
r
fo
en
ng
t.
yi Co
op
Smooth pipe with a diameter or 5x1 mm or 6x1 mm can be re C py
t. rig
paired with EPDM hose.
gh ht
pyri by
Vo
co lksw
by
Cut damaged section (cuts straight through pipe) out of the Prote
cted AG.
agen
smooth pipe to be repaired.
In the Electronic parts catalogue (ETKA) , select the ap
propriate EPDM hose -2- and cable ties.
Cut EPDM hose -2- to size so that smooth-type pipe ends
-1- and -3- can be inserted approx. 10 mm into EPDM hose
-2-.
Secure repair position on both sides with cable ties -1-.
2.3 Repairing corrugated pipe

Hot air blower -VAS 5179- or

Hot air blower -V.A.G 1416- or
AG. Volkswagen AG d
agen oes
olksw not
yV gu
Hot air blower -VAS 1978/14- ed b ara
nte
ris
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
Note
ss o
cial p
f in
Repair points must not be subjected to pulling or bending
form
mer
forces.
atio
m
If the damaged section is longer than 20 mm, a new piece of

o
n
c
i
or
n
corrugated pipe must be used and the procedure described
thi
e
below must be performed twice.

t
sd
iva
o
pr
cum
r
fo
en
Cut damaged piece (cuts straight through pipe) out of the cor
ng
t.
yi Co
rugated pipe to be repaired. ht. Cop py
rig
rig ht
In Electronic parts catalogue (ETKA) , select appropriate py by
co Vo
connecting pieces -2- and -3- and appropriate heat-shrink
by lksw
cted agen
Prote
hose.
AG.
Heat end of corrugated pipe -1- with hot air blower.

Push connecting piece -2- into corrugated pipe -1- -arrow A-.
Heat end of corrugated pipe -4- with hot air blower.
Push connecting piece -3- into corrugated pipe -4- -arrow B-.
2. Hose repair 57
Cut heat-shrink hose so that ends of corrugated pipe are each

covered by about 20 mm -dimension x- of heat-shrinkghose.
en AG. V
olkswagen AG
d wa oes
olks not
Push heat-shrink hose on both sides over corrugated
by
V pipe gu
ara
ed
-x- and connect connection pieces. or
is nte
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ut ra
Heat heat-shrink hose on both sides with
ss
a
hot air blower to se c
cure section to be repaired.
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94 Lights, bulbs, switches

olks
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1 Operation and safety notes for gas
r
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discharge bulbs ss c
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un
pt
an
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If repair work is done on headlights with gas discharge bulbs, fol
itte
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lowing instructions must be observed: rm
ab
pe
ility
Notes on dangerous high voltage/currents page 59
ot
wit
, is n
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Notes on pressure, temperature, radiation/arcs page 60
hole
spec
es, in part or in w
Assembly notes for gas discharge bulbs page 61
t to the co
Disposal regulations for gas discharge bulbs page 61
rrectness of i
Safety goggles
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Gloves
nform
ercia
WARNING
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a
com
tion in
It is absolutely necessary to disconnect the battery earth strap
r
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before working on parts of the gas discharge headlights
s
iva
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marked with yellow high voltage symbols.
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Then switch dipped beam on and off again. This will eliminate
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any possible residual voltage. Cop py
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The gas discharge lamp control unit must never be operated p by
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without a gas discharge lamp.
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Prote AG.
Due to the high voltage (above 28000 V when igniting the gas
discharge bulb) and temperatures, the gas discharge bulb
must only be operated in the headlight housing.
WARNING
Never change bulbs if you are not familiar with the appro
priate procedures, safety precautions and tools.
Notes on dangerous high voltage and current
WARNING
Control units for light system, connectors and components per

taining to bulb holders conduct lethally high voltage.
Operating the control unit and the starter unit is permitted only
with the bulb fitted.
1. Operation and safety notes for gas discharge bulbs 59

WARNING
Switch off ignition and all electrical loads, and pull out ig
nition key. en AG. V
olkswagen AG
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When working onbyheadlight
Vol
k
system, ensure thatnthere
ot g
ua is
no voltage in any
ris components, including the dissipationanof
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tee
residual voltage
au
tho after the headlights are switched off. or
a
ss c
Residual voltage can be dissipated by turning the dipped
ce
le
un
beam on and then off again after withdrawing the ignition
pt
an
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key.
itte
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When working on the headlight system, ensure that the
ility
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lights cannot be switched on.
wit
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Notes on pressure, temperature, radiation/arcs
t to the co
WARNING
rrectne
The bulbs may be operated in the headlight housing only
(protection against contact due to very hot bulbs, absorp
ss
tion of UV radiation, avoidance of dazzling light, protection
o
cial p
f i
against explosion).
nform
mer
The glass of the bulbs can become very hot - danger of

atio
m
burns!
o
n
c
i
or
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Avoid looking directly into the collimated beam as the UV

te
sd
a
radiation from the gas discharge bulb is about 2.5 times

iv
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greater than from normal halogen bulbs.

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Never look directly into the light beam (danger of glare);
Co
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otherwise vision may be impaired for a substantial length
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WARNING
Avoid contact with burst glass bulbs.

H7 bulbs and gas discharge bulbs (xenon and bi-xenon)
are under pressure and can explode while being changed
- danger of injury.
Always wear eye protection and gloves when removing
and installing gas discharge bulbs!
60 Rep. gr.94 - Lights, bulbs, switches - exterior

Repair notes for gas discharge bulbs
Caution
Before renewing a bulb, always switch off the concerned

electrical consumer.
Switch off ignition and all electrical loads, and pull out ig
nition key.
Do not touch the bulb glass with bare fingers. Use clean
fabric gloves. When the light bulb is switched on, the heat
would vaporise the oil of the finger prints which would then
settle on the reflector, impairing the brightness of the
headlight.
A light bulb must always be renewed with a bulb of the
same sort. The designation appears on the base of the
bulb or on the bulb glass.
Properly engage connectors during installation and the
connection is seated tightly.
AG. Volkswagen AG d
agen oes
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Disposal regulations for gas discharge
byV
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bulbs gu
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WARNING ss a ra
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Gas discharge bulbs must be disposed of as hazardous
du
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waste; never dispose of gas discharge bulbs as consumer
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ab
waste.
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Gas discharge bulbs contain metallic mercury (Hg) and
, is n
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traces of thallium; never destroy these bulbs.
hole
These components must be recycled in the correct man spec

es, in part or in w
t to the co
ner according to national law.
Only dispose of in containers intended for this purpose at
an authorised collection point.
rrectness of i
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ion
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ate
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1. Operation and safety notes for gas discharge bulbs 61

96 Lights, bulbs, switches - interior

1 12 V socket agen
AG. Volkswagen AG d
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1.1 Removing and installing 12 V sockete d by , page 62 ara
nte
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1.2 Removing and installing socket
aut
h
illumination bulb L42 , ra
page 64 ss c
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un
pt
1.1 Removing and installing 12 V socket
an
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Caution
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If excessive force is exerted on sockets without illumination,
spec
the retaining sleeve may be damaged.
es, in part or in w
t to the co
Only illuminated sockets (cigarette lighter) can be removed
with the puller T 40148.
rrectness of i
The puller does not manage to release the locking lugs of
sockets without illuminated retaining sleeve.
l purpos
Usually sockets without illumination cannot be removed with

out being damaged.
nform
mercia
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Note
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The illustrations apply to all vehicle models; for this reason, they
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do not show the original vehicle environment.
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Puller -T40148-
Prote AG.
Removing:
Remove knurled nut from puller and take top section of puller
off.
62 Rep. gr.96 - Lights, bulbs, switches - interior

Insert the lower section of puller into socket in such a way that
the 2 locking lugs on the puller engage in the openings for this
purpose in the socket -arrow-. If necessary, turn the lower
section of the puller back and forth a little in the socket until
the puller has engaged in the openings.
Fit puller -T40148- -1- in place and place it onto socket as

shown.
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Turn knurled nut of puller in -direction of arrow A- so that sock kswagen AG does
et is pulled out of its mounting in -direction of arrow B-. by Vol not
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Remove socket and release and disconnect connector.
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1. 12 V socket 63
Using a small screwdriver, press in the two locking lugs of the

puller -arrow- and pull socket off puller.
Note
It is recommended that a bench vice be used to remove puller

from socket as pushing in the locking lugs of the puller and pulling
the puller out of the socket at the same time requires a certain
amount of force.
Installing:
Attach connector to socket and engage it.
Push socket into its mounting slot until it latches into place.
Note
In some socket brackets, the installation position of the socket

is prescribed by a groove.
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gen AG
When installing, align the socket to the groove in the socket Volkswa
does
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1.2 Removing and installing socket illumi
ce
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nation bulb -L42-
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The removal of the socket illumination bulb -L42- is performed in
ility
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the same way as the removal of the cigarette lighter illumination
wit
, is n
bulb -L28- page 69 .
h re
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es, in part or in w
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2 Cigarette lighter -U1-

2.1 General description - cigarette lighter U1 , page 65
2.2 Assembly overview - cigarette lighter U1 , page 66
2.3 Removing and installing cigarette lighter socket ,
page 66
2.4 Removing and installing cigarette lighter illumination bulb
L28 , page 69
2.1 General description - cigarette lighter -

U1-
The following descriptions apply to the rear left cigarette lighter -
U3- , rear right cigarette lighter -U7- , rear cigarette lighter -U9- ,
12 V socket 2 -U18- , 12 V socket 3 -U19- , 12 V socket 4 -U20- ,
cigarette lighter 2 -U25- and 12 V socket 5 -U26- so far as they
are illuminated.
Caution

out being damaged.
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On some vehicles, the illumination
ksw
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AG is not provided
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not
but by an LED (light-emitting
by Vol
diode), depending on the gequipment
ua
level. This LED risisepermanently attached to the retaining sleeve
d ran
tee
and cannot beau
t renewed separately.
ho
or
a
ss c
Retaining sleeves with a light bulb are available in different ver
ce
e
nl
sions. On the one version, the light bulb can be replaced sepa
pt
du
an
itte
rately; on the other version, the light bulb cannot be replaced

y li
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separately. In this case, the bulb carrier has to be replaced to

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gether with the light bulb.

wit
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Depending on the space requirement, the vehicles are equipped

hole
with various electric sockets and cigarette lighter sockets. They

spec
differ in length and have different electrical connections. In the

es, in part or in w
t to the co
case of electric sockets or cigarette lighter sockets with wiring

harness, it may be necessary to perform additional work in order
to gain access to the connector.
rrectness of i
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2. Cigarette lighter U1 65
2.2 Assembly overview - cigarette lighter -U1-
1 - Cigarette lighter socket with

wiring harness
2 - Cigarette lighter
3 - Socket
4 - Cigarette lighter socket
5 - Spring pin
6 - Light bulb W 5 12 V,
1.2 watts
7 - Bulb carrier
AG. Volkswagen AG d
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2.3 Removing and installing cigarette lighter
cial p
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socket
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Note
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The removal and installation procedure is the same for all sockets
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and is therefore described here only for the cigarette lighter sock
t.
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Caution

out being damaged.

Puller -T 40148-
Removing:
Remove cigarette lighter, cigarette lighter dummy etc. from
socket.
AG. Volkswagen AG d
agen oes
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Note by Vol
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For reasons of clarity, theaut socket is removed in the illustration.
h
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Caution
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The socket or the retaining sleeve can be damaged.

wit
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Ensure that the puller is seated correctly in the socket, other

hole
spec
wise the retaining lugs of the spring pin will not be released.
es, in part or in w
t to the co
Push puller -arrow- into socket so that locking lugs -1- engage
in recesses -2-.
rrectness of i
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orm
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Pull grip -3- in -direction of arrow- to release locking lugs of

retaining sleeve.
Pull socket out of retaining sleeve using puller.
Caution
The socket wiring can be damaged. AG. Volkswagen AG d

agen oes
olksw not
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Pull out the socket only as far as the connected ised wiring
b allows. ara
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or eo
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aut ra
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un
pt
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itte
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Depending on the fitting location, it is recommended to use the
erm
ab
thrust piece 40148/1 -2- with the knurled nut -1-.
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ole,
Caution
spec
t to the co
When using the thrust piece, ensure that no surrounding com
ponents are damaged.
rrectne
Release and disconnect connector from socket.
ss o
cial p
f i
Note
nform
mer
atio
Depending on the space requirement, the vehicles are equipped
om
n
with various electric sockets and cigarette lighter sockets. They
c
i
or
n
differ in length and have different electrical connections. In the
thi
te
sd
a
case of electric sockets or cigarette lighter sockets with wiring

iv
o
pr
c
harness, it may be necessary to perform additional work in order
um
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fo
to gain access to the connector.

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Release locking lugs of puller by pressing spindle -1- in
op Vo
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-direction of arrow B-. Then release press tool -2- by turning it cted agen
Prote AG.
slightly to left -arrow A- and pull puller out of socket.
Note
When pulling out the puller, ensure that its locking lugs are not
spread.
Caution
The cigarette lighter might be ejected out of the socket after

the heating phase.
When connecting the puller, the socket retaining springs are
pressed apart and the retaining force of the cigarette lighter is
reduced.
After removing socket, carefully press together retaining
springs and check if cigarette lighter remains in removal posi
tion after the heating phase.

Carefully press together retaining springs of socket -arrows-.

Check if cigarette lighter remains in removal position after
heating phase and ensure it is not ejected into vehicle interior.
AG. Volkswagen AG d
Installing: agen oes
olksw not
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by ara
Install in reverse order of removal. rised
nte
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aut ra
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nl
pt
du
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itte
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ility
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2.4 Removing and installing cigarette lighter
hole
spec
illumination bulb -L28-
es, in part or in w
t to the co
Note
rrectness of i
l purpos
On some vehicles, the illumination is not provided by a light

bulb, but by an LED (light-emitting diode), depending on the
equipment level. This LED is permanently attached to the re
nform
ercia
taining sleeve and cannot be renewed separately.

m
at
om
Retaining sleeves with a light bulb are available in different
ion
c
versions. On the one version, the light bulb can be replaced
in t
or
separately; on the other version, the light bulb cannot be re
his
ate
placed separately. In this case, the bulb carrier has to be
do
priv
c
replaced together with the light bulb.
um
for
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Removing:
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Remove socket page 66 .
op Vo
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cted agen
Prote AG.
Press retaining lugs -arrows- and remove spring pin with bulb
carrier.
Unclip bulb carrier from spring pin.
Separate bulb carrier parts -A- and -B-.

Open part -B- of bulb carrier.
Pull out bulb -1- in -direction of arrow-.

Installing:
Install in the reverse order of removal. When doing this, note the
following:
Note
A defective bulb must always be renewed with a new bulb of

the same sort.
The designation is indicated on the base of the bulb or on the
bulb glass.
lkswage es n
o ot g
byV ua
d ran
ir se tee
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a ac
ss
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nl
pt
du
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es, in part or in w
t to the co
rrectness of i
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97 Wiring
1 Vehicle diagnostic, testing and infor
mation systems
1.1 General description - vehicle diagnosis, testing and infor
mation system, page 71
1.2 Connecting vehicle diagnostic tester , page 72
1.1 General description - vehicle diagnosis,

testing and information system
WARNING
During testing or measuring operations using a vehicle di

agnostic information system there is a risk of serious or
even fatal injury!
If the vehicle diagnostic information system is situated in
the activation area of an airbag during testing or measur olksw
ing operations, serious or even fatal injury may resultageifnan
AG. V agen AG
does
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airbag is triggered! by Vol not
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During testing and measuring operations, ho work together
ri e
aut
with a person who can operate the vehicle diagnosis and
or
ac
s
information system from one of the sback seats.
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Note
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hole
All the procedures described, e.g. adaptation and coding, can
spec
be performed using the vehicle diagnosis, testing and infor
es, in part or in w
t to the co
mation system -VAS 5051B- and the vehicle diagnosis and
service information system -VAS 5052 A- .
All work procedures can be found in guided fault finding and
rrectness of i
guided functions modes.
l purpos
For fault finding, use vehicle diagnosis, testing and information

system -VAS 5051B- or vehicle diagnosis and service infor
nform
ercia
mation system -VAS 5052 A- in Guided fault finding mode.

m
Observe the current operating instructions for the vehicle di

at
om
io
agnosis, testing and information system to be connected.

n
c
in t
or
his
e
Additional information:
at
do
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for
Self-study programme No. 202 ; Vehicle diagnostic, testing

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and information system VAS 5051
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Self-study programme No. 256 ; VAS 5052
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Self-study programme No. 294 ; Online connection of VAS
agen
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5051
Self-study programme No. 295 ; Diagnosis with VAS 5051,
VAS 5052 or VAS 5053
1. Vehicle diagnostic, testing and information systems 71

1.2 Connecting vehicle diagnostic tester
Note
Observe the latest operating instructions for the vehicle diagnosis

tester , which are displayed after selecting the Administration
and Operating Manual buttons.

Vehicle diagnosis tester
Diagnostic cable -VAS 5051/6A- (5 m)

lkswage es n
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Diagnostic cable -VAS 5051/5A- (3 m)

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f inform
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Only these cables are to be used for diagnosis, as they are the
only ones fitted with CAN bus wiring and therefore allowing CAN
diagnosis and/or CAN communication.
Connecting vehicle diagnostic tester :

Set handbrake.
72 Rep. gr.97 - Wiring

Vehicles with automatic gearbox, move selector lever to posi

tion P or N.
Vehicles with manual gearbox, move gear lever to neutral po
sition.
With ignition switched off, connect vehicle diagnosis tester us
ing diagnosis cable -VAS 5051/6A- or diagnosis cable -VAS
5051/5A- to diagnostic connection -enlargement- of vehicle.
Exemplary illustration of diagnostic connection
Switch on ignition. lkswage es n
o ot g
yV ua
Switch off all electrical consumers.
ir se
d b ran
tee
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a ac
ss
Note
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un
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All other and the following vehicle diagnosis, testing and informa
erm
ab
tion systems or vehicle diagnosis and service information sys
ility
ot p
tems are connected accordingly in the sequence described
wit
is n
above.
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
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om
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1. Vehicle diagnostic, testing and information systems 73

2 Wiring harness and connector re

pairs
2.1 Wiring harness repair set, page 74
2.2 Tool descriptions, page 76
AG. Volkswagen
2.3 General notes concerning repairs to lkvehicle
wage electrical sys does n
n AG
o s
tem, page 79 db
y V ot g
ua
e ran
ris tee
2.4 Repairs to electrical wiringuthharnesses,
o page 82 or
sa ac
2.5 Repairs to fibre optic cables,
s
page 92
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le
un
pt
2.6 Repairing connector housings and connectors,
an
d
itte
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page 99
rm
ab
pe
ility
2.7 Releasing and dismantling connector housings,
ot
wit
, is n
page 103
h re
hole
spec
2.1 Wiring harness repair set
es, in part or in w
t to the co
2.1.1 Wiring harness repair set VAS 1978 , page 74
2.1.2 Upgrade kit VAS 1978/50 , page 74
rrectness of i
2.1.3 Wiring harness repair set VAS 1978A , page 75
l purpos
2.1.4 Release tool set VAS 1978/35 , page 75
nform
2.1.1 Wiring harness repair set -VAS 1978-
mercia
a
Wiring harness repair set -VAS 1978- allows optimal repair quality
com
tion in
to be achieved in the area of vehicle electrics. Using the tools,
r
te o
repairs to connectors and wiring open circuits can be carried out.

thi
s
iva
To do this, complete repair wire sections with contacts already do

r
rp
crimped on are used and joined to the vehicle's own wiring har
um
fo
ness with the aid of crimp connectors. A special set of pliers with
en
ng
t.
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3 different crimp recesses and a hot air blower for shrinking the Cop py
crimp connectors make a perfect electrical connection.
t. rig
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Prote AG.
Note
Operating instructions Wiring harness repair set -VAS 1978-
2.1.2 Upgrade kit -VAS 1978/50-

Upgrade kit -VAS 1978/50- is required to bring old wiring har
ness repair set -VAS 1978- up to the latest standard of wiring
harness repair set -VAS 1978A- . The upgrade kit comprises of 4
assembly and 10 release tools, a new set of crimping pliers for
crimp connectors with head adapter 0.35 - 2.5 mm2 -VAS
1978/1-1- , 4.0 - 6.0 mm2 -VAS 1978/2 A- and head adapter for
JPT contacts -VAS 1978/9-1- . Also included are new stickers, a
new set of operating instructions, crimp connectors for 0.35
mm2 cable cross-section and a roll of black felt adhesive tape.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
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ed
hoAmarok
ris 2011 , Caddy 2004 , Caddy n2011
tee , Crafter 2006 , Transpo ...
aut Electrical System, General
or
ac Information - Edition 09.2012
ss
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un
pt
2.1.3 Wiring harness repair set -VAS 1978A-
an
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ab
The new wiring harness repair set -VAS 1978A- allows optimal
ility
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repair quality to be achieved in the area of vehicle electrics. Using
wit
is n
the new pliers, repairs to connectors and wiring open circuits can
h re
ole,
be carried out. To do this, complete repair wire sections with con
spec
tacts already crimped on are used and joined to the vehicle's own
wiring harness with the aid of four different types of crimp con
t to the co
nectors. A new set of crimping pliers with head adapters and a
hot air blower for shrinking the crimp connectors make a perfect
electrical connection.
rrectness
Note
o
cial p
f inform
mer
atio
om
n
Operating instructions Wiring harness repair set -VAS 1978A-
c
i
or
n thi
te
sd
va
2.1.4 Release tool set -VAS 1978/35-

i
o
pr
cum
r
fo
en
ng
t.
Release tool set -VAS 1978/35- serves as a means of releasing
yi Co
op
various primary and secondary locking devices in Group vehicles.
C py
ht. rig
The set comprises of 26 different tools with which, for example,
rig ht
py by
o Vo
round connector systems, flat contacts with 1 or 2 fasteners and by c lksw
cted agen
also single wire seals can be released or installed. Prote AG.
Allocation of the correct release tool to the respective locking

mechanisms can be gleaned from the table in the Operating
instructions of -VAS 1978/35- .
2. Wiring harness and connector repairs 75

2.2 Tool descriptions

2.2.1 Special pliers with insert, page 76
2.2.2 Release tools for contacts, page 76
2.2.3 Assembly tools for single wire seals, page 77
2.2.4 Wire strippers VAS 1978/3 , page 77
2.2.5 Hot air blower, 220 V / 50 Hz VAS 1978/14 ,
page 78
2.2.6 Crimping pliers VAS 1978/1A
olks
wage, page 78 es n
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yV ua
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2.2.1 Special pliers with insert
ran
ir se tee
ho
aut or
ac
The special pliers without
ss insert -VAS 1978/1- with insert for spe
cial pliers -VAS 1978/2- is part of the wiring harness repair set -
ce
e
nl
pt
du
VAS 1978- and is used to crimp connectors during wiring harness
an
itte
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repairs.
erm
ab
ility
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Colour allocation of crimp connectors to crimp recess:
wit
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h re
Colour of crimp Colour of crimp re Wiring cross section
hole
spec
connector cess
es, in part or in w
t to the co
Yellow Yellow 0.35 mm2
Red Red 0.5 mm2 - 1.0 mm2
rrectness of i
Blue Blue 1.5 mm2 - 2.5 mm2
l purpos
Yellow Yellow 4.0 mm2 - 6.0 mm2
nf
ercia
o
Note
rm
m
atio
om
n in
As an alternative, the connectors can also be crimped with

or c
crimping pliers (base tool) -VAS 1978/1-2- in conjunction with

thi
te
sd
a
head adapters -VAS 1978/1-1- or -VAS 1978/2A-

iv
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cu
page 78 .
o
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f
en
ng
t.
It is essential to ensure that the correct crimp recess is chosen
yi Co
op py
for the crimp connector being used page 76 . t. C rig
gh ht
pyri by
The insulation on the wires must not be crimped.
co Vo
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cted agen
Prote AG.
2.2.2 Release tools for contacts

The various release tools serve as a means of detaching the dif
ferent contacts from the connector housings without damage.
A selection of release tools is included in the wiring harness repair
set -VAS 1978- and wiring harness repair set -VAS 1978A- . The
complete set of release tools is included in release tool set -VAS
1978/35- page 75 .
WARNING
Some tools are equipped with a tool safety device.

This must be pushed over the tip of the tool after use in order
to protect the tip and prevent injuries to personnel.
Releasing and dismantling connector housings page 103 .

2.2.3 Assembly tools for single wire seals

The assembly tools serve as a means of sliding the single wire
seals fully into the connector housing without damage and there
by assure complete sealing between single wire and connector
housing. n AG. Volkswagen A ge G do
swa es
4 assembly tools for single
by
Vowire
lk seals are included in each
not
guwiring
ara
harness repair set -VAS
ris
e 1978 B- and previous versions.
d
nte
tho eo
Installing singless wire
au seals page 100 . ra
c
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un
pt
an
d
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rm
ab
pe
ility
ot
wit
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h re
hole
2.2.4 Wire strippers -VAS 1978/3-
spec
es, in part or in w
t to the co
Wire strippers -VAS 1978/3- serve as a means of stripping insu
lation off wires and cutting wires in the correct manner.
Wire strippers -VAS 1978/3- are included in wiring harness repair
rrectness of i
set -VAS 1978 B- and previous versions.
l purpos
The wire strippers have an adjustable limit stop within the pliers
jaws, with which the desired length of insulation to be removed
nform
ercia
can be adjusted.
m
Stripping:
a
com
tion in
Set sliding stop in jaws of pliers to desired insulation stripping
r
te o
thi
length.
s
iva
do
r
rp
cum
fo
en
ng
Insert end of wire from front onto stop into jaws of pliers and
t.
yi Co
op
press pliers together fully. C py
t. rig
gh ht
yri by
Open pliers again and remove stripped insulation from end of
cop Vo
by lksw
wire. cted agen
Prote AG.
If necessary, cut wire with cutting part on upper side of wire

strippers.

G. Volkswagen AG d
2.2.5 Hot air blower, 220 V / 50 Hz -VAS olkswagen A oes
not
1978/14-
V gu
by ara
ed nte
ris
tho eo
s au ra
c
Caution s
ce
e
nl
pt
du
an
itte
When shrink-fitting crimp connections, make sure not to dam
y li
erm
ab
age any other wiring, plastic parts or insulating material with
ility
ot p
the hot nozzle of the hot air blower.
wit
, is n
h re
Close attention to operating instructions for hot air blower is
hole
essential!
spec
es, in part or in w
t to the co
The hot air blower, 220 V / 50 Hz -VAS 1978/14- is used in con
junction with shrink element for hot air blower -VAS 1978/15- to
rrectness of i
shrink fit the crimp connectors. After crimping, the crimp connec
tor has to be shrink fitted using the hot air blower in order to
l purpos
prevent any ingress of moisture.
nf
ercia
Hot air blower, 220 V/50 Hz -VAS 1978/14- is included in wiring
orm
harness repair set -VAS 1978 B- and previous versions.
m
atio
om
n in
Shrink fitting crimp connectors using hot air blower, 220 V / 50 Hz
or c
-VAS 1978/14- page 88 , or page 90 .
thi
te
sd
iva
o
r
rp
cu
2.2.6 Crimping pliers -VAS 1978/1A-
o
m
f
en
ng
t.
yi Co
op
Crimping pliers -VAS 1978/1A- or crimping pliers (base tool) -VAS
C py
ht. rig
1978/1-2- together with head adapter 0.35 - 2.5 mm -VAS
rig ht
py by
o Vo
1978/1-1- or head adapter 4.0 - 6.0 mm -VAS 1978/2A- are used by c lksw
cted agen
to squeeze together crimp connectors from the wiring harness Prote AG.
repair sets.
Crimping connectors using crimping pliers -VAS 1978/1A-
page 90 .
The following heads adapters are available for crimping pliers
(base tool) -VAS 1978/1-2- :
Head adapter 0.35 mm2 - 2.5 mm2 -VAS 1978/1-1-
Head adapter 4.0 mm2 - 6.0 mm2 -VAS 1978/2A-
Head adapter for JPT contacts -VAS 1978/9-1-
In conjunction with head adapter for JPT contacts -VAS
1978/9-1- , the crimping pliers are used to crimp contacts to single
wires during repairs to wiring with cross sections up to 0.35
mm2 page 85 .
Interchanging head adapter:
Open crimping pliers fully.
Disengage both locking pins -arrows- from main body of crimp

ing pliers.

Insert required head adapter in main body of crimping pliers

from above -arrow-.
Lock head adapter by pressing pins -arrows- into main body

of crimping pliers.
2.3 General notes concerning repairs to ve

hicle electrical system
Caution
AG. Volkswagen AG d
agen oes
lksw not
To disconnect and connect the battery, the procedure descri byV
o gu
ara
bed in the workshop manual should be strictly adhered oristo
ed
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Electrical system; Rep. gr. 27 ; Disconnecting and connecting
aut
h eo
ra
battery . ss c
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un
pt
an
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ab
WARNING
ility
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wit
is n
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Some tools are equipped with a tool safety device.
ole,
spec
This must be pushed over the tip of the tool after use in order t to the co
to protect the tip and prevent injuries to personnel. rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Observe the latest notes in the respective workshop manual

when carrying out repairs.
Observe country-specific regulations.
Always disconnect the battery earth strap before working on
the electrical system. Disconnecting the battery earth strap
(open circuit) provides a safe working environment for repairs
to the electrical system. The battery positive wire need only be
disconnected for removal of the battery.
Before starting a repair, it is important to identify and rectify
the cause of damage (e.g. sharp edges on body panels, de
fective electrical consumers, corrosion, etc.).
For additional information, e.g. removal and installation of in
dividual components, refer to the relevant workshop manual.
Soldering is not permitted for repairs to vehicle wiring.
Wiring harness and connector repairs to onboard supply sys
tem may be carried out using wiring harness repair set -VAS
1978 B- and previous versions only. Only use yellow wires
from wiring harness repair set -VAS 1978 B- .
Wiring harness repairs may not be integrated in the vehicle's
own wiring harness and must be marked with the use of yellow
adhesive tape. This indicates a previous repair.
Crimp connectors may never be repaired. If necessary, route
a cable parallel to the defective one. After crimping, the crimp
connector has to be shrink fitted using the hot air blower in
order to prevent any ingress of moisture.
It is essential that the supplementary notes
AG. Volkare
swagobserved
en AG re
garding repairs to wiring harnesses agen
ksw in airbag and belt tension
does
ol not
er systems, fibre optic cables,
d b CAN bus lines, aerial cables anduara
yV g
wiring with cross sectionsrise up to 0.35 mm2 page 82 . nte
tho eo
au ra
Carry out a function
ss test after every repair. It may be necessary c
ce
le
to read and delete the event memory and/or to reset the sys
un
pt
tems.
an
d
itte
y li
erm
ab
If possible, do not loosen any earth wires from the body (dan
ility
ot p
ger of corrosion).
wit
is n
h re
Wiring harness repair set -VAS 1978 B- and previous versions

ole,
spec
do not cover all wiring cross sections that occur in the vehicle.
If the required wiring cross section is not available, use the

t to the co
next largest one.

Screened wires must not be repaired. If damaged they must
rrectne
be replaced complete.
Heat resistant wiring can be found in various places in the ve
s
hicle, mainly in the engine compartment. Heat resistant wiring

s o
cial p
can be identified by its slightly matt and softer insulation. To

f in
repair these wires, only heat resistant wiring may be used.

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

2.4 Repairs to electrical wiring harnesses

2.4.1 Notes on repairs to airbag and belt tensioner wiring,
page 82
AG. Volkswagen AG d
2.4.2 Repairing CAN bus wiring, page 83 lksw
agen oes
not
Vo gu
y
2.4.3 Renewal of aerial wiring, page 84 rise
d b ara
nte
tho eo
2.4.4 Repairs to electrical wiring with cross sectionssup
a to 0.35
u ra
c
mm2 , page 85 s
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le
un
pt
2.4.5 Wiring open circuit with one repair position, page 88
an
d
itte
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erm
ab
2.4.6 Wiring open circuit with two repair positions, page 90
ility
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wit
2.4.1 Notes on repairs to airbag and belt ten is n
h re
ole,
sioner wiring
spec
t to the co
In addition to the general notes on repairs to wiring harnesses,
the following instructions must be observed on how to repair wir
ing in airbag and belt tensioner systems:
rrectne
WARNING
ss o
cial p
f
Airbag and seat belt tensioner can fail.
inform
mer
Faulty repairs to the airbag and seat belt tensioning sys
atio
tem can cause malfunctions in the passenger protection
om
n
system.
c
i
or
n thi
te
sd
For repairs to airbag and belt tensioner wiring harnesses,
iva
o
r
only contacts, connectors and wiring designed specifically

p
cum
r
fo
for this purpose may be used Electronic parts catalogue
en
ng
t.
yi
(ETKA) .
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Note
Wires from airbag and belt tensioner wiring harness may only
be repaired using wiring harness repair set -VAS 1978 B- and
previous versions.
Adhere to general instructions concerning repairs to vehicle
electrical system page 79 .
AG. Volkswagen A
gen G do
swa es
Observe vehicle
by
Vol
k stickers indicating high voltage
not
gu components.
Beforeriscarrying
ed out repairs, discharge residualaravoltage
nte
General
utho body repairs, interior; Rep. gr. 69 ; Occupant
e o safety .
r
sa ac
For
s
repairs to wiring in the airbag and belt tensioner system,
ce
e
a maximum of 2 repairs may be performed. The more the re

nl
pt
du
an
pairs there are in the wiring, the greater the resistance and this
itte
y li
can trigger faults in the self-diagnosis of the system.
erm
ab
ility
ot p
To avoid corrosion, the crimp connectors are always to be
wit
, is n
shrink-fitted when performing airbag or belt tensioner wiring
h re
hole
harness repairs.
spec
es, in part or in w
Do not incorporate the repaired wiring back in the vehicle's
t to the co
own wiring harness. Mark the repair position clearly with yel
low insulating tape.
rrectness of i
Repairs in the area of the airbag or belt tensioner should not
be conducted more than 30 cm from the next connector hous
l purpos
ing. Together with the yellow insulating tape, this gives a clear
indication of repairs that have already been carried out.
nf
ercia
The wires to the triggering units (airbags) are entwined as

rm
standard with a twine spacing of 20 mm 5. This spacing is

m
atio
m
assured for series production via industrial standard numbers

o
n in
c
for wiring pairs and it is essential that it is adhered to on the

or
thi
e
repair lengths of entwined wiring.

t
sd
iva
o
r
rp
cu
During repairs, the wiring to the triggering units (airbags) must

o
m
f
en
ng
have the same length. When wires -1- and -2- are entwined,
t.
yi Co
the twine spacing of A = 20 mm 5 must be adhered to without
Cop py
t. rig
fail. opyri
gh by
Vo
ht
by c
There must not be any section of wiring, for example in the
lksw
cted agen
Prote
vicinity of crimp connectors -arrow-, longer than B = 100 mm
AG.
with the wires not twisted.
2.4.2 Repairing CAN bus wiring
Note
Adhere to general instructions concerning repairs to vehicle elec

trical system page 79 .

An unshielded two-wire line -1- and -2- with a cross section of

0.35 mm2 or 0.5 mm2 is used for CAN bus wiring.
Colour codes of CAN bus wiring:
Powertrain CAN, high wire Orange/black
Convenience CAN, high wire Orange/green
Infotainment CAN, high wire Orange/violet
CAN low wire, (all) orange/brown
Repairs to CAN bus wiring can be carried out either with sec
tions of repair wiring with the correct cross section or with
entwined wires green/yellow or white/yellow from the elec
tronic parts catalogue Electronic parts catalogue (ETKA) .
When repairs are performed, both CAN bus wires must have
the same length. When twisting the wires -1- and -2- together,
the length of each complete twist must be A = 20 mm.
There must not be any section of wiring, for example in the
vicinity of crimp connectors -arrow-, longer than B = 50 mm
with the wires not twisted. lks AG. Vo wagen AG
agen does
Mark the repair position with yellow insulationVotape
lksw to make it not
gu
easy to identify. se
d by ara
nte
ri
utho eo
ra
a
2.4.3 Renewal of aerial wiring ss c
ce
e
nl
pt
du
A new approach to repair work on aerial wires has been devel
an
itte
y li
oped. Now connecting wires in different lengths and various
erm
ab
adapter cables are available as replacement parts instead of a
ility
ot p
complete aerial wire.
wit
, is n
h re
General description:
hole
spec
es, in part or in w
Aerial wires must not be repaired, but if repair is required, they
t to the co
must be replaced only by connecting wires and adapter cables
offered as genuine parts.
rrectness of i
Replacement parts can be found in the Parts catalogue
(ETKA): Special catalogue; Electrical connections; Genuine
l purpos
accessories; Subgroup 35 from illustration No. 035-20 .

These genuine parts are suitable for all aerial wires and wire
nform
ercia
diameters which may need to be replaced.

m
at
The connector housings for aerial cables are only available as

om
io
replacement parts in one colour. However, they can be used

n
c
in t
or
for all colours of aerial connector.

his
ate
do
riv
No provision has been made for replacement of individual

p
cum
or
aerial connectors in the event of repair.

f
en
ng
t.
yi Co
op
The wires can be used retroactively for all VW models, with all C py
t. rig
installed aerial wire diameters. gh ht
pyri by
Vo
co lksw
by
All adapter and connection wires are suitable for all transmitter Prote
cted AG.
agen
and receiver signals.
This repair method can also be used for testing or retrofitting.

Assembly overview of aerial cable:

Example: aerial wire between radio and aerial is defective. The
following wires are required for the repair:
1- Adapter cable, to radio connection. Length approx. 30 cm.
2- Connecting wire, available in different lengths.
3- Adapter cable, to aerial connection. Length approx. 30 cm.
Installing a new aerial cable:
Note
Note that complete route of an aerial cable may be split into sec
tions through aerial diversity control units, traffic data control units
or aerial amplifiers depending on vehicle equipment level. Only
the defective section of aerial wire must be replaced.
Pull connectors of defective aerial cable off devices.

Ascertain routing of defective aerial cable in vehicle and meas
ure total length of aerial connection to be renewed in vehicle.
The total length of aerial connecting wire is the sum of the length
of adapter cables required -1- and -3- and the connecting wire
-2-. Volkswa AG. gen AG
agen do
To determine the length of yconnecting
Vol
ksw wire required, subtract
es n
ot g
60 cm from the measured ed total
b length of aerial connecting wire ua
ran
-2-. oris tee
th o
au ra
c
ss
Procure the required adapter cables -1- and -3- and connect
ce
e
ing wire -2- at length calculated as genuine part from the

nl
pt
du
an
Electronic parts catalogue (ETKA).

itte
y li
erm
ab
Cut off connectors from defective aerial cable.

ility
ot p
wit
The remainder of the defective aerial wire remains in the vehicle.

, is n
h re
hole
Connect adapter cables -1- and -3- to equipment in vehicle.

spec
es, in part or in w
Lay and secure connecting wire -2- in direct vicinity of where

t to the co
wiring is laid in series-produced vehicles.

rrectness of i
Note
l purpos
Do not kink or excessively bend aerial wires! The bending radius

must not be below 50 mm.
nform
mercia
at
om
Connect connecting cable -2- to adapter cables -1- and -3-.

ion
c
in t
or
Perform a function test.

his
ate
do
priv
cum
2.4.4 Repairs to electrical wiring with cross

for
en
ng
t.
yi
sections up to 0.35 mm2
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
Note
agen
Prote AG.


Crimping pliers, complete -VAS 1978/1 A-

Head adapter 0.35 mm - 2.5 mm -VAS 1978/1-1-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
For repairs to wiring with cross sections up to 0.35 mm2, it is es
sential that contacts are crimped on using crimping pliers for JPT
t to the co
contacts -VAS 1978/9A- or crimping pliers (base tool) -VAS
1978/1-2- with attached head adapter for JPT contacts -VAS
1978/9-1- . Due to the low current strength of these wires in the
rrectne
micro and thousandths range, incorrectly crimped contacts cause
electrical resistances and result in faults or failure in the respec
s
tive system. The most common applications of these contacts are:
s o
cial p
f i
Lambda probe
nform
mer
Engine speed sender
atio
om
n
c
Air mass meter
i
or
n thi
te
sd
With the use of crimping pliers for JPT contacts -VAS 1978/9A-
iva
o
r
or crimping pliers (base tool) -VAS 1978/1-2- with attached head

p
cum
r
fo
adapter for JPT contacts -VAS 1978/9-1- , the correct connection
en
ng
t.
yi
between crimp contact, wire and single wire seal is assured. The
Co
op py
tool is only to be used for the application described.
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
Note
Crimped to the repair wiring are normal contacts and gold-plated

contacts. The repair contact must always be the same type as the
contact installed in the factory.
Crimping on new contact with single wire seal

Insert head adapter for JPT contacts -VAS 1978/9-1- in crimp
ing pliers (base tool) -VAS 1978/1-2- page 78 .
Connect single wire seal to repair wire -arrow-.
Note
When doing this, the small diameter of the single wire seal must
face the contact to be crimped on.

Open crimping pliers and insert end of repair wire into insula
tion-stripping opening of crimping pliers -arrow-.
Close crimping pliers fully.

Open crimping pliers again and remove stripped insulation
from end of wire. AG. Volkswagen AG d
swagen oes
k n ol ot g
yV ua
edb ran
ris tee
tho or
au ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
Push single wire seal towards stripped wire end until it is flush
es, in part or in w
t to the co
with wiring insulation.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
Insert new crimp contact into mounting of crimping pliers

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

Insert stripped wire end with pre-positioned single wire seal in

crimp contact until it comes to rest on wire stop.
Crimp together contact, wire and single wire seal by closing
crimping pliers fully.
Open crimping pliers again and remove ready-crimped con
tact.
Successful crimping can be identified by clean and equal appli

cation of pressure on the wire and single wire seal in the contact.
Furthermore, there is a stamp on the rear that indicates the cor
rect tool was used in the correct manner to carry out the crimping
process.
2.4.5 Wiring open circuit with one repair posi

tion
Note agen
AG. Volkswagen AG d
oes
olksw not
V gu
by ara
Adhere to general instructions concerning repairs ris to vehicle elec
ed
nte
trical system page 79 . ho eo
aut ra
ss c
ce
e
Repair position with single crimp connector

nl
pt
du
an
itte
y li
Place the wire to be repaired to one side (about 20 cm either

erm
ab
side of repair position).

ility
ot p
wit
, is n
If necessary, remove binding around wiring harness using

h re
folding knife.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Cut out damaged section of wire using wire strippers -VAS

nf
ercia
1978/3- .
rm
m
atio
om
n in
or c
Note
thi
te
sd
iva
o
r
rp
If, after the damaged wire has been cut out, both ends of the ve
cu
o
m
f
hicle's own single wire are too short for a repair using single crimp
en
ng
t.
yi
connector, use a piece of repair wire of the appropriate length with
Co
Cop py
2 crimp connectors page 90 .
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Use wire strippers to strip 6-7 mm of insulation from ends of

wire.
Slide crimp connector onto both stripped ends of vehicle's own

single wire and crimp together using crimping pliers.
Note
It is essential to ensure that the correct crimp recess isnchosen

wage
AG. Volkswagen AG d
oe
for the crimp connector being used page 76
yV
ol.ks s no
t gu
b ara
ed
The insulation on the wires must not be horiscrimped. nte
eo
t
au ra
c
ss
After crimping, the crimp connector has to be shrink fitted using
ce
le
un
pt
the hot air blower in order to prevent any ingress of moisture.
an
d
itte
y li
Place shrink element for hot air blower -VAS 1978/15- on hot
rm
ab
pe
ility
air blower, 220 V / 50 Hz -VAS 1978/14- .
ot
wit
, is n
h re
hole
Caution
spec
es, in part or in w
t to the co
When shrink-fitting crimp connections, take care not to dam
rrectness of i
l purpos
essential!
nform
ercia
Heat up crimp connector using hot air blower along a straight

m
a
com
line, working from centre outwards, until it is sealed completely

ion in
and adhesive escapes from ends.

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.

Note
If several wires need to be repaired, ensure that the crimp

connectors are not directly adjacent to each other. To prevent
the circumference of the wiring harness from becoming to
great, position the crimp connectors so they are offset slightly.
If the repair position was already wrapped, this section has AtoG. Volkswagen
be wrapped again with yellow insulation tape once theksw repair
agen AG do
es n
has been carried out. y Vol ot g
ua
db e ran
ris tee
Attach the repaired wiring harness with a ucable
tho tie, if neces or
sary, to prevent it from generating noisesswhen
a the vehicle is in ac
motion.
ce
e
nl
pt
du
an
itte
y li
erm
ab
2.4.6 Wiring open circuit with two repair posi
ility
ot p
tions
wit
, is n
h re
hole
spec
es, in part or in w
Note
t to the co
rrectness of i
l purpos
Repair position with interlinked wire.

Place wire to be repaired to side at 2 points (about 20 cm to
nform
ercia
both sides of respective repair position).

m
at
om
ion
c
folding knife.
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Place yellow repair wire next to damaged wiring harness and

cut repair wire to required length using wire strippers -VAS
1978/3- .
Cut out damaged section from vehicle's own single wire.

Use wire strippers to strip 6-7 mm of insulation from ends of

wire.
Push crimp connector onto vehicle's own single wires on one
side and push it onto repair wire on other side.
lkswage es n
o ot g
byV ua
d ran
ir se tee
Crimp connector using crimping
autho
pliers to join both ends of wire. or
ac
ss
Repeat process at other end of repair wire.
ce
le
un
pt
an
d
itte
y li
erm
ab
Note
ility
ot p
wit
is n
It is essential to ensure that the correct crimp recess is chosen
h re
ole,
for the crimp connector being used page 76 .
spec
The insulation on the wires must not be crimped.
t to the co
After crimping, the crimp connector has to be shrink fitted using
the hot air blower in order to prevent any ingress of moisture.
rrectne
Place shrink element for hot air blower -VAS 1978/15- on hot
s
air blower, 220 V / 50 Hz -VAS 1978/14- .
s o
cial p
f inform
Caution
mer
atio
om
When shrink-fitting crimp connections, take care not to dam n

c
i
or
n
thi
te
sd
a

iv
o
pr
cum
r
fo

en
ng
t.
yi
essential!
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Heat up crimp connector using hot air blower along a straight
Prote AG.
line, working from centre outwards, until it is sealed completely

and adhesive escapes from ends.

Note

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

2.5.1 Notes on repairs to fibre optic cables, page 92
2.5.2 Preparing fibre optic cable, page 93
2.5.3 Detaching fibre optic cable from cable harness connec
tor, page 98
AG. Volkswagen AG d
agen oes
ksw
2.5.1 Notes on repairs to fibre optic cables d by Vol not
gu
ara
rise nte
It is very difficult to identify the exact location of the defect.uRe
tho eo
ra
place the damaged fibre optic cable by laying a new wiressparallel
a c
to the defective fibre optic cable.
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
Via the menu options of the vehicle diagnosis tester Guided
h re
hole
fault finding or Guided functions, it is possible to ascertain
spec
the components between which the fibre optic cable has been
es, in part or in w
t to the co
damaged.
The colour yellow indicates a fibre optic cable that has al
ready been repaired.
rrectness of i
l purpos
Procedure:
nf
ercia
or
Select operating mode Guided fault finding or select Guided m
m
atio
functions in vehicle diagnosis tester .
om
n in
or c
Using GoTo button, select Functions/component and then

thi
te
the following menu options in succession:

sd
iva
o
r
rp
cu
Body
o
m
f
en
ng
t.
yi Co
Electrical system t. Cop py
rig
gh ht
yri
01 - On Board Diagnostic capable systems p by
co Vo
by lksw
cted agen
Ring break diagnosis Prote AG.
Remove relevant components.

Disengage connectors and pull them off components.
Prepare fibre optic cable page 93

Caution
Do not over-bend fibre optic cables. Minimum radius for bends

is 25 mm.
Do not route fibre optic cables over sharp edges.
Make sure that the ends of the fibre optic cables are not dirty
and do not touch them with your bare hands.
Do not expose fibre optic cables to heat.
It is not permissible to twist together 2 fibre optic cables or one
fibre optic cable with a copper wire.
Protect connectors and connecting cables against dust. Use
protective caps from the case.
2.5.2 Preparing fibre optic cable

Fibre optic cable repair kit -VAS 6223A-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
Cutting pliers -VAS 6228-

hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
Vehicle diagnosis tester

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

Caution
Do not over-bend fibre optic cables. Minimum radius for bends

is 25 mm.
Do not route fibre optic cables over sharp edges.
Make sure that the ends of fibre optic cables are not dirty and
do not touch them with your bare hands.
. Volkswagen AG
Do not expose fibre optic cables
ksw
ato
geheat.
n AG does
not
Vol
y gu
It is not permissible to itwist
se
d b together 2 fibre optic cable or one ara
nte
fibre optic cable withthao copper wire.
r eo
au ra
c
Protect connectors s and connecting cables against dust. Use
s
ce
le
protective caps from the case.

un
pt
an
d
itte
y li
rm
ab
pe
ility
Insert tool adapter into pliers for fibre-optic conductor -VAS
ot
wit
6223/1- :
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tio
Press locking pins -arrows- out.

n in
r
te o
thi
Fit tool adapter onto pliers -arrow- and press back locking pins.
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.
Cutting fibre optic cable to size:

Determine required length of fibre optic cable.
Open pliers for fibre-optic conductor and insert length of fibre
optic cable -1- to be cut -arrow-.
To cut fibre optic cable to size, close pliers for fibre-optic con
ductor fully.

Stripping:
Open fibre optic cable pliers -VAS 6223/1- .
Push down the stripping lever -arrow-.
Insert fibre optic cable into the stripping hole.
The fibre optic cable must be flush with the rear of the cutting
pliers.
Close fibre optic cable pliers as far possible and hold closed.
Push the stripping lever upwards -arrow- and remove fibre op
tic cable.
Cut precisely (making a clean optic surface at end of cable):

Insert fibre optic cable -1- into the cutting hole.
The insulation must be lying against stop of cutting station.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
Close fibre optic cable pliers -VAS 6223/1- and remove cable.
y li
erm
ab
ility
Visually inspect cable-1- to make sure that it has been cut

ot p
wit
correctly and that there are no burrs on the cross-cut surface

is n
h re
at end of cable.
ole,
spec
t to the co
Note
Place the fibre optic cable only on surface or material that is

rrectne
absolutely clean or keep it in your hand.

Use protective caps if there is a danger that the cross-cut sur
ss
face at the ends of the fibre optic cable will be soiled.

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

Crimp brass pin contact to fibre optic cable:
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
Change tool adapter -arrow-. uth o eo
ra
s a c
Move safety catch on plierss for fibre-optic conductor -arrow-
ce
e
nl
so that the word Pin can be seen.
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
Insert a brass pin contact -1- into the hole.
l purpos
Close locking lever on fibre optic cable pliers -arrow-.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote
Push fibre optic cable into brass pin contact -arrow- as far as
AG.
spring-cushioned stop and close pliers for fibre-optic conduc

tor fully.
Open fibre optic cable pliers and remove fibre optic cable to
gether with brass pin contact.
Caution
Do not kink or excessively bend fibre optic cables (min. bend

ing radius 25 mm).

Check that the brass pin contact -2- is correctly attached to

fibre optic cable -1-.
4 crimping points must be visible on the brass connecting pin.
Make sure that the brass pin contact cannot be pulled off fibre
optic cable by hand.
Make sure (visual check) that the cross-cut end surface of the
fibre optic cable is 0.01 0.1 mm behind the brass pin con
tact.
Note
There are push-on couplings that are used to connect fibre

optic cables Electronic parts catalogue .
Installation of the new fibre optic cable in the cable harness
connector page 98 .
Inserting fibre optic cable into corrugated pipe:

Cut corrugated tube to a suitable length.
Use cutting pliers -VAS 6228- or a sharp knife for cutting.
Do not cut the corrugated tube with a paper cutter.
The corrugated tube must be cut at a crest -arrow- not in a
trough.
When the corrugated tube is installed, it must engage audibly
in the housing of the fibre optic cable. swagen AG. Volkswagen AG does
k not
Vol gu
d by ara
e nte
ris
utho eo
ra
a c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Insert fibre optic cable into pliers for fitting the corrugated tube
es, in part or in w
-VAS 6223/10- as shown in the illustration.

t to the co
Position pliers in place on the groove of the corrugated tube.

rrectness of i
Push pliers in groove along the circumference of the corruga

ted tube. This causes the fibre optic cable to be inserted in the
l purpos
corrugated tube.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2.5.3 Detaching fibre optic cable from cable

harness connector
Removing
Disengage and pull fibre optic cable connector off relevant
control unit.
Release locking mechanism in fibre optic cable connector
-1- by pressing it.
Release secondary locking mechanism -2-, using a small
screwdriver.
Remove fibre optic cable.
Caution
Use protective caps from the case in order to protect the

fibre optic cable against dust and dirt.
Use a new housing as the secondary locking mechanism
can be damaged when the fibre optic cable is removed.
Take note of the arrows on the basic module for the as
signment of IN and OUT.
Installing
Install in the reverse order of removal observing the following:
olksw
Install fibre optic cables in accordanceswwith
agenmarkings INAand
AG. V agen G
does
OUT. by Volk not
gu
ara
ed nte
oris e
th or
au ac
ss
Note
ce
e
nl
pt
du
an
itte
Push corrugated pipe into connector housing until it engages

y li
erm
ab
audibly.
ility
ot p
wit
Seal the open connector -2- for fibre optic cable with the pro
, is n
h re
tective cap for cable connector -VAS 6223/9- -item 1-.

hole
spec
The protective cap prevents soiling and mechanical damage

es, in part or in w
t to the co
at the cross-cut end of the fibre optic cable so that the trans
mission of light is not impaired.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen
2.6 Repairing connectorby housings and con
oes
ksw not
Vol gu
ara
nectors ed
ris nte
tho eo
au ra
2.6.1 Notes on repairs to connector
ss housings and connectors, c
page 99
ce
le
un
pt
an
d
itte
2.6.2 Repairing contacts in connector housings, page 99
y li
erm
ab
ility
2.6.3 Installing single wire seals, page 100 ot p
wit
is n
2.6.4 Repairing connector housings using cut and clamp meth
h re
ole,
od, page 102
spec
2.6.1 Notes on repairs to connector housings
t to the co
and connectors
rrectne
Note
ss o
cial p
f
inform
mer
atio
m
Allocation of the appropriate crimp contacts to the connector

o
n
c
housings is by way of the part number stamped on the con
i
or
n thi
nector housing. Listed in illustration 198 (electrical connecting
te
sd
a
elements) in Electronic parts catalogue (ETKA) are the part

iv
o
pr
c
numbers for the connector housings in conjunction with the
um
r
fo
en
ng
associated crimp contacts.

t.
yi Co
op py
Damaged connector housings must always be replaced.
t. C rig
gh ht
pyri by
Vo
o
New connector housings can be ordered from OTC Kassel.
c by lksw
cted agen
Prote AG.
2.6.2 Repairing contacts in connector hous

ings
If necessary, first open or release secondary locking mecha
nism of connector housing page 103 .
Release contact (primary locking mechanism) using suitable
release tool page 103 .
Pull out contact on single wire from connector housing.
Select yellow repair wire with correct contact from wiring har
ness repair set .
Place wire to be repaired from vehicle's own wiring harness to
one side (about 20 cm either side of repair position).
folding knife.
Insert new contact of repair wire into connector housing until

it is engages.
Push single wire seal -A- onto repair wire.
Note
The small diameter of the single wire seal must face the connector
housing.
Push single wire seal into connector housing using correct as

sembly tool -B- page 100 .

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

own single wire using wire strippers.
Crimp stripped ends of repair wire and single wire of vehicle's
own wiring harness using crimping pliers and a crimp connec
tor as described in chapter Wiring open circuits with one
repair position page 88 .
Note

connectors are not directly adjacent to each other. AG. VTo
olksprevent
wagen
the circumference of the wiring harness s agenbecoming to AG does
from
w
olk not
great, position the crimp connectors
d bso they are offset slightly.
yV gu
ara
e nte
ris
If the repair position was already
ut
ho wrapped, this section has to eo
ra
be wrapped again with yellow
ss insulation tape once the repair
a c
has been carried out.
ce
le
un
pt
an
d
Attach the repaired wiring harness with a cable tie, if neces

itte
y li
erm
sary, to prevent it from generating noise when the vehicle is in

ab
ility
motion.
ot p
wit
is n
h re
ole,
spec
2.6.3 Installing single wire seals

t to the co
Note
rrectne
Single wire seals prevent the ingress of moisture and dirt in

the connector housing. They are installed, for example, in the
ss o
engine compartment and must always be reinstalled following

cial p
f in
repairs.
form
mer
As standard, the single wire seal is crimped together with the

atio
m
contact on the wire; this is not the case with the repair wires.
o
n
c
Before crimping the repair line, the single wire seal must there
or
n thi
e
fore first be pushed onto the wire.

t
sd
iva
o
pr
cum
It is essential that the single wire seals are of the correct size
r
fo
en
ng
to fit the cross section of the repair wire. The outer diameter
t.
yi Co
of the single wire seal is based on the socket diameter of the Cop py
t. rig
connector housing. Only carry out installation using the ap gh ht
yri by
propriate assembly tool. cop Vo
by lksw
cted agen
Prote AG.

Installing single wire seal:

Disengage contact locking mechanism using appropriate re
lease tool -A- and pull wire with single wire seal backwards
-arrow- out of connector housing.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
Cut out old contact with single wire
ut seal from vehicle's own
ho eo
ra
wiring harness. ss a c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Push repair wire with new contact into respective socket of
l purpos
connector housing until it engages.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
Push single wire seal -A- onto free end of repair wire.
AG.
Note
The small diameter of the single wire seal must face the connector
housing.
Push single wire seal -A- on repair wire up to connector hous

ing.

Push single wire seal -A- to stop into connector housing using
respective assembly tool -B-.
Trim repair wire and single wire of vehicle's own wiring harness
accordingly using wire strippers -VAS 1978/3- .
Crimp stripped ends of repair wire and single wire of vehicle's
own wiring harness using crimping pliers and a crimp connec
tor as described in chapter Wiring open circuits with one
repair position page 88 . agen
AG. Volkswagen AG d
oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
2.6.4 Repairing connector housings using cut
wit
, is n
h re
and clamp method
hole
spec
es, in part or in w
t to the co
Note
For technical reasons, the connector housings for the cut and
rrectness of i
clamp method can only be supplied with the cut and clamp
l purpos
contacts inserted.
These contacts can be removed just like in the case of any
nform
ercia
other connector housing if they are not needed.

m
at
Repair wires can be supplied that already have the appropriate
om
io
contacts crimped on Electronics parts catalogue (ETKA) . n
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

2.7 Releasing and dismantling wconnector

agen
AG. Volkswagen AG d
oes
housings db
y Volks not
gu
ar
e an
ris tee
2.7.1 Notes on releasing and dismantling
tho connector housings, or
au
page 103 ss ac
ce
le
un
2.7.2 Secondary locking element, page 103
pt
an
d
itte
y li
2.7.3 Primary locking element, page 104
erm
ab
ility
ot p
2.7.4 Round connector systems, page 105
wit
is n
h re
2.7.5 Flat connector systems, page 105
ole,
spec
2.7.6 Special connector systems, page 107
t to the co
2.7.1 Notes on releasing and dismantling con
nector housings
rrectness
Note
o
cial p
f inform
mer
atio
om
n
c
Always use release tools specifically intended for releasing
i
or
n thi
e
purposes. Under no circumstances should the contacts be

t
sd
va
pulled out of the connector housings with force.

i
o
pr
cum
r
fo
en
Damaged connector housings must always be replaced. New
ng
t.
yi Co
connector housings can be ordered from OTC Kassel. t. Cop py
rig
gh ht
As an aid to disengage the secondary locking mechanisms, a pyri by
Vo
co
small screwdriver can be used.
by lksw
cted agen
Prote AG.
The socket/connector-pin assignment can be found stamped
on the secondary locking mechanism or on the rear of the
connector housing.
For more detailed information about the locations of connec
tors, see Current flow diagrams, Electrical fault finding and
Fitting locations.

mechanisms can be gleaned from the table in the Operating
2.7.2 Secondary locking element

The secondary locking mechanism is a housing catch (second
line locking mechanism) that secures all the wires in one connec
tor housing. If a secondary locking mechanism is fitted to a
connector housing, this must always be opened or removed using
the appropriate tool before releasing and pulling out individual
crimp contacts.
The secondary locking mechanism is different in colour from the
rest of the connector housing. This makes it easier to identify the
secondary locking mechanism and clarifies its intended function.
The types of connector housing shown here are just a few exam
ples to show the different functions of secondary locking mecha
nism.

Example 1:
The housing catch is disengaged by removing a toothed ele
ment -arrow-.
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Example 2:
h re
hole
spec
The housing catch is disengaged by opening a flap -arrow-.
es, in part or in w
t to the co
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nf
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m
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or c
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Example 3:
t
sd
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The housing catch can be disengaged by detaching a slide

o
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-arrow-.
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2.7.3 Primary locking element

The primary locking mechanism is what fixes an individual crimp
contact in the connector housing.
If necessary, any housing catches in place (secondary locking
mechanisms) must be released or removed prior to disengaging
the contacts using the prescribed tool page 103 .
The types of primary locking mechanisms shown as follows are
just a few examples to show the different functions of primary
locking mechanism.
Round connector systems page 105
Flat connector systems page 105
Special connector systems page 107
mechanism can be gleaned from the table in the operating

2.7.4 Round connector systems
Note

Insert corresponding connector housing release tool in release

port of connector housing.
Hold contact on wire and push it into connector housing lightly
-arrow-. G. Volkswage nA n AG d
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Volks not
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By pushing the contact in the
s direction of the connector housing,
ce
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the locking tabs of the contact are lifted up by the housing edge
un
pt
an
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and can be disengaged using the release tool.

itte
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At the same time, push release tool in direction of connector
wit
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housing -arrow- and pull released contact out of connector
h re
housing.
ole,
spec
t to the co
The release tool can be pulled out of the connector housing
again once the contact has been removed.
rrectness o
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2.7.5 Flat connector systems

t.
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Prote
cted AG.
agen

Flat connector with one locking tab:

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

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


housing and pull released contact out of connector housing
-arrow-.
Flat connector with 2 locking tabs:

Hold contact on wire and push it into connector housing
-arrow- as far as it will go.
Note

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housing and pull released contact out of connectoruthhousing
o
or
-arrow-. ss
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un
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Asymmetrical:
ss

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mer
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and can be disengaged using the release tool. t. C rig
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-arrow-.
2.7.6 Special connector systems
Note

Faston contacts:
Insert corresponding connector housing release tool into re
lease port of connector housing -arrow-.
agen
AG. Volkswagen AG d
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Hold contact on wire and push
db
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t gu
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t to the co
-arrow-.
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GT 150/280 contacts:
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Insert corresponding connector housing release tool into con
Co
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nector housing by guiding it below locking tab. t. C rig
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Push release tool to stop -arrow- into connector housing.
co Vo
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The contact is ejected from the connector housing.

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

Insert corresponding connector housing release tool into con
nector housing by guiding it below locking tab.
Push release tool onto stop, lifting slightly while doing so
-arrow-.
AG. Volkswagen AG d
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The contact is ejected from the connector housing.
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es, in part or in w
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3 Contact surface cleaning set -VAS

6410-
3.1 General description - contact surface cleaning set VAS
6410, page 109
3.2 Repairing ring terminals, page 109
3.3 Repairing threaded electrical connections, page 112
3.4 Cleaning battery terminal clamp and battery terminal,
page 114
3.5 Preserving threaded electrical connections, page 115
3.1 General description - contact surface

cleaning set VAS 6410
The contact surface cleaning set -VAS 6410- allows optimal repair
quality to be achieved in the area of vehicle electrics. The tools
allow performing repair work in the area of the sensor in wiring
harnesses for threaded connections in the high-current circuit
(starting and charge current). The contact gen Asurface
G. Volkswcleaning
agen AG
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swa s no
VAS 6410- is adapted to the structural
y Volk conditions of vehicles and t gu
ensures the process security rise of repair work as well as a comfort
db ara
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able procedure. ut
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Note
an
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ab
The illustrations shown here are just a few examples of repair
ility
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work.
wit
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Special tools and workshop equipment required spec

es, in part or in w
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Contact surface cleaning set -VAS 6410-
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nf
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or c
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3.2 Repairing ring terminals Cop py
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rig ht
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Special tools and workshop equipment required co Vo
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3. Contact surface cleaning set VAS 6410 109

Torque wrench -V.A.G 1331- AG. Volkswagen AG d

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t to the co
Caution
rrectne
Risk of damage!
ss o
Penetrating fluid, contact spray or grease etc. may not be used
cial p
f in
for threaded connections.
form
mer
Missing adhesion in the threads may cause a torque excess
atio
m
and, therefore, the break of the threaded connection.

o
n
c
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After cleaning, ensure that threaded connections are dry and

t
sd
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bolt them together without applying lubricants.

i
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pr
cum
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fo
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t.
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Cop py
t. rig
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yri by
Note op Vo
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Prote AG.
The grey sanding pads are suitable for light dirt and soft surfa
ces. The red sanding pads are suitable for heavy dirt and hard
surfaces.
WARNING

Disconnect battery Electrical system; Rep. gr. 27 ; Discon

necting and connecting battery .

Unscrew captivated nut and remove ring terminal from con

nection thread.
Check ring terminal for corrosion, dirt, etc.
Select matching adapter and sanding pad for ring terminal
from contact surface cleaning set -VAS 6410- .
Note
As an alternative, the sanding block may also be used.

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Cautionrised ran
tee
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Risk of corrosion! ss
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un
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If the tin coating of ring terminals is worn down to the copper
an
d
itte
layer, a galvanic cell may be produced which destroys metal
y li
erm
ab
and causes faulty repair.
ility
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wit
The cleaning process of the ring terminals must be performed
is n
h re
step by step and a visual check is necessary between the
ole,
steps.
spec
t to the co
Position adapter in ring terminal and remove corrosion and dirt
rrectne
with circular motion.
Periodically check the progress of cleaning and clean further
ss
if necessary. o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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cum
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fo
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t.
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Electrical System, General Information - Edition 09.2012 olksw AG. V agen AG
agen does
lksw not
If necessary, remove burring around hole of ring terminal usingd by Vo gu
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deburring tool. ris
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Fit ring terminal onto connection thread again, and tighten
ra
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ss
specified torque Current flow diagrams, Electrical fault find
ce
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nl
pt
ing and Fitting locations.
du
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itte
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Note
wit
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hole
Optimum contact is ensured when the bolted components are
spec
tightened to the specified torque after cleaning.
es, in part or in w
t to the co
Apply appropriate anti-corrosion treatment to threaded con
nection page 115
rrectness of i
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WARNING
nf
ercia
o
rm
m
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n in
or c
Connect battery Electrical system; Rep. gr. 27 ; Discon
thi
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Perform all given work steps such as window regulator setting,
f
en
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t.
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clock setting and radio coding after connecting the battery.
Co
Cop py
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3.3 Repairing threaded electrical connec
op Vo
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tions
Prote AG.

Torque wrench -V.A.G 1331-
Caution
Risk of damage!
bolt them together without applying lubricants.

Note
The grey sanding pads are suitable for light dirt and soft surfa
ces. The red sanding pads are suitable for heavy dirt and hard
surfaces.
WARNING
Danger of injury! Comply with the warning notices and safety gen AG. Volkswagen AG
regulations page 1 ! Vol
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not
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Disconnect battery Electrical system; Rep. gr.
s au 27 ; Discon ra
c
s
ce
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nl
pt
du
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Unscrew captivated nut and remove ring terminal from con
itte
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nection thread.
erm
ab
ility
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Check ring terminal for corrosion, dirt, etc.
wit
, is n
h re
Select matching adapter and sanding pad for threaded con
hole
spec
nection from contact surface cleaning set -VAS 6410- .
es, in part or in w
t to the co
Caution
rrectness of i
Risk of corrosion!
l purpos
If the tin coating is worn down to the copper layer, a galvanic

cell may be produced which destroys metal and causes faulty
repair.
nf
ercia
orm
The cleaning process of the threaded connection must be per
m
atio
m
formed step by step and a visual check is necessary between

o
n in
c
the steps.
or
thi
te
sd
iva
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cu
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f
en
ng
t.
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Cop py
t. rig
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pyri by
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by
cted agen
Prote AG.

Fit adapter onto threaded connection and remove corrosion

and dirt with circular motions.
Periodically check the progress of cleaning and clean further
if necessary.
Tighten connection and (if necessary) anti-rotation tab to
specified torque Current flow diagrams, Electrical fault find
ing and Fitting locations.
Note

Apply appropriate anti-corrosion treatment to threaded con

nection page 115
WARNING

Connect battery Electrical system; Rep. gr. 27 ; Discon

3.4 Cleaning battery terminal clamp and AG. Volkswagen AG d

agen
battery terminal Volksw
oes
not
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Special tools and workshop equipment required horis
eo
aut ra
Torque wrench -V.A.G 1331- ss c
ce
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un
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an
d
itte
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erm
ab
ility
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wit
is n
h re
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spec
t to the co
rrectness o
cial p
f i
Caution
nform
mer
atio
Risk of damage!
om
n
c
i
or

thi
te

sd
iva
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pr
cum
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fo
en
ng

t.
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Cop py
t. rig
gh ht
yri by
bolt them together without applying lubricants. op Vo
by c lksw
cted agen
Prote AG.

WARNING

Disconnect battery Electrical system; Rep. gr. 27 ; Discon

Check battery terminal clamp and battery terminal for corro
sion or dirt.
Insert wire brush of battery terminal cleaner into battery ter
minal clamp and clean it with circular movements.
Connect bottom side of battery terminal cleaner to battery ter

minal and clean it with circular movements.
WARNING
. Volkswagen AG
gen AG does
swa
Danger of injury!byComply
Volk with the warning notices not and safety
gu
regulations rispage
ed 1! ara
nte
ho eo
aut ra
ss c
Connect battery and tighten battery terminals to specified tor
ce
le
un
pt
que Electrical system; Rep. gr. 27 ; Disconnecting and

an
d
itte
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connecting battery .
rm
ab
pe
ility
ot
wit
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Note
h re
hole
spec

es, in part or in w
t to the co

rrectness of i

l purpos
3.5 Preserving threaded electrical connec

nform
ercia
tions
m
a
com
tion in
Caution
r
te o
thi
s
iva
do
Missing anti-corrosion treatment results in damage to the on

r
rp
cum
board supply.
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
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Prote AG.

Note
All threaded connections must be tightened to specified tor

que.
AG. Volkswagen AG d
agen
Always use hose supplied with anticorrosive
Vol agent tin.
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oes
not
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db ara
Use protection wax for cold area. orise nte
eo
th
au ra
Use cavity sealing agent for warm
ss area. c
ce
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nl
The sealing agent independently reaches the respective
pt
du
an
points through capillary action.
itte
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erm
ab
ility
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Hold nozzle under ring terminal and spray all around stud.
wit
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h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
m
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om
n in
c
Fit nozzle over ring terminal and spray all around stud and ring
or
thi
terminal.
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t.
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Prote AG.

4 Renewing Lambda probe

4.1 General notes - renewing Lambda probe, page 117
4.2 Types of protective tube on uniform Lambda probes, page
117
4.3 Renewing LSF Lambda probe (4-pin), page 118
4.4 Renewing LSU Lambda probe (6-pin), page 119
4.1 General notes - renewing Lambda

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

malfunctions.
If necessary, replace attachment parts, cable ties or marking
rings to match the uniform probe to the defective probe as
specified.
If necessary, identify the Lambda probe on basis of the pro
tective tube page 117 .
4.2 Types of protective tube on uniform agen

AG. Volkswagen AG d
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Lambda probes db
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ar
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ris tee
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Note ss
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un
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an
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In addition to identifying by way of the part number, the protective

itte
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erm
tube can also be used as a means of identification.
ab
ility
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Type D1:
h re
ole,
spec
6 openings, each 3.5 mm
t to the co
Only used on 4-pin LSF Lambda probes.
rrectness o
cial p
f inform
mer
atio
om
n
c
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or
n thi
Type D2:
te
sd
iva
o
pr
6 openings, each 2 mm
cum
r
fo
en
ng
t.
Used on 4-pin LSF lambda probes and 6-pin LSU lambda probes.
yi Co
Cop py
t. rig
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pyri by
Vo
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by
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Prote AG.
4. Renewing Lambda probe 117

Type D4:
12 openings, each 1.4 mm
Used on 4-pin LSF lambda probes and 6-pin LSU lambda probes.
4.3 Renewing LSF Lambda probe (4-pin)
Note
If necessary, replace attachment parts, cable ties or marking

rings to match the uniform probe to the defective probe as
specified.
Do not repair Lambda probe wires, since this can result in
malfunctions.
Remove defective Lambda probe Power unit; Rep. gr. 26 ;

Exhaust system .
Place both Lambda probes next to each other so that sensor
housings are at same height.
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a ac
ss
ce
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nl
pt
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itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
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orm
m
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om
n in
or c
thi
te
sd
iva
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cu
o
m
f
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ng
t.
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Cop py
t. rig
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pyri by
Vo
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Prote AG.

Tie back any excess in uniform probe length (approx. 50 - 250

mm) to size of defective probe and secure with cable ties -1-.
olkswagen AG
en AG. V
Check that connector housing ofolLambda
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ag probe is compatible
does
not
with onboard supply side. ed by V gu
ara
ris nte
If necessary, replace onboard
au
tho supply system connector with eo
ra
Lambda probe connector
ss housing supplied page 99 . c
ce
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un
pt
an
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Note
erm
ab
ility
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The connector housing should only be replaced on older ve
wit
is n
hicles. On new vehicles, the connector housing coding match
h re
ole,
es.
spec
Observe correct connector pin assignment. For reasons of
t to the co
clarity, respective pins in new connector housing have a colour
marking.
rrectne
Further notes can be found in the leaflet of the new Lambda
probe.
ss o
cial p
f
Install new Lambda probe in vehicle Power unit; Rep. gr.
inform
26 ; Exhaust system .
mer
atio
om
4.4 Renewing LSU Lambda probe (6-pin)
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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Note
fo
en
ng
t.
yi Co
op py
If necessary, replace attachment parts, cable ties or marking t. C rig
gh ht
rings to match the uniform probe to the defective probe as yri
p by
o Vo
specified.
c by lksw
cted agen
Prote AG.
The wires should not be crimped or cut as otherwise the func
tion of the Lambda probe will be impaired.
Remove defective Lambda probe Power unit; Rep. gr. 26 ;

Exhaust system .
Place both Lambda probes next to each other so that sensor
housings are at same height.
4. Renewing Lambda probe 119

Tie back any excess in uniform probe length (approx. 50 - 250

mm) to size of defective probe and secure with cable ties -1-.
Install new Lambda probe in vehicle Power unit; Rep. gr.
26 ; Exhaust system .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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rise nte
tho eo
au ra
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rm
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ot
wit
, is n
h re
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spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
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t.
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Cop py
t. rig
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Vo
co lksw
by
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Prote AG.

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Service

Service Department. Technical Information

Copyright 2012 Volkswagen AG, Wolfsburg D4B8025555B

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

4 Cruise control system (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

4.1 General description - cruise control system (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

4.2 Activating and deactivating cruise control system (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . . 51

1.3 Hose couplings - headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

2.1 General description - hose repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

2.2 Repairing smooth pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

2.3 Repairing corrugated pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

1.2 Connecting vehicle diagnostic tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

27 Starter, current supply, CCS

To ensure long use of the battery, the battery must be checked,

has other tasks: it acts as a buffer and supplies electrical energy

to the complete electrical onboard supply of the vehicle.

1.2 Warning notices and safety regulations

1.2.1 Dangers when handling vehicle batter

Untrained personnel e.g. apprentices, trainees etc. may

handling batteries. Avoid sparks as well as electrostatic discharge

Therefore never lay a tool on a battery.

2. - Wear eye protection before commencing work on battery.

3. - Keep children away from acid and batteries.

4. - Disposal: old batteries are classed as hazardous waste. They

may only be disposed of through a suitable collection centre and

6. - There is a danger of an explosion when working with batteries.

A highly explosive gas is produced when batteries are charged.

trical System, General Information; Rep. gr. 27 ; Battery; Warning

notices and safety regulations and in the operating manual.

8. - Battery acid is very caustic; therefore wear eye protection and

leak out of the gas vents of some batteries.

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

No stickers may be removed and do not replenish with distilled

Only perform visual inspections on batteries.

It is not permissible to test or charge batteries whose colour

This battery is equipped with a colour indicator. The colour indi

1.3.2 Battery with enhanced colour indica

No stickers may be removed and do not replenish with distilled

An EFB battery may only be replaced with another EFB bat

The EFB battery has a colour indicator to enable the electrolyte

1.3.3 Absorbent glass mat battery

Always replace an absorbent glass mat battery with another ab

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

1.4 Battery terminal connection

2.1.1 Checking a battery with colour indicator

Danger of injury! Comply with the warning notices and safety

To prevent damage to the battery or to the vehicle, observe

Observe the chapter "Battery" in the Maintenance ; Booklet for

Perform the checks in the following sequence:

It is not permissible to test or charge batteries whose colour

3. Battery test with battery tester with printer -VAS 6161-

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

2.1.2 Absorbent glass mat battery

Danger of injury! Comply with the warning notices and safety

Observe the chapter "Battery" in the Maintenance ; Booklet for

the respective vehicle!

Perform the checks in the following sequence:

Danger of injury! Comply with the warning notices and safety

To prevent damage to the battery or to the vehicle, observe

Before taking extensive measurements, visually check the con

Observe the chapter Battery in the Maintenance ; Booklet for

The battery will be damaged if the battery is not secured

Performing this test establishes:

2.3 Checking colour indicator in battery cov