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ELECTRICAL Electrical Equipment - General Information <meta name="InColGX" content=""> </head> <body bgcolor="white" text="black"> <h1>ELECTRICAL</h1> <h1>Electrical Equipment - General Information</h1><a name="S26316976462008020700000"></a><h2 class="clsHeadOne">27 - Battery, Starter, Generator, Cruise control</h2><a name="S04258192722008020700000"></a><h2 class="clsHeadTwo">Battery, General Information</h2><a name="S02330065532008020700000"></a><h2 class="clsHeadThree">Battery, General Information</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Danger of injury!<ul class="clsBULLET"> <li>Prior to handling or servicing batteries, read, understand and observe the Warnings and Safety Measures --> <a class="clsHyperlink" href="#S00323802832008020700000">Lead-Acid Battery, Safety Precautions</a> !</li> </ul> </td> </tr> </table></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Risk of damage to battery or vehicle.<ul class="clsBULLET"> <li>Vehicles with non-maintenance-free batteries: Observe notes --> <a class="clsHyperlink" href="#S23245985022008020700000">Battery, Visual Inspection</a>.</li> <li>Vehicles with maintenance-free batteries: Observe notes --> <a class="clsHyperlink" href="#S23245985022008020700000">Battery, Visual Inspection</a>.</li> </ul> </td> </tr> </table></span></p> <p>The battery is one of the most important electrical components in the modern automobile. A battery that provides trouble-free service has a great influence on customer satisfaction. To ensure trouble-free service and optimum service life, batteries must be checked, serviced and maintained as per the instructions in this information.</p> <p>Apart from starting the engine, the battery has other tasks. It acts as a buffer and also supplies electrical energy to the complete vehicle electrical system. In addition, the cyclical and capacity demands on the battery have increased due to additional safety and convenience features (electrical consumers) being installed.</p> <p>The automobile battery has undergone many technical changes and improvements, and development of new battery technologies continues.</p> <p>A new generation of maintenance free batteries uses physically and constructively optimized, lead-calcium coated positive electrodes. Advantages include minimal electrolyte consumption and servicing requirements, as well as improved charge stability over a longer period of time. Simplified checking of these batteries is also achieved with the "Magic Eye" charge indicator.</p> <p>--> <a class="clsHyperlink" href="#S28544342402008020700000">Safety Precautions</a></p> <p>--> <a class="clsHyperlink" href="#S00323802832008020700000">Lead-Acid Battery, Safety Precautions</a></p><a name="S01607505372008020700000"></a><h2 class="clsHeadThree">Safety Precautions</h2><a name="S22447166942008020700000"></a><h2 class="clsHeadFour">Safety Precautions</h2> <p>Before beginning work, technicians must be acquainted with the possible risks when handling batteries.</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Personnel instructed in protection, such as e. g. a trainee or apprentice, may only perform work on vehicle batteries under supervision of technical personnel such as e. g. a master automotive mechanic or a master automotive electrician.</li> <li>Acid has strong corrosive properties. If batteries are handled inappropriately, there is a risk that personal injury may result from exposure to harmful electrolyte influences. Therefore, suitable remedies for acid damage must be kept readily available. Suitable remedy is e.g. soap solution.</li> <li>If electrolyte drips out from the battery, skin can be acid-burned, and the vehicle may be affected by acid erosion and corrosion. It is a possibility that safety-related vehicle components can be damaged.</li> <li>When charging and when resting after charging, explosive gas is present. In extreme cases, if battery is handled inappropriately, the emitted gases may cause the battery to explode.</li> </ul> <ul class="clsBULLET"> <li>Batteries with a colorless or light yellow "Magic Eye" charge indicator must be replaced. They may not be tested or charged and jump starting may not be used. There is a risk of explosion during testing, charging or jump starting.</li> <li>Generating sparks by sanding, welding, separating work and open flame, e.g. smoking in vicinity of the battery, is prohibited. Producing sparks through electrostatic discharge must also be avoided. Always touch the vehicle body before touching the battery.</li> <li>Only perform battery procedures in suitable and well-ventilated rooms.</li> </ul> </td> </tr> </table></span></p><a name="S00323802832008020700000"></a><h2 class="clsHeadThree">Lead-Acid Battery, Safety Precautions</h2><a name="S20580279052008020700000"></a><h2 class="clsHeadFour">Lead-Acid Battery, Safety Precautions</h2> <p>Recognizing and preventing risks</p> <p>Working with batteries can be hazardous. Danger can be avoided if the warnings on the battery, in the owners manual and in the repair information are heeded.</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004077" name="S31296304692008020700000">Fig. 1: Battery Safety Label</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>Explanation of battery symbols</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>1 - Keep open flames and sparks away and DO NOT smoke near batteries! Avoid sparks when working with cables and electrical units. Always reinstall battery positive (B+) or negative (-) terminal covers if removed during servicing.<ul class="clsBULLET"> <li>Avoid sparks when working with cables and electrical units.</li> <li>Always reinstall battery positive (B+) or negative (-) terminal covers if removed during servicing.</li> </ul> <p>2 - Always wear eye protection when working with electrolyte!</p> <ul class="clsBULLET"> <li>If electrolyte gets into eyes, flush with large quantities of water. Seek medical attention immediately!</li> </ul> <p>3 - Keep children away from batteries!</p> <p>4 - Dispose of batteries properly!</p> <ul class="clsBULLET"> <li>Waste batteries must only be disposed of in appropriate waste disposal sites. Refer to local regulations pertaining to battery disposal.</li> </ul> <p>5 - Never dispose of batteries in household waste!</p> <p>6 - Danger of explosion!</p> <ul class="clsBULLET"> <li>Batteries produce explosive gasses while being charged.</li> <li>Keep open flames and sparks away and DO NOT smoke near batteries.</li> <li>The battery charger MUST be turned off when connecting or disconnecting the cables at the battery.</li> <li>Battery cell caps must NOT be removed while charging.</li> </ul> <ul class="clsBULLET"> <li>Ensure that battery is charged in a well ventilated area.</li> <li>Avoid short circuits. Always reinstall battery positive (B+) or negative (-) terminal covers if removed during servicing.</li> </ul> <p>7 - Read and follow all instructions on battery, contained in Repair Information, Electrical Equipment, and in Owners Manual!</p> <p>8 - Battery acid can cause severe burns!</p> <ul class="clsBULLET"> <li>When working with electrolyte always wear eye protection, rubber gloves and a suitable apron. If electrolyte is spilled on eyes, skin, clothing (or painted surfaces), flush at once with large quantities of water.</li> <li>Never tip a battery on edge. Electrolyte can spill from the ventilation openings.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>There is a risk of injury from the battery acid.<ul class="clsBULLET"> <li>Can cause severe injury to the eyes, skin and mucous membranes.</li> <li>Inhalation can damage the respiratory system.</li> <li>Swallowing is harmful to the digestive system.</li> <li>First Aid: Rinse eyes and immediately consult first aid station or inform doctor.</li> </ul> <ul class="clsBULLET"> <li>Never tilt battery. Electrolyte may leak out of vents.</li> <li>Soak up spilled electrolyte with appropriate absorbent material and neutralize remaining electrolyte with commercial acid neutralizer (or water and baking soda). A soapy solution, for example, is a suitable remedy.</li> <li>Never allow electrolyte to come into contact with bare hands.</li> <li>Avoid contact with skin.</li> </ul> <ul class="clsBULLET"> <li>Never touch mouth, nose or eyes with soiled hands.</li> <li>Immediately remove electrolyte-contaminated clothing and place in water.</li> <li>Do not eat, drink or store food in work areas.</li> <li>Wash thoroughly before breaks and on completion of work.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Protect against injury by using protective eyewear and clothing.<ul class="clsBULLET"> <li>Wear safety goggles and an acid-resistant apron or alternatively electrolyte-proof overalls.</li> <li>Wear electrolyte-proof gloves.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Risk of explosion due to the explosive gas that forms during battery charging.<ul class="clsBULLET"> <li>The gas resulting from charging and partially when resting after charging is explosive. In extreme cases, if battery is handled inappropriately, the emitted gases may cause the battery to explode.</li> <li>Smoking, open flame, fire and sparks (from sanding, welding or separating work) are prohibited when working near the battery.</li> <li>Avoid short circuits when working with electrical wires and devices. Do not place any tools on the battery.</li> <li>To prevent sparks from forming due to electrostatic discharge, always touch the vehicle body before touching the battery.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Protect against explosion.<ul class="clsBULLET"> <li>On batteries with a "magic eye" , the battery must not be tested or charged if the indicator has no color or is light yellow. Jump starting must not be used! There is a risk of explosion during testing, charging or jump starting. The battery must be replaced.</li> <li>Used batteries (lengthy period of use over 6 months) must be treated with an anti-static spray "Neostatic Antistatikum HB 155" (or equivalent) prior to handling.</li> <li>On batteries that are not maintenance-free, the sealing plugs must be securely installed when charging the battery.</li> <li>Charging of batteries removed from the vehicle is only permitted in vented cubicles with extraction system.</li> </ul> <ul class="clsBULLET"> <li>After charging, battery must be left in charging area with extraction system for an appropriate length of time.</li> <li>Only perform battery procedures in suitable and well-ventilated rooms.</li> <li>Batteries are always to be transported in conductive metal containers.</li> <li>Electrostatically chargeable materials are not to be used for securing purposes.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Risk of damage to vehicle.<ul class="clsBULLET"> <li>Safety-related vehicle components could be damaged by acid burns and corrosion due to escaping battery acid.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Personal injury and environmental risk.<ul class="clsBULLET"> <li>Old batteries require special disposal. They contain poisonous lead (Pb) and sulfuric acid.</li> <li>Follow disposal requirements, only dispose of used batteries in suitable containers at an authorized collection site.</li> </ul> </td> </tr> </table></span></p><a name="S32586538272008020700000"></a><h2 class="clsHeadTwo">Lead-Acid Battery without Visual Indicator</h2><a name="S18881144452008020700000"></a><h2 class="clsHeadThree">Lead-Acid Battery without Visual Indicator</h2> <p>Lead acid batteries with removable battery cell sealing caps, without charge indicator "Magic Eye" and filled with fluid electrolyte (wet battery) require regular maintenance. The removable sealing caps allow for topping off with distilled water.</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Risk of injury from direct exposure to battery acid!<ul class="clsBULLET"> <li>Prior to handling or servicing batteries, read, understand and observe the Warnings and Safety Measures --> <a class="clsHyperlink" href="#S26316976462008020700000">27 - Battery, Starter, Generator, Cruise control</a> .</li> </ul> <p>Risk of explosion due to the explosive gas that forms during battery charging.</p> <ul class="clsBULLET"> <li>Observe warning notes and safety precautions --> <a class="clsHyperlink" href="#S26316976462008020700000">27 - Battery, Starter, Generator, Cruise control</a> .</li> </ul> </td> </tr> </table></span></p> <p>--> <a class="clsHyperlink" href="#S31763096642008020700000">Central Venting System</a></p> <p>--> <a class="clsHyperlink" href="#S21089855072008020700000">Battery Post and Terminal, Handling Instructions</a></p> <p>--> <a class="clsHyperlink" href="#S05425240742008020700000">Lead-Acid Battery without Visual Indicator, Checking</a></p> <p>--> <a class="clsHyperlink" href="#S23245985022008020700000">Battery, Visual Inspection</a></p> <p>--> <a class="clsHyperlink" href="#S16186294752008020700000">Battery Electrolyte Level, Checking</a></p> <p>--> <a class="clsHyperlink" href="#S28728729202008020700000">Battery Specific Gravity, Measuring in All Cells</a></p><a name="S24552299532008020700000"></a><h2 class="clsHeadThree">Central Venting System</h2><a name="S26258075922008020700000"></a><h2 class="clsHeadFour">Central Venting System</h2> <p>To prevent vapors produced by the battery during charging from causing damage or posing a health at risk, vapors are discharged centrally through an opening on the top cover side of the battery.</p> <ul class="clsDASH"> <li>Ensure the central venting hose or tube is always secured on the battery.</li> </ul> <ul class="clsDASH"> <li>Ensure the central venting hose or tube is not pinched. Only then can battery be properly vented.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Newer generation batteries have a fine mesh flame trap at the central venting exit point. The "flame trap" is a round fiberglass matt approximately 15 mm wide and 2 mm thick that works like a valve. On the one hand, it allows the gas formed during battery charging to flow out and on the other hand, prevents the explosive gas in the battery from igniting.</li> </ul> </td> </tr> </table></span></p><a name="S21089855072008020700000"></a><h2 class="clsHeadThree">Battery Post and Terminal, Handling Instructions</h2><a name="S28130805692008020700000"></a><h2 class="clsHeadFour">Battery Post and Terminal, Handling Instructions</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017185" name="S25488493742008020700000">Fig. 2: Identifying Battery Posts</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>In order to prevent damage to the battery terminals and battery posts, observe the following:<ul class="clsBULLET"> <li>Battery terminals must only be placed on battery posts - <span class="clsEmphBOLD">arrows</span> - without using force (by hand only).</li> <li>Do not apply grease to battery terminals or posts.</li> <li>Battery terminals must be securely and fully seated on the battery post before tightening (battery post flush with terminal or protruding slightly from terminal).</li> <li>Battery terminals that are torqued to specification must NOT be tightened any further. Terminal damage will result.</li> </ul> <ul class="clsBULLET"> <li>Battery terminal tightening torques depend on model and application. Refer to appropriate model <a class="clsExtHyperlink" id="A00278929_S42401837392008020700000">27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL</a> .</li> </ul> </td> </tr> </table></span></p><a name="S05425240742008020700000"></a><h2 class="clsHeadThree">Lead-Acid Battery without Visual Indicator, Checking</h2><a name="S13111965422008020700000"></a><h2 class="clsHeadFour">Lead-Acid Battery without Visual Indicator, Checking</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Risk of injury and explosion!<ul class="clsBULLET"> <li>Prior to handling or servicing batteries, read, understand and observe the Warnings and Safety Measures --> <a class="clsHyperlink" href="#S00323802832008020700000">Lead-Acid Battery, Safety Precautions</a> !</li> </ul> </td> </tr> </table></span></p> <p>Perform battery checks in the following sequence:</p> <ul class="clsDASH"> <li>Visual check --> <a class="clsHyperlink" href="#S23245985022008020700000">Battery, Visual Inspection</a>.</li> </ul> <ul class="clsDASH"> <li>Check battery electrolyte level --> <a class="clsHyperlink" href="#S16186294752008020700000">Battery Electrolyte Level, Checking</a>.</li> </ul> <ul class="clsDASH"> <li>Test battery --> <a class="clsHyperlink" href="#S00153588082008020700000">Battery, Testing with Midtronics Battery/Starting/Charging System Analyzer MCR340A</a> or measure battery specific gravity --> <a class="clsHyperlink" href="#S28728729202008020700000">Battery Specific Gravity, Measuring in All Cells</a>.</li> </ul> <ul class="clsDASH"> <li>Depending on the results of battery test or battery specific gravity measurement --> <a class="clsHyperlink" href="#S25851475632008020700000">Battery, Load Testing with Midtronics Diagnostic Conductance Charging Station INC-940</a>.</li> </ul><a name="S23245985022008020700000"></a><h2 class="clsHeadThree">Battery, Visual Inspection</h2><a name="S05276454682008020700000"></a><h2 class="clsHeadFour">Battery, Visual Inspection</h2> <ul class="clsDASH"> <li>Before performing extensive measurements, inspect visually.</li> </ul> <ul class="clsBULLET"> <li>External battery condition;</li> </ul> <ul class="clsBULLET"> <li>Battery connections;</li> </ul> <ul class="clsBULLET"> <li>Secure battery seating.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Risk of explosion, inadequate crash safety, risk of corrosion, shortened service life.<ul class="clsBULLET"> <li>A lose battery retaining bracket can damage the battery housing and allow battery acid to leak.</li> <li>A battery that is mounted incorrectly can sustain vibration damage resulting in damage to the battery plates.</li> <li>Battery retaining bracket bolt tightening torque depends on model and application. Refer to appropriate model Electrical Equipment Repair Manual.</li> </ul> <p>Risk of malfunction in the electrical system or wiring burn.</p> <ul class="clsBULLET"> <li>Wiring connection contact is not guaranteed if the battery terminals are damaged or the battery clamps are loose. Check the condition of the battery terminals; battery terminal clamp and auxiliary clamp tightening torque --> <a class="clsExtHyperlink" id="A00278929_S42401837392008020700000">27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL</a> .</li> <li>Risk of corrosion due to leaking battery acid.</li> <li>To ensure the various battery connection systems are free of leaks, the batterys original sealing plugs must be installed in the battery openings. Only replace missing or damaged sealing plugs with the same type of original plugs.</li> <li>The sealing plugs must be equipped with an O-ring.</li> </ul> </td> </tr> </table></span></p><a name="S16186294752008020700000"></a><h2 class="clsHeadThree">Battery Electrolyte Level, Checking</h2><a name="S35623758532008020700000"></a><h2 class="clsHeadFour">Battery Electrolyte Level, Checking</h2> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00007547" name="S41229064902008020700000">Fig. 3: Battery fill bottle VAS 5045</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Battery filler VAS 5045</li> </ul> <p><span class="clsEmphBOLD">Procedure</span> </p> <p>Maintaining the correct electrolyte level in the battery is an important factor affecting the length of the batterys service life.</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Risk of injury from direct exposure to battery acid.<ul class="clsBULLET"> <li>Follow accident prevention regulations when working with battery acid --> <a class="clsHyperlink" href="#S26316976462008020700000">27 - Battery, Starter, Generator, Cruise control</a> .</li> <li>Wear protective eyewear and clothing --> <a class="clsHyperlink" href="#S26316976462008020700000">27 - Battery, Starter, Generator, Cruise control</a> .</li> </ul> <p>Risk of explosion due to open flame, fire and smoking.</p> <ul class="clsBULLET"> <li>Only illuminate the inside of the battery housing with a flashlight.</li> <li>Never illuminate the inside of the battery housing with an open flame.</li> <li>Never handle open flame or burning cigarettes near batteries.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>If the "min" and "max" marking on the outside of the battery can be seen, simply inspect by sight.</li> </ul> <ul class="clsBULLET"> <li>The electrolyte level must be above the "min" marking but must only go as high as the "max" marking.</li> </ul> <ul class="clsDASH"> <li>If it is difficult to see the "min" and "max" markings on the outside of the battery or they cannot be seen because the battery housing is opaque, remove the sealing plugs.</li> </ul> <ul class="clsDASH"> <li>Check electrolyte level by visually checking the inside of the battery.</li> </ul> <ul class="clsBULLET"> <li>The electrolyte level must coincide with the internal level mark (plastic web). This corresponds to the outer "max" marking.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Risk of corrosion due to leaking battery acid.<ul class="clsBULLET"> <li>To ensure the various battery connection systems are free of leaks, the batterys original sealing plugs must be installed in the battery openings. Only replace missing or damaged sealing plugs with the same type of original plugs.</li> <li>The sealing plugs must be equipped with an O-ring.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Thread in battery cell sealing plugs.</li> </ul> <p><span class="clsEmphBOLD">Electrolyte level too low</span> </p> <p>If the electrolyte level is too low, a loss of battery capacity (power) occurs due to cell plates drying out. If the cell plates are not surrounded by electrolyte (sulfuric acid-water mixture), the plates, plate straps, and cell connectors will corrode. The corrosion damages battery operation, the battery can no longer be used.</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004080" name="S42752963902008020700000">Fig. 4: VAS 5045 Battery Filling Bottle</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>If electrolyte level is too low, use battery filler VAS 5045 to add distilled water until max mark is reached.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>The filler neck of the Battery filler VAS 5045 is designed to prevent over-filling of the battery cell and electrolyte leakage. The flow of distilled water into the battery cell is interrupted on reaching the max. level.</li> <li>Always use distilled water for topping up to prevent electrolyte contamination which results in increased self-discharge.</li> </ul> </td> </tr> </table></span></p><a name="S28728729202008020700000"></a><h2 class="clsHeadThree">Battery Specific Gravity, Measuring in All Cells</h2><a name="S02294206472008020700000"></a><h2 class="clsHeadFour">Battery Specific Gravity, Measuring in All Cells</h2> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00000147" name="S14018368102008020700000">Fig. 5: Identifying Refractometer T10007</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Refractometer T10007 or</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004084" name="S18011723472008020700000">Fig. 6: Identifying Commercially Available Hydrometer</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Commercially available hydrometer</li> </ul> <p><span class="clsEmphBOLD">Prerequisites</span> </p> <ul class="clsBULLET"> <li>The temperature of the battery acid must be at least +10 C.</li> </ul> <p><span class="clsEmphBOLD">Procedure</span> </p> <p>In conjunction with battery test --> <a class="clsHyperlink" href="#S00153588082008020700000">Battery, Testing with Midtronics Battery/Starting/Charging System Analyzer MCR340A</a> , the specific gravity measurement gives information about the condition of the battery.</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Risk of injury from direct exposure to battery acid.<ul class="clsBULLET"> <li>Follow accident prevention regulations when working with battery acid --> <a class="clsHyperlink" href="#S26316976462008020700000">27 - Battery, Starter, Generator, Cruise control</a> .</li> <li>Wear protective eyewear and clothing --> <a class="clsHyperlink" href="#S26316976462008020700000">27 - Battery, Starter, Generator, Cruise control</a> .</li> </ul> </td> </tr> </table></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Specific gravity of electrolyte can be checked immediately after charging battery.</li> <li>Remove all battery cell sealing plugs.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004086" name="S31216924542008020700000">Fig. 7: Hydrometer Specific Gravity Reading</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Dip hydrometer into battery cell and siphon off enough electrolyte until float floats freely in electrolyte.</li> </ul> <ul class="clsBULLET"> <li>The higher the specified weight of the siphoned battery acid, the higher the float will float.</li> </ul> <ul class="clsBULLET"> <li>The acid density of the electrolyte can be read off in kg/dm <sup>3</sup> on the hydrometer scale (specified density of the battery acid).</li> </ul> <ul class="clsDASH"> <li>Compare hydrometer reading to values given in table.</li> </ul> <p><span class="clsArticleTable"><a name="S022942064720080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1" width="132px"> <col span="1" id="COL2" width="132px"> <col span="1" id="COL3" width="132px"> </colgroup> <tbody> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Charge condition</td> <td colspan="2" valign="TOP" align="LEFT" class="clsCellNormal">Electrolyte density in kg/dm 3</td> </tr> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal"> </td> <td valign="TOP" align="LEFT" class="clsCellNormal">in normal climates</td> <td valign="TOP" align="LEFT" class="clsCellNormal">in the tropics</td> </tr> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Discharged</td> <td valign="TOP" align="LEFT" class="clsCellNormal">1.12</td> <td valign="TOP" align="LEFT" class="clsCellNormal">1.08</td> </tr> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Partial charge</td> <td valign="TOP" align="LEFT" class="clsCellNormal">1.20</td> <td valign="TOP" align="LEFT" class="clsCellNormal">1.16</td> </tr> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Fully charged</td> <td valign="TOP" align="LEFT" class="clsCellNormal">1.28</td> <td valign="TOP" align="LEFT" class="clsCellNormal">1.23</td> </tr> </tbody> </table></span></p> <p>Specified acid density must be at least 1.24 kg/dm <sup>3</sup> in moderate climate zones. If the acid density in all battery cells is too low:</p> <ul class="clsDASH"> <li>Charge battery and repeat acid density test.</li> </ul> <p><span class="clsArticleTable"><a name="S022942064720080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1" width="57px"> <col span="1" id="COL2" width="57px"> <col span="1" id="COL3" width="56px"> <col span="1" id="COL4" width="57px"> <col span="1" id="COL5" width="56px"> <col span="1" id="COL6" width="57px"> <col span="1" id="COL7" width="56px"> </colgroup> <tbody> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Example 1</td> <td valign="TOP" align="LEFT" class="clsCellNormal"> </td> <td valign="TOP" align="LEFT" class="clsCellNormal"> </td> <td valign="TOP" align="LEFT" class="clsCellNormal"> </td> <td valign="TOP" align="LEFT" class="clsCellNormal"> </td> <td valign="TOP" align="LEFT" class="clsCellNormal"> </td> <td valign="TOP" align="LEFT" class="clsCellNormal"> </td> </tr> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Battery cell</td> <td valign="TOP" align="CENTER" class="clsCellNormal">1</td> <td valign="TOP" align="CENTER" class="clsCellNormal">2</td> <td valign="TOP" align="CENTER" class="clsCellNormal">3</td> <td valign="TOP" align="CENTER" class="clsCellNormal">4</td> <td valign="TOP" align="CENTER" class="clsCellNormal">5</td> <td valign="TOP" align="CENTER" class="clsCellNormal">6</td> </tr> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Electrolyte density per cell in kg/dm 3</td> <td valign="TOP" align="CENTER" class="clsCellNormal">1.24</td> <td valign="TOP" align="CENTER" class="clsCellNormal">1.25</td> <td valign="TOP" align="CENTER" class="clsCellNormal">1.25</td> <td valign="TOP" align="CENTER" class="clsCellNormal">1.10 1)</td> <td valign="TOP" align="CENTER" class="clsCellNormal">1.24</td> <td valign="TOP" align="CENTER" class="clsCellNormal">1.25</td> </tr> <tr> <td colspan="7" valign="TOP" align="LEFT" class="clsCellNormal">1) Acid density in cell 4 is too low (deviation greater than 0.03 kg/dm 3 ).</td> </tr> </tbody> </table></span></p> <p><span class="clsArticleTable"><a name="S022942064720080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1" width="57px"> <col span="1" id="COL2" width="57px"> <col span="1" id="COL3" width="56px"> <col span="1" id="COL4" width="57px"> <col span="1" id="COL5" width="56px"> <col span="1" id="COL6" width="57px"> <col span="1" id="COL7" width="56px"> </colgroup> <tbody> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Example 2</td> <td valign="TOP" align="LEFT" class="clsCellNormal"> </td> <td valign="TOP" align="LEFT" class="clsCellNormal"> </td> <td valign="TOP" align="LEFT" class="clsCellNormal"> </td> <td valign="TOP" align="LEFT" class="clsCellNormal"> </td> <td valign="TOP" align="LEFT" class="clsCellNormal"> </td> <td valign="TOP" align="LEFT" class="clsCellNormal"> </td> </tr> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Battery cell</td> <td valign="TOP" align="CENTER" class="clsCellNormal">1</td> <td valign="TOP" align="CENTER" class="clsCellNormal">2</td> <td valign="TOP" align="CENTER" class="clsCellNormal">3</td> <td valign="TOP" align="CENTER" class="clsCellNormal">4</td> <td valign="TOP" align="CENTER" class="clsCellNormal">5</td> <td valign="TOP" align="CENTER" class="clsCellNormal">6</td> </tr> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Electrolyte density per cell in kg/dm 3</td> <td valign="TOP" align="CENTER" class="clsCellNormal">1.26</td> <td valign="TOP" align="CENTER" class="clsCellNormal">1.26</td> <td valign="TOP" align="CENTER" class="clsCellNormal">1.25</td> <td valign="TOP" align="CENTER" class="clsCellNormal">1.14 1)</td> <td valign="TOP" align="CENTER" class="clsCellNormal">1.18 1)</td> <td valign="TOP" align="CENTER" class="clsCellNormal">1.24</td> </tr> <tr> <td colspan="7" valign="TOP" align="LEFT" class="clsCellNormal">1) Acid density in cells 4 and 5 too low (deviation greater than 0.03 kg/dm 3 ).</td> </tr> </tbody> </table></span></p> <ul class="clsDASH"> <li>If the specified values are not reached, replace battery.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>The measured values for the specific gravity of the individual battery cells must not deviate by more than 0.03 kg/dm <sup>3</sup> , otherwise the battery should be replaced.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Risk due to leaking battery acid.<ul class="clsBULLET"> <li>To ensure the various battery connection systems are free of leaks, the batterys original sealing plugs must be installed in the battery openings. Only replace missing or damaged sealing plugs with the same type of original plugs.</li> <li>The sealing plugs must be equipped with an O-ring.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>If the specified values are reached, reinstall battery cell sealing plugs.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>If the battery must be replaced, follow the disposal regulations --> <a class="clsHyperlink" href="#S26316976462008020700000">27 - Battery, Starter, Generator, Cruise control</a> .</li> </ul> </td> </tr> </table></span></p><a name="S01213191042008020700000"></a><h2 class="clsHeadTwo">Maintenance-Free Batteries</h2><a name="S26145516762008020700000"></a><h2 class="clsHeadThree">Maintenance-Free Batteries</h2> <p>Only maintenance-free batteries conforming to standards "TL82506" (as of December 1997) and "VW75073" (as of August 2001) may be installed.</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Risk of injury due to contact with battery acid!<ul class="clsBULLET"> <li>Prior to handling or servicing batteries, read, understand and observe the Warnings and Safety Measures --> <a class="clsHyperlink" href="#S26316976462008020700000">27 - Battery, Starter, Generator, Cruise control</a> .</li> </ul> <p>Risk of explosion due to the explosive gas that forms during battery charging.</p> <ul class="clsBULLET"> <li>Observe warning notes and safety precautions --> <a class="clsHyperlink" href="#S26316976462008020700000">27 - Battery, Starter, Generator, Cruise control</a> .</li> </ul> </td> </tr> </table></span></p> <p>--> <a class="clsHyperlink" href="#S07566575862008020700000">Maintenance-Free Battery with Visual Indicator</a></p> <p>--> <a class="clsHyperlink" href="#S20776469132008020700000">Maintenance-Free Battery with Visual Indicator, Checking</a></p> <p>--> <a class="clsHyperlink" href="#S34421138582008020700000">Absorbent Glass Mat Battery without Visual Indicator</a></p> <p>--> <a class="clsHyperlink" href="#S08979432312008020700000">Absorbent Glass Mat Battery, Checking</a></p> <p>--> <a class="clsHyperlink" href="#S31763096642008020700000">Central Venting System</a></p> <p>--> <a class="clsHyperlink" href="#S00728456412008020700000">Battery Post and Terminal, Handling Instructions</a></p> <p>--> <a class="clsHyperlink" href="#S33435860842008020700000">Battery, Visual Inspection</a></p> <p>--> <a class="clsHyperlink" href="#S19899860282008020700000">Maintenance-Free Battery with Visual Indicator, Checking Color Display</a></p> <p>--> <a class="clsHyperlink" href="#S01245972812008020700000">Battery Electrolyte Level, Checking</a></p><a name="S31106079212008020700000"></a><h2 class="clsHeadThree">Maintenance-Free Battery with Visual Indicator</h2><a name="S07566575862008020700000"></a><h2 class="clsHeadFour">Maintenance-Free Battery with Visual Indicator</h2> <p>Lead acid batteries with non-removable battery cell sealing caps, with charge indicator "Magic Eye" and filled with fluid electrolyte (wet battery) are considered maintenance-free. Sealing caps are not removable for topping off with distilled water.</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>If batteries with a "magic eye" are equipped with sealing plugs for production reasons only, the plugs are covered with plastic sheeting.</li> <li>The covering must not be removed and distilled water must not be added.</li> <li>Only perform a visual inspection.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017015" name="S26614442382008020700000">Fig. 8: Locating Magic Eye</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>The "magic eye" - <span class="clsEmphBOLD">arrow</span> - gives information about the electrolyte level and charge condition of the battery by means of a color display. Possible color displays --> <a class="clsHyperlink" href="#S19899860282008020700000">Maintenance-Free Battery with Visual Indicator, Checking Color Display</a>.</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Risk of explosion on discharged battery with magic eye.<ul class="clsBULLET"> <li>If the magic eye has no color or is light yellow, the battery may not be tested or charged. Jump starting must not be used! There is a risk of explosion during testing, charging or jump starting. The battery must be replaced.</li> </ul> </td> </tr> </table></span></p><a name="S20776469132008020700000"></a><h2 class="clsHeadThree">Maintenance-Free Battery with Visual Indicator, Checking</h2><a name="S09048920452008020700000"></a><h2 class="clsHeadFour">Maintenance-Free Battery with Visual Indicator, Checking</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Risk of injury and explosion!<ul class="clsBULLET"> <li>Prior to handling or servicing batteries, read, understand and observe the Warnings and Safety Measures --> <a class="clsHyperlink" href="#S00323802832008020700000">Lead-Acid Battery, Safety Precautions</a></li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Perform battery checks in the following sequence:</span> </p> <ul class="clsDASH"> <li>Visual check --> <a class="clsHyperlink" href="#S33435860842008020700000">Battery, Visual Inspection</a>.</li> </ul> <ul class="clsDASH"> <li>Check charge indicator "magic eye" color display --> <a class="clsHyperlink" href="#S19899860282008020700000">Maintenance-Free Battery with Visual Indicator, Checking Color Display</a>.</li> </ul> <ul class="clsDASH"> <li>Check battery electrolyte level --> <a class="clsHyperlink" href="#S01245972812008020700000">Battery Electrolyte Level, Checking</a>.</li> </ul> <ul class="clsDASH"> <li>Test battery --> <a class="clsHyperlink" href="#S00153588082008020700000">Battery, Testing with Midtronics Battery/Starting/Charging System Analyzer MCR340A</a>.</li> </ul> <ul class="clsDASH"> <li>Depending on result of battery test --> <a class="clsHyperlink" href="#S25851475632008020700000">Battery, Load Testing with Midtronics Diagnostic Conductance Charging Station INC-940</a>.</li> </ul><a name="S34421138582008020700000"></a><h2 class="clsHeadThree">Absorbent Glass Mat Battery without Visual Indicator</h2><a name="S38783242282008020700000"></a><h2 class="clsHeadFour">Absorbent Glass Mat Battery without Visual Indicator</h2> <ul class="clsBULLET"> <li>AGM batteries are deep cycle-resistant and leak-proof.</li> </ul> <ul class="clsBULLET"> <li>Lead acid AGM (Absorbent Glass Mat) batteries are filled with electrolyte contained in an absorbent glass mat. The battery is closed and equipped with breather valves.</li> </ul> <ul class="clsBULLET"> <li>These batteries do not utilize a "Magic Eye" due to the fixed electrolyte. AGM batteries are marked with "AGM" on the battery.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>AGM batteries cannot and must not be opened and distilled water must not be added.</li> <li>Only perform a visual inspection.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Crash safety is inadequate if the incorrect battery is installed.<ul class="clsBULLET"> <li>If the vehicle was originally equipped with an AGM battery, another AGM battery must be installed when replacing.</li> </ul> </td> </tr> </table></span></p><a name="S08979432312008020700000"></a><h2 class="clsHeadThree">Absorbent Glass Mat Battery, Checking</h2><a name="S17663733752008020700000"></a><h2 class="clsHeadFour">Absorbent Glass Mat Battery, Checking</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Risk of injury and explosion!<ul class="clsBULLET"> <li>Prior to handling or servicing batteries, read, understand and observe the Warnings and Safety Measures --> <a class="clsHyperlink" href="#S00323802832008020700000">Lead-Acid Battery, Safety Precautions</a> !</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Perform battery checks in the following sequence:</span> </p> <ul class="clsDASH"> <li>Visual check --> <a class="clsHyperlink" href="#S33435860842008020700000">Battery, Visual Inspection</a>.</li> </ul> <ul class="clsDASH"> <li>Test battery --> <a class="clsHyperlink" href="#S00153588082008020700000">Battery, Testing with Midtronics Battery/Starting/Charging System Analyzer MCR340A</a>.</li> </ul> <ul class="clsDASH"> <li>Depending on result of battery test --> <a class="clsHyperlink" href="#S25851475632008020700000">Battery, Load Testing with Midtronics Diagnostic Conductance Charging Station INC-940</a>.</li> </ul><a name="S31763096642008020700000"></a><h2 class="clsHeadThree">Central Venting System</h2><a name="S02238974522008020700000"></a><h2 class="clsHeadFour">Central Venting System</h2> <p>To prevent vapors produced by the battery during charging from causing damage or posing a health at risk, vapors are discharged centrally through an opening on the top cover side of the battery.</p> <ul class="clsDASH"> <li>Ensure that the central venting hose or tube is always secured on the battery.</li> </ul> <ul class="clsDASH"> <li>Ensure that the central venting hose or tube is not pinched. Only then can battery be properly vented.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Newer generation batteries have a fine mesh flame trap at the central venting exit point. The "flame trap" is a round fiberglass matt approximately 15 mm wide and 2 mm thick that works like a valve. On the one hand, it allows the gas formed during battery charging to flow out and on the other hand, prevents the explosive gas in the battery from igniting.</li> </ul> </td> </tr> </table></span></p><a name="S00728456412008020700000"></a><h2 class="clsHeadThree">Battery Post and Terminal, Handling Instructions</h2><a name="S15518995462008020700000"></a><h2 class="clsHeadFour">Battery Post and Terminal, Handling Instructions</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017185" name="S27299907342008020700000">Fig. 9: Identifying Battery Posts</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>In order to prevent damage to the battery terminals and battery posts, observe the following:<ul class="clsBULLET"> <li>Battery terminals must only be placed on battery posts - <span class="clsEmphBOLD">arrows</span> - without using force (by hand only).</li> <li>Do not apply grease to battery terminals or posts.</li> <li>Battery terminals must be securely and fully seated on the battery post before tightening (battery post flush with terminal or protruding slightly from terminal).</li> <li>Battery terminals that are torqued to specification must NOT be tightened any further. Terminal damage will result.</li> </ul> <ul class="clsBULLET"> <li>Battery terminal tightening torques depend on model and application. Refer to <a class="clsExtHyperlink" id="A00278929_S42401837392008020700000">27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL</a> .</li> </ul> </td> </tr> </table></span></p><a name="S33435860842008020700000"></a><h2 class="clsHeadThree">Battery, Visual Inspection</h2><a name="S21414004642008020700000"></a><h2 class="clsHeadFour">Battery, Visual Inspection</h2> <ul class="clsDASH"> <li>Before performing extensive measurements, inspect visually.</li> <li>External battery condition;</li> <li>Battery connections;</li> <li>Secure battery seating.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Risk of explosion, inadequate crash safety, risk of corrosion, shortened service life.<ul class="clsBULLET"> <li>A lose battery retaining bracket can damage the battery housing and allow battery acid to leak.</li> <li>A battery that is mounted incorrectly can sustain vibration damage resulting in damage to the battery plates.</li> <li>Tighten retaining bracket bolt; tightening torque --> <a class="clsExtHyperlink" id="A00278929_S42401837392008020700000">27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL</a> .</li> </ul> <p>Risk of malfunction in the electrical system or wiring burn.</p> <ul class="clsBULLET"> <li>Wiring connection contact is not guaranteed if the battery terminals are damaged or the battery clamps are loose. Check the condition of the battery terminals; battery terminal clamp and auxiliary clamp tightening torque --> <a class="clsExtHyperlink" id="A00278929_S42401837392008020700000">27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL</a> .</li> </ul> </td> </tr> </table></span></p><a name="S19899860282008020700000"></a><h2 class="clsHeadThree">Maintenance-Free Battery with Visual Indicator, Checking Color Display</h2><a name="S30588853992008020700000"></a><h2 class="clsHeadFour">Maintenance-Free Battery with Visual Indicator, Checking Color Display</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017015" name="S00830343662008020700000">Fig. 10: Locating Magic Eye</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Procedure</span> </p> <ul class="clsDASH"> <li>To obtain an accurate reading, gently tap the magic eye - <span class="clsEmphBOLD">arrow</span> - with a screwdriver handle or rock the vehicle slightly.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>When recharging the battery and while driving, air bubbles can form below the "magic eye" and result in an incorrect color display. Tapping releases the air bubbles under the "magic eye".</li> <li>The "magic eye" can be installed at various locations on top of battery.</li> <li>Because the "magic eye" is located in a single cell, the indication is only valid for that cell. The procedure for making an accurate assessment of the battery condition depends on the vehicle: on vehicles without the Energy Management Control Module J644 --> <a class="clsHyperlink" href="#S00153588082008020700000">Battery, Testing with Midtronics Battery/Starting/Charging System Analyzer MCR340A</a> , on vehicles with the Energy Management Control Module J644 --> <span class="clsEmphBOLD">Battery - Vehicles with Energy Management Control Module, Testing with Vehicle Diagnosis, Testing and Information System VAS 5051B</span> .</li> <li>If no diagnostic system is available, the battery test can be performed on vehicles with the Energy Management Control Module J644 using the Battery Tester With Printer VAS 5097A --> <a class="clsHyperlink" href="#S00153588082008020700000">Battery, Testing with Midtronics Battery/Starting/Charging System Analyzer MCR340A</a>.</li> <li>Check the battery condition using the color indicator. There are three possible color indications:</li> </ul> </td> </tr> </table></span></p> <p><span class="clsArticleTable"><a name="S305888539920080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1" width="198px"> <col span="1" id="COL2" width="198px"> </colgroup> <tbody> <tr> <td valign="TOP" align="CENTER" class="clsCellNormal">Color indicator</td> <td valign="TOP" align="CENTER" class="clsCellNormal">Battery status</td> </tr> <tr> <td valign="TOP" align="CENTER" class="clsCellNormal">Green</td> <td valign="TOP" align="LEFT" class="clsCellNormal">Battery adequately charged for testing</td> </tr> <tr> <td valign="TOP" align="CENTER" class="clsCellNormal">Black</td> <td valign="TOP" align="LEFT" class="clsCellNormal">No charge or charge too low.</td> </tr> <tr> <td valign="TOP" align="CENTER" class="clsCellNormal">Colorless or yellow</td> <td valign="TOP" align="LEFT" class="clsCellNormal">Risk of explosion, the battery must not be tested or charged.</td> </tr> </tbody> </table></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Risk of explosion on discharged battery with magic eye.<ul class="clsBULLET"> <li>If the magic eye has no color or is light yellow, the battery may not be tested or charged. Jump starting must not be used! There is a risk of explosion during testing, charging or jump starting. The battery must be replaced.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>If the battery must be replaced, follow the disposal regulations --> <a class="clsHyperlink" href="#S26316976462008020700000">27 - Battery, Starter, Generator, Cruise control</a> .</li> </ul> </td> </tr> </table></span></p><a name="S01245972812008020700000"></a><h2 class="clsHeadThree">Battery Electrolyte Level, Checking</h2><a name="S27491350772008020700000"></a><h2 class="clsHeadFour">Battery Electrolyte Level, Checking</h2> <p><span class="clsEmphBOLD">Procedure</span> </p> <p>Maintaining the correct electrolyte level in the battery is an important factor affecting the length of the batterys service life.</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Risk of injury due to contact with battery acid.<ul class="clsBULLET"> <li>Follow accident prevention regulations when working with battery acid --> <a class="clsHyperlink" href="#S26316976462008020700000">27 - Battery, Starter, Generator, Cruise control</a> .</li> <li>Wear protective eyewear and clothing --> <a class="clsHyperlink" href="#S26316976462008020700000">27 - Battery, Starter, Generator, Cruise control</a> .</li> <li>If the electrolyte level is too low, the battery must be replaced. It must not be opened and distilled water must not be added.</li> </ul> <p>Risk of explosion due to open flame, fire and smoking.</p> <ul class="clsBULLET"> <li>Never handle open flame or burning cigarettes near batteries.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>If the "min" and "max" marking on the outside of the battery can be seen, inspect by sight.</li> </ul> <ul class="clsBULLET"> <li>The electrolyte level must be above the "min" marking but must only go as high as the "max" marking.</li> </ul><a name="S16446383932008020700000"></a><h2 class="clsHeadTwo">Battery, Testing</h2><a name="S11519604692008020700000"></a><h2 class="clsHeadThree">Battery, Testing</h2> <p>Maintenance-free batteries must not be opened. Otherwise, the warranty is void.</p> <p>--> <a class="clsHyperlink" href="#S00153588082008020700000">Battery, Testing with Midtronics Battery/Starting/Charging System Analyzer MCR340A</a></p> <p>--> <span class="clsEmphBOLD">Battery - Vehicles with Energy Management Control Module, Testing with Vehicle Diagnosis, Testing and Information System VAS 5051B</span> </p> <p>--> <span class="clsEmphBOLD">Battery No-Load Voltage - Vehicles without Energy Management Control Module, Checking</span> under</p> <p>--> <a class="clsHyperlink" href="#S04514642112008020700000">Battery No-Load Voltage - Vehicles with Energy Management Control Module, Checking</a></p> <p>--> <a class="clsHyperlink" href="#S25851475632008020700000">Battery, Load Testing with Midtronics Diagnostic Conductance Charging Station INC-940</a></p><a name="S00153588082008020700000"></a><h2 class="clsHeadThree">Battery, Testing with Midtronics Battery/Starting/Charging System Analyzer MCR340A</h2><a name="S33647220922008020700000"></a><h2 class="clsHeadFour">Battery, Testing with Midtronics Battery/Starting/Charging System Analyzer MCR340A</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Risk of injury from battery acid.<ul class="clsBULLET"> <li>Prior to handling or servicing batteries, read, understand and observe the Warnings and Safety Measures for lead-acid batteries for lead-acid batteries --> <a class="clsHyperlink" href="#S28544342402008020700000">Safety Precautions</a> !</li> <li>Wear protective eyewear and clothing --> <a class="clsHyperlink" href="#S26316976462008020700000">27 - Battery, Starter, Generator, Cruise control</a> .</li> <li>If the magic eye has no color or is light yellow, the battery may not be tested or charged. Jump starting must not be used! There is a risk of explosion during testing, charging or jump starting. The battery must be replaced.</li> <li>DO NOT battery test batteries which are gassing. Otherwise there is a risk of explosion.</li> </ul> <ul class="clsBULLET"> <li>Dispose of electrolyte (sulfuric acid/water mixture) properly! Waste electrolyte must only be disposed of in appropriate waste disposal sites. Refer to local regulations pertaining to electrolyte disposal.</li> <li>The following notes and procedures must be followed to ensure correct measurements.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004275" name="S15666616742008020700000">Fig. 11: Battery VAS Tester</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Midtronics Battery/Starting/Charging System Analyzer MCR340A (VAS tester illustrated here for reference only)</li> </ul> <p><span class="clsEmphBOLD">Procedure</span> </p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> <li>Refer to Midtronics Battery/Starting/Charging System Analyzer MCR340A Instruction Manual.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>On battery with charge indicator "Magic Eye" , check color display --> <a class="clsHyperlink" href="#S19899860282008020700000">Maintenance-Free Battery with Visual Indicator, Checking Color Display</a>.</li> </ul> <ul class="clsDASH"> <li>Check no-load voltage --> <span class="clsEmphBOLD">Battery No-Load Voltage - Vehicles without Energy Management Control Module, Checking</span> .</li> </ul> <ul class="clsDASH"> <li>Connect tester cable clamps to battery terminal --> MCR340A Instruction Manual. Tester leads must be securely fastened and make proper contact with battery posts.</li> </ul> <ul class="clsDASH"> <li>Select test mode "IN-VEHICLE" or "OUT-OF-VEHICLE" as appropriate --> MCR340A Instruction Manual.</li> </ul> <ul class="clsDASH"> <li>Select battery type (AGM or conventional) --> MCR340A Instruction Manual</li> </ul> <ul class="clsDASH"> <li>Set tester to "Warranty Test" --> MCR340A Instruction Manual.</li> </ul> <ul class="clsDASH"> <li>Perform battery test by setting load current on tester according to battery (DIN) capacity --> MCR340A Instruction Manual.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Use print function of MCR340A in event test results are required for warranty claims.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Battery test results:</span> </p> <p><span class="clsArticleTable"><a name="S336472209220080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1" width="198px"> <col span="1" id="COL2" width="198px"> </colgroup> <tbody> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Battery Tester Display / Printout</td> <td valign="TOP" align="LEFT" class="clsCellNormal">Required action</td> </tr> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Good Battery</td> <td valign="TOP" align="LEFT" class="clsCellNormal">None</td> </tr> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Good - Recharge</td> <td valign="TOP" align="LEFT" class="clsCellNormal">Charge battery where necessary</td> </tr> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Use inCHARGE</td> <td valign="TOP" align="LEFT" class="clsCellNormal">Charge battery</td> </tr> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Replace Battery</td> <td valign="TOP" align="LEFT" class="clsCellNormal">Replace battery. Electrical Equipment 27 Battery.</td> </tr> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Bad Cell - Replace</td> <td valign="TOP" align="LEFT" class="clsCellNormal">Replace battery. Electrical Equipment 27 Battery.</td> </tr> </tbody> </table></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>If battery is replaced, follow disposal regulations --> <a class="clsHyperlink" href="#S26316976462008020700000">27 - Battery, Starter, Generator, Cruise control</a> .</li> </ul> </td> </tr> </table></span></p><a name="S16017005742008020700000"></a><h2 class="clsHeadThree">Battery - Vehicles with Energy Management Control Module, Testing with Vehicle Diagnosis, Testing and Information System VAS 5051B</h2><a name="S25315654322008020700000"></a><h2 class="clsHeadFour">Battery - Vehicles with Energy Management Control Module, Testing with Vehicle Diagnosis, Testing and Information System VAS 5051B</h2> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <ul class="clsBULLET"> <li>e.g. Vehicle Diagnosis, Testing and Information System VAS 5051B (or any of the VAS 505X class testers) with diagnostic cable</li> </ul> <p><span class="clsEmphBOLD">Prerequisites</span> </p> <ul class="clsBULLET"> <li>Battery must not be in process of being charged.</li> </ul> <ul class="clsBULLET"> <li>Engine must not be running.</li> </ul> <ul class="clsBULLET"> <li>Battery temperature must be at least -10 C.</li> </ul> <ul class="clsBULLET"> <li>Diagnostic system temperature must be between +5 and 45 C.</li> </ul> <p><span class="clsEmphBOLD">Procedure</span> </p> <ul class="clsDASH"> <li>Connect Vehicle Diagnosis, Testing and Information System VAS 5051B --> <a class="clsHyperlink" href="#S11317004502008020700000">Vehicle Diagnosis, Testing and Information System VAS 5051B, Connecting</a>.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>If an error message appears on the display --> , VAS 5051B operating instructions.</li> <li>Press Guided Functions button on operating mode selection screen.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00015769" name="S19931783952008020700000">Fig. 12: Display On VAS 5051 - (1st Control Element In Test & Evaporative Emission (EVAP) Canister Purge Regulator Valve-N80-)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>Display:</p> <ul class="clsDASH"> <li>Enter vehicle identification number (VIN) in field - <span class="clsEmphBOLD">1</span> - in selection - <span class="clsEmphBOLD">A</span> -.</li> </ul> <p>The Vehicle Diagnosis, Testing and Information System VAS 5051B then switches to the next selection level. The following example shows how vehicle type, engine and vehicle system of function could be selected (some steps may be skipped):</p> <p>The following information is given as an example only. Always enter required information as it pertains to vehicle being serviced.</p> <p><span class="clsArticleTable"><a name="S253156543220080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1" width="198px"> <col span="1" id="COL2" width="198px"> </colgroup> <tbody> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Selection</td> <td valign="TOP" align="LEFT" class="clsCellNormal">Text lines to be selected</td> </tr> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Select brand</td> <td valign="TOP" align="LEFT" class="clsCellNormal">Audi</td> </tr> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Select model (example)</td> <td valign="TOP" align="LEFT" class="clsCellNormal">Audi A6 2005 ></td> </tr> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Select model year (example)</td> <td valign="TOP" align="LEFT" class="clsCellNormal">2006 (6)</td> </tr> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Select version (example)</td> <td valign="TOP" align="LEFT" class="clsCellNormal">Sedan</td> </tr> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Select engine code (example)</td> <td valign="TOP" align="LEFT" class="clsCellNormal">BXA 5.2L FSI / 320 kW</td> </tr> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">If vehicle identification was performed correctly, then press button to confirm</td> <td valign="TOP" align="LEFT" class="clsCellNormal"> </td> </tr> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Select vehicle system or function</td> <td valign="TOP" align="LEFT" class="clsCellNormal">61 - Battery control</td> </tr> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Select vehicle system or function</td> <td valign="TOP" align="LEFT" class="clsCellNormal">A - Battery, test (<a class="clsExtHyperlink" id="A00278929_S42401837392008020700000">27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL</a> )</td> </tr> </tbody> </table></span></p> <ul class="clsDASH"> <li>Follow VAS 5051B instructions and prompts. Depending on results, the following will be displayed:</li> </ul> <ul class="clsBULLET"> <li>Battery is OK.</li> </ul> <ul class="clsBULLET"> <li>Charge battery.</li> </ul> <ul class="clsBULLET"> <li>Replace battery.</li> </ul> <p>After battery test:</p> <ul class="clsDASH"> <li>Tap button Go to.</li> </ul> <ul class="clsDASH"> <li>Select function "Exit".</li> </ul> <ul class="clsDASH"> <li>Where applicable, follow tester prompts regarding warranty requirements.</li> </ul> <ul class="clsDASH"> <li>Switch ignition off and disconnect tester from Data Link Connector (DLC).</li> </ul> <ul class="clsDASH"> <li>If necessary, charge battery --> <span class="clsEmphBOLD">Battery, Charging with Midtronics Diagnostic Conductance Charging Station INC-940</span> </li> </ul> <ul class="clsDASH"> <li>If necessary, replace battery. --> <a class="clsExtHyperlink" id="A00278929_S42401837392008020700000">27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL</a> </li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>If battery is replaced, follow disposal regulations --> <a class="clsHyperlink" href="#S26316976462008020700000">27 - Battery, Starter, Generator, Cruise control</a> .</li> </ul> </td> </tr> </table></span></p><a name="S17846552462008020700000"></a><h2 class="clsHeadThree">Battery No-Load Voltage - Vehicles without Energy Management Control Module, Checking</h2><a name="S14464080732008020700000"></a><h2 class="clsHeadFour">Battery No-Load Voltage - Vehicles without Energy Management Control Module, Checking</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Measuring the no-load voltage, e.g. within the prescribed maintenance and service work on vehicles in storage, determines if the battery must be recharged --> Maintenance Tables.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00000696" name="S26980651482008020700000">Fig. 13: Portable Multimeter V.A.G 1526C</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Multimeter VAG 1526C , Multimeter Fluke 83 or equivalent (VAG tester illustrated here for reference only).</li> </ul> <p>To ensure correct measurements, follow prerequisites and procedure exactly as given:</p> <p><span class="clsEmphBOLD">Prerequisites</span> </p> <ul class="clsBULLET"> <li>If no-load voltage on battery installed in vehicle is measured, disconnect ground cable.</li> </ul> <ul class="clsBULLET"> <li>Battery must not be discharged by electrical consumers within 2 hours prior to measurement.</li> </ul> <ul class="clsBULLET"> <li>Battery must not be charged within 12 hours prior to measurement.</li> </ul> <ul class="clsBULLET"> <li>Battery temperature must be at least -10 C.</li> </ul> <p><span class="clsEmphBOLD">Procedure</span> </p> <ul class="clsDASH"> <li>Disconnect battery ground cable. --> <a class="clsExtHyperlink" id="A00278929_S42401837392008020700000">27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL</a> </li> </ul> <p>After a holding time of at least 12 hours:</p> <ul class="clsDASH"> <li>Use multimeter to measure voltage between battery terminals.</li> </ul> <ul class="clsBULLET"> <li>Specified value: 12.5 Volts or above = Battery OK.</li> </ul> <ul class="clsDASH"> <li>If no-load voltage is under 12.5 Volts, charge battery --> <span class="clsEmphBOLD">Battery, Charging with Midtronics Diagnostic Conductance Charging Station INC-940</span> .</li> </ul> <ul class="clsDASH"> <li>After charging for 5 minutes, perform load test --> <a class="clsHyperlink" href="#S25851475632008020700000">Battery, Load Testing with Midtronics Diagnostic Conductance Charging Station INC-940</a>.</li> </ul> <ul class="clsDASH"> <li>If battery no-load voltage is below 11.7 Volts, battery is severely discharged.</li> </ul> <ul class="clsDASH"> <li>If no-load voltage is OK, reconnect battery.</li> </ul> <ul class="clsDASH"> <li>Follow measures required after reconnecting battery. --> <a class="clsExtHyperlink" id="A00278929_S42401837392008020700000">27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL</a> </li> </ul><a name="S04514642112008020700000"></a><h2 class="clsHeadThree">Battery No-Load Voltage - Vehicles with Energy Management Control Module, Checking</h2><a name="S20619565792008020700000"></a><h2 class="clsHeadFour">Battery No-Load Voltage - Vehicles with Energy Management Control Module, Checking</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>No-load voltage measurement for assessment of battery condition is only appropriate if it is not possible to test battery with any of the VAS 505X class testers.</li> <li>Measuring the no-load voltage, e.g. within the prescribed maintenance and service work on vehicles in storage, determines if the battery must be recharged --> Maintenance Tables.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00000696" name="S11597374532008020700000">Fig. 14: Portable Multimeter V.A.G 1526C</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Multimeter VAG 1526C , Multimeter Fluke 83 or equivalent (VAG tester illustrated here for reference only).</li> </ul> <p>To ensure correct measurements, follow prerequisites and procedure exactly as given:</p> <p><span class="clsEmphBOLD">Prerequisites</span> </p> <ul class="clsBULLET"> <li>Battery remains installed in vehicle. DO NOT disconnect battery ground cable.</li> </ul> <ul class="clsBULLET"> <li>Open front hood or rear lid as appropriate for access to battery terminals.</li> </ul> <ul class="clsBULLET"> <li>Manually place rear lid lock in "Closed" position to prevent illumination of luggage compartment lamp</li> </ul> <ul class="clsBULLET"> <li>Manually close front hood switch where applicable to prevent activation of front hood alarm.</li> </ul> <ul class="clsBULLET"> <li>Lock vehicle with remote control.</li> </ul> <ul class="clsBULLET"> <li>Battery must not be discharged by electrical consumers within 2 hours prior to measurement.</li> </ul> <ul class="clsBULLET"> <li>Battery must not be charged within 12 hours prior to measurement.</li> </ul> <ul class="clsBULLET"> <li>Battery temperature must be at least -10 C.</li> </ul> <p><span class="clsEmphBOLD">Procedure</span> </p> <ul class="clsDASH"> <li>Perform any model-specific preparations necessary to gain access to battery terminals or battery jump-start terminals. --> <a class="clsExtHyperlink" id="A00278929_S42401837392008020700000">27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL</a> </li> </ul> <p>After a holding time of at least 2 hours:</p> <ul class="clsDASH"> <li>Use multimeter to measure voltage between battery terminals or between battery jump-start terminals as applicable.</li> </ul> <ul class="clsBULLET"> <li>Specified value: 12.5 Volts or above = Battery OK.</li> </ul> <ul class="clsDASH"> <li>If no-load voltage is under 12.5 Volts, charge battery --> <span class="clsEmphBOLD">Battery, Charging with Midtronics Diagnostic Conductance Charging Station INC-940</span> .</li> </ul> <ul class="clsDASH"> <li>After charging for 5 minutes, perform load test --> <a class="clsHyperlink" href="#S25851475632008020700000">Battery, Load Testing with Midtronics Diagnostic Conductance Charging Station INC-940</a>.</li> </ul> <ul class="clsDASH"> <li>If battery no-load voltage is below 11.7 Volts, battery is severely discharged.</li> </ul> <ul class="clsDASH"> <li>If no-load voltage is OK, reconnect battery.</li> </ul> <ul class="clsDASH"> <li>Follow measures required after reconnecting battery. --> <a class="clsExtHyperlink" id="A00278929_S42401837392008020700000">27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL</a> </li> </ul><a name="S25851475632008020700000"></a><h2 class="clsHeadThree">Battery, Load Testing with Midtronics Diagnostic Conductance Charging Station INC-940</h2><a name="S12027714692008020700000"></a><h2 class="clsHeadFour">Battery, Load Testing with Midtronics Diagnostic Conductance Charging Station INC-940</h2> <p>The Midtronics Diagnostic Conductance Charging Station INC-940 (also known as "inCHARGE 940" ) integrates battery conductance and load testing with charging.</p> <p>By checking a batterys current draw capacity during charging, a decision can be made as to whether a severely discharged battery --> <a class="clsHyperlink" href="#S26835291852008020700000">Totally Discharged Batteries, Charging</a> can be made usable again by recharging, or if it must be replaced.</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Risk of injury from battery acid.<ul class="clsBULLET"> <li>Prior to handling or servicing batteries, read, understand and observe the Warnings and Safety Measures for lead-acid batteries for lead-acid batteries --> <a class="clsHyperlink" href="#S28544342402008020700000">Safety Precautions</a> !</li> <li>Wear protective eyewear and clothing --> <a class="clsHyperlink" href="#S26316976462008020700000">27 - Battery, Starter, Generator, Cruise control</a> .</li> <li>On non-maintenance-free batteries, the sealing plugs must be installed tightly.</li> <li>Provide sufficient ventilation.</li> </ul> <ul class="clsBULLET"> <li>If the magic eye has no color or is light yellow, the battery may not be tested or charged. Jump starting must not be used! There is a risk of explosion during testing, charging or jump starting. The battery must be replaced.</li> <li>DO NOT battery test batteries which are gassing. Otherwise there is a risk of explosion.</li> <li>Rapid-charging batteries --> <a class="clsHyperlink" href="#S36202259322008020700000">Battery, Quick Charging</a>.</li> <li>Dispose of electrolyte (sulfuric acid/water mixture) properly! Waste electrolyte must only be disposed of in appropriate waste disposal sites. Refer to local regulations pertaining to electrolyte disposal.</li> </ul> <ul class="clsBULLET"> <li>The following notes and procedures must be followed to ensure correct measurements.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Risk of damaging AGM batteries.<ul class="clsBULLET"> <li>Specific charging procedures are required for AGM batteries.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00007554" name="S35681577962008020700000">Fig. 15: Battery charging unit VAS 5900</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Midtronics Diagnostic Conductance Charging Station INC-940 (VAS tester illustrated here for reference only)</li> </ul> <p><span class="clsEmphBOLD">Prerequisite</span> </p> <p>Battery temperature must be at least +10 C.</p> <p><span class="clsEmphBOLD">Procedure</span> </p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> <li>Refer to Midtronics Diagnostic Conductance Charging Station INC-940 Instruction Manual.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Perform any model-specific preparations necessary to gain access to battery terminals or battery jump-start terminals. --> <a class="clsExtHyperlink" id="A00278929_S42401837392008020700000">27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL</a> </li> </ul> <ul class="clsDASH"> <li>Connect tester cable clamps to battery terminals --> INC-940 Instruction Manual. Tester leads must be securely fastened and make proper contact with battery posts.</li> </ul> <ul class="clsDASH"> <li>Select charge mode "Automatic" --> INC-940 Instruction Manual</li> </ul> <ul class="clsDASH"> <li>Select test mode "IN-VEHICLE" or "OUT-OF-VEHICLE" as appropriate --> INC-940 Instruction Manual.</li> </ul> <ul class="clsDASH"> <li>Select battery type (AGM or conventional) --> INC-940 Instruction Manual</li> </ul> <ul class="clsDASH"> <li>Set tester to "Warranty Test" --> INC-940 Instruction Manual.</li> </ul> <ul class="clsDASH"> <li>Select battery DIN rating value as appropriate --> INC-940 Instruction Manual.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Use the "Generate Test Code" function of INC-940 in event test results are required for warranty claims.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Battery load test results:</span> </p> <p><span class="clsArticleTable"><a name="S120277146920080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1" width="198px"> <col span="1" id="COL2" width="198px"> </colgroup> <tbody> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Battery Tester Display / Printout</td> <td valign="TOP" align="LEFT" class="clsCellNormal">Required action</td> </tr> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">GOOD BATTERY</td> <td valign="TOP" align="LEFT" class="clsCellNormal">None (reinstall where necessary)</td> </tr> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">CHARGING REQUIRED</td> <td valign="TOP" align="LEFT" class="clsCellNormal">Analysis finds that the battery has a low state of charge. The inCHARGE 940 will display an approximate charge time and begin fast charging. The accumulated CCA (Cold Cranking Amps) and remaining charging time are displayed and updated at intervals.</td> </tr> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">REPLACE BATTERY</td> <td valign="TOP" align="LEFT" class="clsCellNormal">Replace battery. Electrical Equipment 27 Battery</td> </tr> </tbody> </table></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>If battery is replaced, follow disposal regulations --> <a class="clsHyperlink" href="#S26316976462008020700000">27 - Battery, Starter, Generator, Cruise control</a> .</li> </ul> </td> </tr> </table></span></p><a name="S36679846402008020700000"></a><h2 class="clsHeadTwo">Battery, Charging</h2><a name="S39327244292008020700000"></a><h2 class="clsHeadThree">Battery, Charging</h2><a name="S10887028592008020700000"></a><h2 class="clsHeadFour">Battery, Charging</h2> <p>--> <span class="clsEmphBOLD">Battery, Charging with Midtronics Diagnostic Conductance Charging Station INC-940</span> </p> <p>--> <a class="clsHyperlink" href="#S26835291852008020700000">Totally Discharged Batteries, Charging</a></p> <p>--> <a class="clsHyperlink" href="#S36202259322008020700000">Battery, Quick Charging</a></p> <p>--> <a class="clsHyperlink" href="#S41296336902008020700000">Battery, Support Mode with Midtronics Battery Maintainer PSC-550 or Midtronics Battery Maintainer CXC-2115</a></p><a name="S21867009152008020700000"></a><h2 class="clsHeadThree">Battery, Charging with Midtronics Diagnostic Conductance Charging Station INC-940</h2><a name="S00406930522008020700000"></a><h2 class="clsHeadFour">Battery, Charging with Midtronics Diagnostic Conductance Charging Station INC-940</h2> <p>The Midtronics Diagnostic Conductance Charging Station INC-940 (also known as "inCHARGE 940" ) integrates battery conductance and load testing with charging.</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Battery charger Midtronics Diagnostic Conductance Charging Station INC-940 charges without current and voltage peaks. Batteries can therefore be charged when installed. When doing this, heed all safety precautions.</li> <li>When performing electrical troubleshooting or otherwise working on the electrical system with consumers temporarily switched on, and for working with any of the VAS 505X class testers in operating mode "Guided Fault Finding" , the battery must be charged during these procedures with a battery maintainer in battery support mode to prevent damage to the battery --> <a class="clsHyperlink" href="#S41296336902008020700000">Battery, Support Mode with Midtronics Battery Maintainer PSC-550 or Midtronics Battery Maintainer CXC-2115</a>.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Risk of injury from battery acid.<ul class="clsBULLET"> <li>Prior to handling or servicing batteries, read, understand and observe the Warnings and Safety Measures for lead-acid batteries for lead-acid batteries --> <a class="clsHyperlink" href="#S28544342402008020700000">Safety Precautions</a> !</li> <li>Wear protective eyewear and clothing --> <a class="clsHyperlink" href="#S26316976462008020700000">27 - Battery, Starter, Generator, Cruise control</a> .</li> <li>On non-maintenance-free batteries, the sealing plugs must be installed tightly.</li> <li>Provide sufficient ventilation.</li> </ul> <ul class="clsBULLET"> <li>If the magic eye has no color or is light yellow, the battery may not be tested or charged. Jump starting must not be used! There is a risk of explosion during testing, charging or jump starting. The battery must be replaced.</li> <li>DO NOT battery test batteries which are gassing. Otherwise there is a risk of explosion.</li> <li>Rapid-charging batteries --> <a class="clsHyperlink" href="#S36202259322008020700000">Battery, Quick Charging</a>.</li> <li>Dispose of electrolyte (sulfuric acid/water mixture) properly! Waste electrolyte must only be disposed of in appropriate waste disposal sites. Refer to local regulations pertaining to electrolyte disposal.</li> </ul> <ul class="clsBULLET"> <li>The following notes and procedures must be followed to ensure correct charging.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Risk of damaging AGM batteries.<ul class="clsBULLET"> <li>Specific charging procedures are required for AGM batteries.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00007554" name="S31433755472008020700000">Fig. 16: Battery charging unit VAS 5900</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Midtronics Diagnostic Conductance Charging Station INC-940 (VAS tester illustrated here for reference only)</li> </ul> <p><span class="clsEmphBOLD">Prerequisite</span> </p> <p>Battery temperature must be at least +10 C.</p> <p><span class="clsEmphBOLD">Procedure</span> </p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> <li>Refer to Midtronics Diagnostic Conductance Charging Station INC-940 Instruction Manual.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Perform any model-specific preparations necessary to gain access to battery terminals or battery jump-start terminals. --> <a class="clsExtHyperlink" id="A00278929_S42401837392008020700000">27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL</a> </li> </ul> <ul class="clsDASH"> <li>Connect tester cable clamps to battery terminals or battery jump-start terminals --> INC-940 Instruction Manual. Tester leads must be securely fastened and make proper contact with battery posts or jumper terminals.</li> </ul> <ul class="clsDASH"> <li>Select charge mode "Automatic" or "Manual" --> INC-940 Instruction Manual</li> </ul> <ul class="clsDASH"> <li>Select test mode "IN-VEHICLE" or "OUT-OF-VEHICLE" as appropriate --> INC-940 Instruction Manual.</li> </ul> <ul class="clsDASH"> <li>Select battery type (AGM or conventional) --> INC-940 Instruction Manual</li> </ul> <ul class="clsDASH"> <li>Set tester to "Warranty Test" --> INC-940 Instruction Manual.</li> </ul> <ul class="clsDASH"> <li>Select battery DIN rating value as appropriate --> INC-940 Instruction Manual.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Use the "Generate Test Code" function of INC-940 (available in "Automatic" mode only) in event test results are required for warranty claims.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>When the battery is completely charged --> MCR340A Instruction Manual</li> </ul> <ul class="clsDASH"> <li>Disconnect battery charger clamps.</li> </ul><a name="S26835291852008020700000"></a><h2 class="clsHeadThree">Totally Discharged Batteries, Charging</h2><a name="S39669111362008020700000"></a><h2 class="clsHeadFour">Totally Discharged Batteries, Charging</h2> <ul class="clsBULLET"> <li>Batteries which have not been used for lengthy periods, e.g. in vehicles which have not been driven, are subject to self-discharge.</li> </ul> <ul class="clsBULLET"> <li>Batteries are considered to be severely discharged if open-circuit voltage drops below 11.6 V. With voltage between 12.2 and 11.6 V, the battery is pre-damaged. Measure no-load voltage:</li> </ul> <ul class="clsBULLET"> <li>Vehicles without Energy Management Control Module J644 --> <span class="clsEmphBOLD">Battery No-Load Voltage - Vehicles without Energy Management Control Module, Checking</span> .</li> </ul> <ul class="clsBULLET"> <li>Vehicles with Energy Management Control Module J644 --> <a class="clsHyperlink" href="#S04514642112008020700000">Battery No-Load Voltage - Vehicles with Energy Management Control Module, Checking</a>.</li> </ul> <ul class="clsBULLET"> <li>With severely discharged batteries, the electrolyte (mixture of sulfuric acid and water) is mostly water, with a greatly reduced sulfuric acid content.</li> </ul> <ul class="clsBULLET"> <li>Severely discharged batteries become sulfated, i.e. all the plate surfaces of such batteries become hardened. Instead of being transparent, the electrolyte has a slightly milky appearance.</li> </ul> <ul class="clsBULLET"> <li>The sulfating process may be reversed if a severely discharged battery is recharged immediately.</li> </ul> <ul class="clsBULLET"> <li>If battery is not recharged, plates will continue to harden, and ability to accept a charge will diminish. This results in reduction of battery performance.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Risk of injury from battery acid.<ul class="clsBULLET"> <li>Prior to handling or servicing batteries, read, understand and observe the Warnings and Safety Measures for lead-acid batteries for lead-acid batteries --> <a class="clsHyperlink" href="#S28544342402008020700000">Safety Precautions</a> !</li> <li>Wear protective eyewear and clothing --> <a class="clsHyperlink" href="#S26316976462008020700000">27 - Battery, Starter, Generator, Cruise control</a> .</li> <li>On non-maintenance-free batteries, the sealing plugs must be installed tightly.</li> <li>Provide sufficient ventilation.</li> </ul> <ul class="clsBULLET"> <li>If the magic eye has no color or is light yellow, the battery may not be tested or charged. Jump starting must not be used! There is a risk of explosion during testing, charging or jump starting. The battery must be replaced.</li> <li>DO NOT battery test batteries which are gassing. Otherwise there is a risk of explosion.</li> <li>Rapid-charging batteries --> <a class="clsHyperlink" href="#S36202259322008020700000">Battery, Quick Charging</a>.</li> <li>Dispose of electrolyte (sulfuric acid/water mixture) properly! Waste electrolyte must only be disposed of in appropriate waste disposal sites. Refer to local regulations pertaining to electrolyte disposal.</li> </ul> <ul class="clsBULLET"> <li>The following notes and procedures must be followed to ensure correct charging.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Risk of severely discharged batteries freezing.<ul class="clsBULLET"> <li>Severely discharged batteries freeze at low temperatures, the housing can crack.</li> <li>Batteries that have frozen must no longer be used.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Prerequisite</span> </p> <ul class="clsBULLET"> <li>Battery temperature must be at least +10 C.</li> </ul> <p><span class="clsEmphBOLD">Procedure</span> </p> <p>Severely discharged (sulfated) batteries must be charged using a low charging current:</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>The Midtronics Diagnostic Conductance Charging Station INC-940 automatically detects severely discharged batteries and carefully starts the charging procedure with a low charging current. The charge current is automatically adjusted to the battery charge state.</li> <li>In order to initiate charging procedure, battery voltage must be at least 0.6 V!</li> </ul> </td> </tr> </table></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Risk of damaging severely discharged batteries.<ul class="clsBULLET"> <li>Do not quick charge severely discharged batteries.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Charge battery --> <span class="clsEmphBOLD">Battery, Charging with Midtronics Diagnostic Conductance Charging Station INC-940</span> .</li> </ul> <ul class="clsBULLET"> <li>The charging voltage may be a maximum of 14.4 V.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>If battery is replaced, follow disposal regulations --> <a class="clsHyperlink" href="#S26316976462008020700000">27 - Battery, Starter, Generator, Cruise control</a> .</li> </ul> </td> </tr> </table></span></p><a name="S36202259322008020700000"></a><h2 class="clsHeadThree">Battery, Quick Charging</h2><a name="S14387491782008020700000"></a><h2 class="clsHeadFour">Battery, Quick Charging</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Risk of injury from battery acid.<ul class="clsBULLET"> <li>Prior to handling or servicing batteries, read, understand and observe the Warnings and Safety Measures for lead-acid batteries for lead-acid batteries --> <a class="clsHyperlink" href="#S28544342402008020700000">Safety Precautions</a> !</li> <li>Wear protective eyewear and clothing --> <a class="clsHyperlink" href="#S26316976462008020700000">27 - Battery, Starter, Generator, Cruise control</a> .</li> <li>On non-maintenance-free batteries, the sealing plugs must be installed tightly.</li> <li>Provide sufficient ventilation.</li> </ul> <ul class="clsBULLET"> <li>If the magic eye has no color or is light yellow, the battery may not be tested or charged. Jump starting must not be used! There is a risk of explosion during testing, charging or jump starting. The battery must be replaced.</li> <li>DO NOT battery test batteries which are gassing. Otherwise there is a risk of explosion.</li> <li>Rapid-charging batteries --> <a class="clsHyperlink" href="#S36202259322008020700000">Battery, Quick Charging</a>.</li> <li>Dispose of electrolyte (sulfuric acid/water mixture) properly! Waste electrolyte must only be disposed of in appropriate waste disposal sites. Refer to local regulations pertaining to electrolyte disposal.</li> </ul> <ul class="clsBULLET"> <li>The following notes and procedures must be followed to ensure correct charging.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Prerequisite</span> </p> <ul class="clsBULLET"> <li>Battery temperature must be at least +10 C.</li> </ul> <p><span class="clsEmphBOLD">Procedure</span> </p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Risk of damaging the battery and vehicle electronic components.<ul class="clsBULLET"> <li>DO NOT quick charge AGM batteries!</li> <li>Batteries in vehicles with Energy Management Control Module J644 must not be quick charged.</li> <li>Do not quick charge severely discharged batteries.</li> <li>Quick charging of batteries should only be performed in exceptional circumstances (e.g. boost starting) as Quick charging may cause damage.</li> </ul> <ul class="clsBULLET"> <li>Battery must not be connected to vehicle electrical system when performing Quick charging. Disconnect the positive and negative cables from battery terminals. Refer to applicable model <a class="clsExtHyperlink" id="A00278929_S42401837392008020700000">27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL</a> .</li> <li>Do not exceed maximum charging voltage of 14.8 Volts.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>If battery is replaced, follow disposal regulations --> <a class="clsHyperlink" href="#S26316976462008020700000">27 - Battery, Starter, Generator, Cruise control</a> .</li> </ul> </td> </tr> </table></span></p><a name="S41296336902008020700000"></a><h2 class="clsHeadThree">Battery, Support Mode with Midtronics Battery Maintainer PSC-550 or Midtronics Battery Maintainer CXC-2115</h2><a name="S00771596192008020700000"></a><h2 class="clsHeadFour">Battery, Support Mode with Midtronics Battery Maintainer PSC-550 or Midtronics Battery Maintainer CXC-2115</h2> <p>During electrical troubleshooting or otherwise working on the electrical system where consumers are temporarily switched on, and for working with any of the VAS 505X class testers in operating mode "Guided Fault Finding" and during software flashing, battery voltage must be must maintained. Use Midtronics Battery Maintainer PSC-550 to prevent excessive battery discharge during servicing as described above.</p> <p>Where it is necessary to maintain battery charge in showroom vehicles for demonstration of electrical features, use Midtronics Battery Maintainer CXC-2115.</p> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <ul class="clsBULLET"> <li>Midtronics Battery Maintainer PSC 550 or</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00007552" name="S28039447612008020700000">Fig. 17: Battery charging unit VAS 5095 A</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Midtronics Battery Maintainer CXC-2115 (VAS charger illustrated here for reference only)</li> </ul> <p><span class="clsEmphBOLD">Procedure</span> </p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off all electrical consumers.</li> <li>Switch ignition off and remove ignition key.</li> <li>Depending on use for temporary power supply or voltage maintainer for showroom use, refer to Midtronics Battery Maintainer PSC 550 or Midtronics Battery Maintainer CXC-2115 Instruction Manuals as necessary.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Perform any model-specific preparations necessary to gain access to battery terminals or battery jump-start terminals. --> <a class="clsExtHyperlink" id="A00278929_S42401837392008020700000">27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL</a> or model specific --> Service Circulars.</li> </ul> <ul class="clsDASH"> <li>Connect battery maintainer cable clamps to battery terminals or battery jump-start terminals as applicable --> PSC 550 or CXC-2115 Instruction Manual. Tester leads must be securely fastened and make proper contact with battery posts or jumper terminals.</li> </ul> <ul class="clsDASH"> <li>Plug battery maintainer into 120V AC supply to initiate charging --> PSC 550 or CXC-2115 Instruction Manual.</li> </ul><a name="S29649821322008020700000"></a><h2 class="clsHeadTwo">Generator, Testing and Servicing</h2><a name="S40071029582008020700000"></a><h2 class="clsHeadThree">Generator, Testing and Servicing</h2> <p>--> <a class="clsHyperlink" href="#S28379245772008020700000">Generator, Testing</a></p> <p>--> <a class="clsHyperlink" href="#S01129567542008020700000">Bosch Generator, through MY 2000, Assembly Overview</a></p> <p>--> <a class="clsHyperlink" href="#S15452912482008020700000">Bosch Generator, from MY 2001, Assembly Overview</a></p> <p>--> <a class="clsHyperlink" href="#S06548951962008020700000">Voltage Regulator, Bosch Generator from MY 2001, Removing and Installing</a></p> <p>--> <a class="clsHyperlink" href="#S02311425942008020700000">Carbon Brushes, Bosch Generator from MY 2001, Checking</a></p> <p>--> <a class="clsHyperlink" href="#S04052071952008020700000">Valeo Generator, through MY 2000, Assembly Overview</a></p> <p>--> <a class="clsHyperlink" href="#S02341203882008020700000">Valeo Generator, from MY 2001, Assembly Overview</a></p> <p>--> <a class="clsHyperlink" href="#S31589437672008020700000">Voltage Regulator, Valeo Generator from MY 2001, Removing and Installing</a></p> <p>--> <a class="clsHyperlink" href="#S10941087842008020700000">Carbon Brushes, Valeo Generator from MY 2001, Checking</a></p> <p>--> <a class="clsHyperlink" href="#S00636375882008020700000">Ribbed Belt Pulley without Freewheel, Removing and Installing</a></p> <p>--> <a class="clsHyperlink" href="#S08862411102008020700000">Ribbed Belt Pulley with Freewheel, Removing and Installing</a></p><a name="S28379245772008020700000"></a><h2 class="clsHeadThree">Generator, Testing</h2><a name="S23669893712008020700000"></a><h2 class="clsHeadFour">Generator, Testing</h2> <ul class="clsDASH"> <li>Test generator using Vehicle Diagnosis, Testing info. System VAS 5051B (or other VAS 505X class tester) in operating mode "Guided Fault Finding".</li> </ul> <ul class="clsDASH"> <li>Connect tester --> <a class="clsHyperlink" href="#S11317004502008020700000">Vehicle Diagnosis, Testing and Information System VAS 5051B, Connecting</a></li> </ul> <p>After tester has established communication with vehicle and interrogated all vehicle systems</p> <ul class="clsDASH"> <li>Select operating mode "Guided Fault Finding"</li> </ul> <ul class="clsDASH"> <li>Press Go to button</li> </ul> <ul class="clsDASH"> <li>Select "Function / Component Selection"</li> </ul> <ul class="clsDASH"> <li>Select "Electrical equipment (<a class="clsExtHyperlink" id="A00278929_S42401837392008020700000">27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL</a> </li> </ul> <ul class="clsDASH"> <li>Select "27 - Battery, Starter, Generator, Cruise Control"</li> </ul> <ul class="clsDASH"> <li>Select "Electrical components"</li> </ul> <ul class="clsDASH"> <li>Select "C - Generator (GEN), testing (RG 27)"</li> </ul> <ul class="clsDASH"> <li>Follow testers prompts</li> </ul><a name="S01129567542008020700000"></a><h2 class="clsHeadThree">Bosch Generator, through MY 2000, Assembly Overview</h2><a name="S03140780982008020700000"></a><h2 class="clsHeadFour">Bosch Generator, through MY 2000, Assembly Overview</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017024" name="S05369255792008020700000">Fig. 18: Bosch Generator, Through MY 2000, Assembly Overview</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Screws</p> <ul class="clsBULLET"> <li>1 Nm</li> </ul> <p>2 - Cover</p> <ul class="clsBULLET"> <li>with 3 retaining tabs</li> </ul> <p>3 - Screws</p> <ul class="clsBULLET"> <li>2 Nm</li> </ul> <p>4 - Voltage Regulator (VR)</p> <ul class="clsBULLET"> <li><span class="clsEmphBOLD">Removing:</span> </li> </ul> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">1</span> - and remove protective cap - <span class="clsEmphBOLD">2</span> -.</li> </ul> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">3</span> - and remove voltage regulator.</li> </ul> <ul class="clsBULLET"> <li>Carbon brush wear limit: 5 mm</li> </ul> <p>5 - Generator (GEN)</p><a name="S15452912482008020700000"></a><h2 class="clsHeadThree">Bosch Generator, from MY 2001, Assembly Overview</h2><a name="S06064690622008020700000"></a><h2 class="clsHeadFour">Bosch Generator, from MY 2001, Assembly Overview</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>The new generators are installed as a running change.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017187" name="S17465088352008020700000">Fig. 19: Bosch Generator, From MY 2001, Assembly Overview</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>1 - Generator (GEN)</p> <p>2 - Voltage Regulator (VR)</p> <ul class="clsBULLET"> <li>Removing and installing --> <a class="clsHyperlink" href="#S06548951962008020700000">Voltage Regulator, Bosch Generator from MY 2001, Removing and Installing</a></li> </ul> <ul class="clsBULLET"> <li>Carbon brushes, checking --> <a class="clsHyperlink" href="#S02311425942008020700000">Carbon Brushes, Bosch Generator from MY 2001, Checking</a></li> </ul> <p>3 - Screw</p> <ul class="clsBULLET"> <li>2.5 Nm</li> </ul> <p>4 - Cover</p> <p>5 - Nut</p> <ul class="clsBULLET"> <li>12 Nm</li> </ul> <p>6 - Nut</p> <ul class="clsBULLET"> <li>30 Nm</li> </ul> <p>7 - Screw</p> <ul class="clsBULLET"> <li>3 Nm</li> </ul> <p>8 - Screw</p> <ul class="clsBULLET"> <li>1.5 Nm</li> </ul><a name="S06548951962008020700000"></a><h2 class="clsHeadThree">Voltage Regulator, Bosch Generator from MY 2001, Removing and Installing</h2><a name="S35817610422008020700000"></a><h2 class="clsHeadFour">Voltage Regulator, Bosch Generator from MY 2001, Removing and Installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017188" name="S07527413442008020700000">Fig. 20: Generator Cover And Screws</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove generator --> <a class="clsExtHyperlink" id="A00278929_S42401837392008020700000">27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL</a> .</li> </ul> <ul class="clsDASH"> <li>Remove screw - <span class="clsEmphBOLD">1</span> - and nuts - <span class="clsEmphBOLD">3</span> - and - <span class="clsEmphBOLD">4</span> -.</li> </ul> <ul class="clsDASH"> <li>Remove cover - <span class="clsEmphBOLD">2</span> - at rear side of generator.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017189" name="S14610350252008020700000">Fig. 21: Voltage Regulator Screws</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> <ul class="clsDASH"> <li>Remove voltage regulator.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <ul class="clsDASH"> <li>When positioning voltage regulator, ensure carbon brushes rest correctly on slides.</li> </ul> <p>Further installation is in reverse order of removal.</p> <ul class="clsBULLET"> <li>Tightening torque --> <a class="clsHyperlink" href="#S15452912482008020700000">Bosch Generator, from MY 2001, Assembly Overview</a>.</li> </ul><a name="S02311425942008020700000"></a><h2 class="clsHeadThree">Carbon Brushes, Bosch Generator from MY 2001, Checking</h2><a name="S36673719202008020700000"></a><h2 class="clsHeadFour">Carbon Brushes, Bosch Generator from MY 2001, Checking</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017190" name="S19361342742008020700000">Fig. 22: Carbon Brushes Wear Limit</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Procedure</span> </p> <ul class="clsDASH"> <li>Remove voltage regulator --> <a class="clsHyperlink" href="#S06548951962008020700000">Voltage Regulator, Bosch Generator from MY 2001, Removing and Installing</a>.</li> </ul> <ul class="clsDASH"> <li>Check carbon brushes for length - <span class="clsEmphBOLD">a</span> -.</li> </ul> <ul class="clsBULLET"> <li>Wear limit: - <span class="clsEmphBOLD">a</span> - = 5 mm.</li> </ul><a name="S04052071952008020700000"></a><h2 class="clsHeadThree">Valeo Generator, through MY 2000, Assembly Overview</h2><a name="S24514225182008020700000"></a><h2 class="clsHeadFour">Valeo Generator, through MY 2000, Assembly Overview</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017025" name="S02166111062008020700000">Fig. 23: Valeo Generator, Through MY 2000, Assembly Overview</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">1 - Generator (GEN)</span> </p> <p><span class="clsEmphBOLD">2 - Voltage Regulator (VR)</span> </p> <ul class="clsBULLET"> <li><span class="clsEmphBOLD">Removing:</span> </li> </ul> <ul class="clsDASH"> <li>Remove nuts - <span class="clsEmphBOLD">5</span> - and cover - <span class="clsEmphBOLD">4</span> -.</li> </ul> <ul class="clsDASH"> <li>Remove screw - <span class="clsEmphBOLD">6</span> - and nuts - <span class="clsEmphBOLD">7</span> - and remove voltage regulator.</li> </ul> <ul class="clsBULLET"> <li>Carbon brush wear limit: 5 mm</li> </ul> <p><span class="clsEmphBOLD">3 - Protective cap</span> </p> <p><span class="clsEmphBOLD">4 - Cover</span> </p> <p><span class="clsEmphBOLD">5 - Nut</span> </p> <ul class="clsBULLET"> <li>2 Nm</li> </ul> <p><span class="clsEmphBOLD">6 - Screw</span> </p> <ul class="clsBULLET"> <li>2 Nm</li> </ul> <p><span class="clsEmphBOLD">7 - Nut</span> </p> <ul class="clsBULLET"> <li>Qty. 2</li> </ul> <ul class="clsBULLET"> <li>3.5 Nm</li> </ul><a name="S02341203882008020700000"></a><h2 class="clsHeadThree">Valeo Generator, from MY 2001, Assembly Overview</h2><a name="S23339345802008020700000"></a><h2 class="clsHeadFour">Valeo Generator, from MY 2001, Assembly Overview</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>The new generators are installed as a running change.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017191" name="S36804903102008020700000">Fig. 24: Valeo Generator, From MY 2001, Assembly Overview</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">1 - Generator (GEN)</span> </p> <p><span class="clsEmphBOLD">2 - Voltage Regulator (VR)</span> </p> <ul class="clsBULLET"> <li>Removing and installing --> <a class="clsHyperlink" href="#S31589437672008020700000">Voltage Regulator, Valeo Generator from MY 2001, Removing and Installing</a></li> </ul> <ul class="clsBULLET"> <li>Carbon brushes, checking --> <a class="clsHyperlink" href="#S10941087842008020700000">Carbon Brushes, Valeo Generator from MY 2001, Checking</a></li> </ul> <p><span class="clsEmphBOLD">3 - Screw</span> </p> <ul class="clsBULLET"> <li>2 Nm</li> </ul> <p><span class="clsEmphBOLD">4 - Cover</span> </p> <p><span class="clsEmphBOLD">5 - Protective cap</span> </p> <p><span class="clsEmphBOLD">6 - Screw</span> </p> <ul class="clsBULLET"> <li>2 Nm</li> </ul><a name="S31589437672008020700000"></a><h2 class="clsHeadThree">Voltage Regulator, Valeo Generator from MY 2001, Removing and Installing</h2><a name="S03691930352008020700000"></a><h2 class="clsHeadFour">Voltage Regulator, Valeo Generator from MY 2001, Removing and Installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017192" name="S33135733392008020700000">Fig. 25: Identifying Cover And Threaded Pins At Rear Side Of Generator</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove generator --> <a class="clsExtHyperlink" id="A00278929_S42401837392008020700000">27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL</a> .</li> </ul> <ul class="clsDASH"> <li>Press out cover from threaded pins at rear side of generator - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017193" name="S37406208312008020700000">Fig. 26: Generator Bolts And Combination Bolt</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove bolts - <span class="clsEmphBOLD">1</span> - and combination bolt - <span class="clsEmphBOLD">2</span> -.</li> </ul> <ul class="clsDASH"> <li>Remove voltage regulator.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017194" name="S23912532492008020700000">Fig. 27: Voltage Regulator And Protective Cap</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Installing</span> </p> <ul class="clsDASH"> <li>Press off protective cap - <span class="clsEmphBOLD">2</span> - from voltage regulator - <span class="clsEmphBOLD">1</span> - in - <span class="clsEmphBOLD">direction of arrow</span> -.</li> </ul> <ul class="clsDASH"> <li>When positioning voltage regulator, ensure carbon brushes rest correctly on slides.</li> </ul> <ul class="clsDASH"> <li>Attach protective cap with voltage regulator installed.</li> </ul> <p>Further installation is in reverse order of removal.</p> <ul class="clsBULLET"> <li>Tightening torque --> <a class="clsHyperlink" href="#S02341203882008020700000">Valeo Generator, from MY 2001, Assembly Overview</a>.</li> </ul><a name="S10941087842008020700000"></a><h2 class="clsHeadThree">Carbon Brushes, Valeo Generator from MY 2001, Checking</h2><a name="S34500337612008020700000"></a><h2 class="clsHeadFour">Carbon Brushes, Valeo Generator from MY 2001, Checking</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017195" name="S22734981902008020700000">Fig. 28: Carbon Brushes, Valeo Generator From MY 2001, Checking</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Procedure</span> </p> <ul class="clsDASH"> <li>Remove voltage regulator --> <a class="clsHyperlink" href="#S31589437672008020700000">Voltage Regulator, Valeo Generator from MY 2001, Removing and Installing</a>.</li> </ul> <ul class="clsDASH"> <li>Check carbon brushes for length - <span class="clsEmphBOLD">a</span> -.</li> </ul> <ul class="clsBULLET"> <li>Wear limit: - <span class="clsEmphBOLD">a</span> - = 5 mm.</li> </ul><a name="S00636375882008020700000"></a><h2 class="clsHeadThree">Ribbed Belt Pulley without Freewheel, Removing and Installing</h2><a name="S25555468922008020700000"></a><h2 class="clsHeadFour">Ribbed Belt Pulley without Freewheel, Removing and Installing</h2> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004139" name="S27597009522008020700000">Fig. 29: Identifying Multi-Point Socket 3310</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Socket 3310</li> </ul> <ul class="clsBULLET"> <li>8 mm hex socket or TORX T50</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004140" name="S36510938722008020700000">Fig. 30: Loosen/Tighten Nut At Pulley With Wrench And Adapter 3310</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove generator --> <a class="clsExtHyperlink" id="A00278929_S42401837392008020700000">27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL</a> .</li> </ul> <ul class="clsDASH"> <li>If present, press the protective cap off the generator pulley.</li> </ul> <ul class="clsDASH"> <li>Counterhold mounting nut using socket 3310 and rotate generator shaft clockwise to loosen it.</li> </ul> <ul class="clsDASH"> <li>Remove ribbed belt pulley.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, observing the following:</p> <ul class="clsDASH"> <li>Turn the generator shaft counterclockwise to tighten.</li> </ul> <ul class="clsDASH"> <li>Clip protective cap onto generator pulley.</li> </ul> <p>Tightening torque</p> <p><span class="clsArticleTable"><a name="S255554689220080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1" width="198px"> <col span="1" id="COL2" width="198px"> </colgroup> <tbody> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Component</td> <td valign="TOP" align="LEFT" class="clsCellNormal">Nm</td> </tr> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Ribbed belt pulley to generator</td> <td valign="TOP" align="LEFT" class="clsCellNormal">65</td> </tr> </tbody> </table></span></p><a name="S08862411102008020700000"></a><h2 class="clsHeadThree">Ribbed Belt Pulley with Freewheel, Removing and Installing</h2><a name="S36020410992008020700000"></a><h2 class="clsHeadFour">Ribbed Belt Pulley with Freewheel, Removing and Installing</h2> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004141" name="S09019772312008020700000">Fig. 31: Identifying Multi-Point Socket 3400</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Multi-point adapter 3400</li> </ul> <ul class="clsBULLET"> <li>8 mm hex socket or TORX T50</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004143" name="S31864757952008020700000">Fig. 32: Tightening/Loosening Nut At Pulley With Wrench And Adapter 3400</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Remove generator --> <a class="clsExtHyperlink" id="A00278929_S42401837392008020700000">27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL</a> .</li> </ul> <ul class="clsDASH"> <li>If present, press the protective cap off the generator pulley.</li> </ul> <ul class="clsDASH"> <li>Counter pulley with Multi-Tooth Adapter 3400 and turn generator shaft clockwise to loosen.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, observing the following:</p> <ul class="clsDASH"> <li>Turn the generator shaft counterclockwise to tighten.</li> </ul> <ul class="clsDASH"> <li>Clip protective cap onto generator pulley.</li> </ul> <p>Tightening torque</p> <p><span class="clsArticleTable"><a name="S360204109920080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1" width="198px"> <col span="1" id="COL2" width="198px"> </colgroup> <tbody> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Component</td> <td valign="TOP" align="LEFT" class="clsCellNormal">Nm</td> </tr> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Ribbed belt pulley with freewheel to generator</td> <td valign="TOP" align="LEFT" class="clsCellNormal">80</td> </tr> </tbody> </table></span></p><a name="S05993110662008020700000"></a><h2 class="clsHeadTwo">Cruise Control System, with Electronic Power Control</h2><a name="S09859986702008020700000"></a><h2 class="clsHeadThree">Cruise Control System, with Electronic Power Control</h2> <p>--> <a class="clsHyperlink" href="#S15513737552008020700000">General Information</a></p> <p>--> <a class="clsHyperlink" href="#S00120491322008020700000">Cruise Control System, Activating and Deactivating</a></p><a name="S06234905172008020700000"></a><h2 class="clsHeadThree">General Information</h2><a name="S38995546712008020700000"></a><h2 class="clsHeadFour">General Information</h2> <p>All cruise control system functions are controlled by the applicable Engine Control Module (ECM). The processing of electronic engine controls and cruise control functions are integrated in the ECM. Other than the cruise control switches on the steering column/multifunction steering wheel, the clutch and brake pedal switches and related wiring, there are no separate cruise control components to be serviced.</p> <p>As all electronic throttle control (EPC) operations are monitored by On Board Diagnostic (OBD), Diagnostic Trouble Codes (DTC) pertaining to engine electronics that are stored in DTC memory may be relevant to cruise control function. Always check DTC memory first before troubleshooting.</p> <p>All CCS troubleshooting and OBD program functions are performed using the Vehicle Diagnosis, Testing info. System VAS 5051B (or other VAS 505X class tester) in operating mode "Guided Fault Finding" or "Vehicle Self Diagnosis".</p><a name="S00120491322008020700000"></a><h2 class="clsHeadThree">Cruise Control System, Activating and Deactivating</h2><a name="S11431243582008020700000"></a><h2 class="clsHeadFour">Cruise Control System, Activating and Deactivating</h2> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <ul class="clsBULLET"> <li>e.g. Vehicle Diagnosis, Testing and Information System VAS 5051B (or any of the VAS 505X class testers) with diagnostic cable</li> </ul> <p><span class="clsEmphBOLD">Procedure</span> </p> <ul class="clsDASH"> <li>Connect Vehicle Diagnosis, Testing and Information System VAS 5051B --> <a class="clsHyperlink" href="#S11317004502008020700000">Vehicle Diagnosis, Testing and Information System VAS 5051B, Connecting</a>.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>If an error message appears on the display --> , VAS 5051B operating instructions.</li> <li>Press Guided Functions button on operating mode selection screen.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00015769" name="S25713471522008020700000">Fig. 33: Display On VAS 5051 - (1st Control Element In Test & Evaporative Emission (EVAP) Canister Purge Regulator Valve-N80-)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>Display:</p> <ul class="clsDASH"> <li>Enter vehicle identification number (VIN) in field - <span class="clsEmphBOLD">1</span> - in selection - <span class="clsEmphBOLD">A</span> -.</li> </ul> <p>The Vehicle Diagnosis, Testing and Information System VAS 5051B then switches to the next selection level. The following example shows how vehicle type, engine and vehicle system of function could be selected (some steps may be skipped):</p> <p><span class="clsEmphBOLD">The following information is given as an example only. Always enter required information as it pertains to vehicle being serviced.</span> </p> <p><span class="clsArticleTable"><a name="S114312435820080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1" width="198px"> <col span="1" id="COL2" width="198px"> </colgroup> <tbody> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Selection</td> <td valign="TOP" align="LEFT" class="clsCellNormal">Text lines to be selected</td> </tr> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Select brand</td> <td valign="TOP" align="LEFT" class="clsCellNormal">Audi</td> </tr> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Select model (example)</td> <td valign="TOP" align="LEFT" class="clsCellNormal">Audi A3 2004 ></td> </tr> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Select model year (example)</td> <td valign="TOP" align="LEFT" class="clsCellNormal">2006 (6)</td> </tr> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Select version (example)</td> <td valign="TOP" align="LEFT" class="clsCellNormal">5-door vehicles</td> </tr> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Select engine code (example)</td> <td valign="TOP" align="LEFT" class="clsCellNormal">BAG 1.6L FSI / 85 kW</td> </tr> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">If vehicle identification was performed correctly, then press button to confirm</td> <td valign="TOP" align="LEFT" class="clsCellNormal"> </td> </tr> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Select vehicle system or function</td> <td valign="TOP" align="LEFT" class="clsCellNormal">01 - Engine electronics</td> </tr> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Select vehicle system or function</td> <td valign="TOP" align="LEFT" class="clsCellNormal">J220 - Cruise control, activating or deactivating</td> </tr> </tbody> </table></span></p> <ul class="clsDASH"> <li>Follow VAS 5051B instructions and prompts.</li> </ul> <p>After successful activation/deactivation:</p> <ul class="clsDASH"> <li>Tap button Go to.</li> </ul> <ul class="clsDASH"> <li>Select function "Exit".</li> </ul> <ul class="clsDASH"> <li>Switch ignition off and disconnect tester from Data Link Connector (DLC).</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>If it is not possible to activate/deactivate the CCS using "Guided Fault Finding" , e.g.: with older Engine Control Module (ECM) generations, CCS function (or lack of CCS function) are hard-programmed into the ECM version. In these cases, ECMs with and without CCS function are identified via different ECM part numbers.</li> </ul> </td> </tr> </table></span></p><a name="S09145933212008020700000"></a><h2 class="clsHeadOne">92 - Windshield wiper and washer system</h2><a name="S31023115862008020700000"></a><h2 class="clsHeadTwo">Washer Hose Couplings</h2> <p><span class="clsEmphBOLD">Disconnecting and Connecting</span> </p> <p>The following hose coupling types are used for connecting hoses to pumps and washer nozzles or as separating points.</p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004276" name="S02066153972008020700000">Fig. 34: Identifying Washer Hose Coupling</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>Unsecured hose coupling</p> <ul class="clsDASH"> <li>Disconnect by pulling apart both parts of coupling.</li> </ul> <ul class="clsDASH"> <li>Reconnect by pushing both halves of coupling together until felt and heard to engage.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004277" name="S28342345672008020700000">Fig. 35: Connecting/Disconnecting Washer Hose Coupling (Type 1)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Secured hose coupling with circlip</span> </p> <ul class="clsDASH"> <li>Disconnect by turning lock ring - <span class="clsEmphBOLD">1</span> - through 90 - <span class="clsEmphBOLD">arrow</span> - and then pulling apart both halves of coupling.</li> </ul> <ul class="clsDASH"> <li>Reconnect by pushing both halves of coupling together and rotating locking ring - <span class="clsEmphBOLD">1</span> - - <span class="clsEmphBOLD">arrow</span> - until it engages.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004278" name="S24575166672008020700000">Fig. 36: Connecting/Disconnecting Washer Hose Coupling (Type 2)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Secured hose coupling with circlip, version 1</span> </p> <ul class="clsDASH"> <li>To disconnect the connection, pull the circlip - <span class="clsEmphBOLD">1</span> - up approximately 1 mm - <span class="clsEmphBOLD">arrow</span> - and remove the hose connection.</li> </ul> <ul class="clsDASH"> <li>To connect, position the hose connection and press the circlip in until it engages.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004279" name="S05631849752008020700000">Fig. 37: Connecting/Disconnecting Washer Hose Coupling (Type 3)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Secured hose coupling with circlip, version 2</span> </p> <ul class="clsDASH"> <li>Disconnect by lifting lock ring - <span class="clsEmphBOLD">1</span> - approx. 1 mm - <span class="clsEmphBOLD">arrow</span> - and then pulling apart both halves of coupling.</li> </ul> <ul class="clsDASH"> <li>Reconnect by pushing both halves of coupling together and clipping locking ring - <span class="clsEmphBOLD">1</span> - until it engages.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004280" name="S34138404262008020700000">Fig. 38: Connecting/Disconnecting Washer Hose Coupling (Headlight Cleaning System)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Headlamp washer system hose connection with circlip</span> </p> <ul class="clsDASH"> <li>Disconnect by depressing clip - <span class="clsEmphBOLD">1</span> - - <span class="clsEmphBOLD">arrow</span> - and then separating coupling from jet.</li> </ul> <ul class="clsDASH"> <li>Reconnect by keeping clip - <span class="clsEmphBOLD">arrow</span> - depressed while pushing coupling onto jet until it engages. Check securing clip for secure locking by attempting to pull it off without depressing clip.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017196" name="S02914635082008020700000">Fig. 39: Headlamp Washer System Hose Connection With Hose Clamp</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Headlamp washer system hose connection with hose clamp</span> </p> <ul class="clsDASH"> <li>Disconnect by removing clamp - <span class="clsEmphBOLD">1</span> - (cut with side cutters) and remove hose.</li> </ul> <ul class="clsDASH"> <li>Reconnect by slide new hose clamp onto hose, position hose connection and install the hose clamp with Hose Clamp Pliers VAG 1275.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017197" name="S38017902522008020700000">Fig. 40: Headlamp Washer System Hose Coupling With Spring Clamp</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Headlamp washer system hose coupling with spring clamp</span> </p> <ul class="clsDASH"> <li>Disconnect opening spring clamp - <span class="clsEmphBOLD">1</span> - with Hose Clip Pliers VAG 1921 and remove hose connection.</li> </ul> <ul class="clsDASH"> <li>Reconnect by opening spring clamp with Hose Clip Pliers VAG 1921 and repositioning hose on connection.</li> </ul><a name="S30051100442008020700000"></a><h2 class="clsHeadTwo">Washer Hoses, Repairing</h2><a name="S38312395752008020700000"></a><h2 class="clsHeadThree">Washer Hoses, Repairing</h2> <p>--> <a class="clsHyperlink" href="#S24727031462008020700000">Smooth Hoses, Repairing</a></p> <p>--> <a class="clsHyperlink" href="#S28535885322008020700000">Corrugated Hoses, Repairing</a></p><a name="S24727031462008020700000"></a><h2 class="clsHeadThree">Smooth Hoses, Repairing</h2><a name="S42845949152008020700000"></a><h2 class="clsHeadFour">Smooth Hoses, Repairing</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Smooth hoses with a 5x1mm or 6x1 mm diameter can be replaced with EPDM (Ethylene Propylene Diene Monomer) hose.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004188" name="S11198399162008020700000">Fig. 41: Repairing Smooth Washer Hose</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Trim and remove damaged sections of hose.</li> </ul> <ul class="clsDASH"> <li>Select the appropriate EPDM hose - <span class="clsEmphBOLD">2</span> - and cable tie.</li> </ul> <ul class="clsDASH"> <li>Cut a length of EPDM hose - <span class="clsEmphBOLD">2</span> - so that the ends of the smooth hose - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">3</span> - can be pushed approximately 10 mm into the EPDM hose - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004189" name="S15331541082008020700000">Fig. 42: Securing Hose With Cable Ties</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Secure with cable ties as illustrated - <span class="clsEmphBOLD">1</span> -.</li> </ul> <ul class="clsDASH"> <li>Check for function and leaks.</li> </ul><a name="S28535885322008020700000"></a><h2 class="clsHeadThree">Corrugated Hoses, Repairing</h2><a name="S35672862642008020700000"></a><h2 class="clsHeadFour">Corrugated Hoses, Repairing</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Corrugated hoses can be replaced with heat-shrink sleeves.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004285" name="S31556040442008020700000">Fig. 43: Wiring Harness Repair Set VAS 1978A</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Hot Air Gun VAS 1978/14 from Wiring Harness Repair Set VAS 1978A.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017198" name="S17672989722008020700000">Fig. 44: Air Hose Pliers VAS 6228</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Air Hose Pliers VAS 6228</li> </ul> <ul class="clsBULLET"> <li>Connecting piece 1J0 955 875 R</li> </ul> <ul class="clsBULLET"> <li>Connecting piece 1J0 955 875</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017199" name="S18532596982008020700000">Fig. 45: Connecting Ends Of The Washer Fluid Line With Connector Pieces</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Procedure</span> </p> <ul class="clsDASH"> <li>Disconnect damaged part of washer fluid hose with the Air Hose Pliers VAS 6228.</li> </ul> <ul class="clsDASH"> <li>Connect ends - <span class="clsEmphBOLD">1 and 4</span> - of the washer fluid line with connector pieces - <span class="clsEmphBOLD">2 and 3</span> -.</li> </ul> <ul class="clsDASH"> <li>Slide the heat-shrink sleeve - <span class="clsEmphBOLD">5</span> - over an end of the washer fluid line and connect the connector pieces with each other.</li> </ul> <ul class="clsDASH"> <li>Slide the heat-shrink sleeve over the washer fluid connector pieces.</li> </ul> <ul class="clsDASH"> <li>After sliding on, the heat-shrink sleeve must be shrunk with the Hot Air Gun VAS 1978/14.</li> </ul> <ul class="clsBULLET"> <li>The heat-shrink sleeve must be heated from the center outward until it seals completely.</li> </ul> <ul class="clsBULLET"> <li>Set the hot air gun to the correct temperature according to the operating instructions.</li> </ul> <ul class="clsBULLET"> <li>When shrinking, ensure no other lines, plastic parts or insulation material is damaged by the hot nozzle.</li> </ul> <ul class="clsDASH"> <li>Check for function and leaks.</li> </ul><a name="S31585995652008020700000"></a><h2 class="clsHeadOne">94 - Lights, Switches - Exterior</h2><a name="S38154573232008020700000"></a><h2 class="clsHeadTwo">HID Headlamps, Safety Precautions</h2> <p>Prior to servicing vehicles with HID headlamps, technicians must read, understand and heed the following safety precautions:</p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>HIGH VOLTAGE!<ul class="clsBULLET"> <li>Switch off the ignition, switch off all electrical consumers and remove ignition key.</li> <li>Disconnect battery prior to servicing HID headlamp components marked with yellow HIGH VOLTAGE! symbols.</li> <li>After disconnecting battery, switch low beam on and off again in order to discharge any residual voltage.</li> <li>Do not operate HID lamp control module without gas-discharge lamp installed.</li> </ul> <ul class="clsBULLET"> <li>Due to high voltage (over 28000 V when igniting the lamp), do not operate HID lamp outside the headlamp housing.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Risk of injury due to burning, UV rays, blinding and explosion.<ul class="clsBULLET"> <li>When removing and installing HID bulbs, always wear safety glasses and gloves.</li> <li>Due the high temperatures, absorption of UV rays, and the risk of blinding, the gas-discharge lamp should only be operated inside the headlamp housing.</li> <li>Do not look into the beam of light. It may interfere with the ability to see for a significant period of time.</li> <li>Gas-discharge lamps are under pressure and can crack when bulbs are replaced.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Environmental risk.<ul class="clsBULLET"> <li>Gas-discharge bulbs require special disposal. They contain metallic mercury (Hg) and traces of thallium.</li> <li>Do not destroy gas-discharge lamps. Avoid contact with burst glass bulbs.</li> <li>Follow disposal requirements, only dispose of gas-discharge lamps in suitable containers at an authorized collection site.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Do not touch gas-discharge bulbs with bare hands. The remaining fingerprint would evaporate due to the heat of the operated bulb and condense on the reflector which would impair headlamp luminosity. Use clean cloth gloves to insert the gas-discharge lamp.</li> <li>Only replace faulty gas-discharge lamps with the same type of bulbs. Bulb identification can be found on bulb socket or glass cone.</li> <li>Harness connectors must engage correctly when installed and must be checked for proper connection.</li> </ul> </td> </tr> </table></span></p><a name="S15312696572008020700000"></a><h2 class="clsHeadOne">96 - Lights, Switches - Interior, Anti-theft</h2><a name="S03796796322008020700000"></a><h2 class="clsHeadTwo">Anti-Theft Immobilizer, without Access/Start Control Module</h2><a name="S37555487712008020700000"></a><h2 class="clsHeadThree">Anti-Theft Immobilizer, without Access/Start Control Module</h2> <p>--> <a class="clsHyperlink" href="#S06234905172008020700000">General Information</a></p> <p>--> <a class="clsHyperlink" href="#S15032932632008020700000">Faulty Transponder or Lost Key</a></p> <p>--> <a class="clsHyperlink" href="#S03304153952008020700000">Induction Coil, Replacing</a></p> <p>--> <a class="clsHyperlink" href="#S16880356632008020700000">Lock Set, Replacement Procedure</a></p><a name="S15513737552008020700000"></a><h2 class="clsHeadThree">General Information</h2><a name="S26687344522008020700000"></a><h2 class="clsHeadFour">General Information</h2> <p>The immobilizer control module is integrated in the instrument cluster. The immobilizer control module is replaced together with the instrument cluster.</p> <ul class="clsDASH"> <li>If the control module is replaced, use Vehicle Diagnosis, Testing info. System VAS 5051B (or other VAS 505X class tester) in operating mode "Guided Functions" and select the "Replace" function for the respective control module.</li> </ul><a name="S15032932632008020700000"></a><h2 class="clsHeadThree">Faulty Transponder or Lost Key</h2><a name="S22393656262008020700000"></a><h2 class="clsHeadFour">Faulty Transponder or Lost Key</h2> <ul class="clsBULLET"> <li>The transponder is integrated in the vehicle key and cannot be replaced separately.</li> </ul> <ul class="clsBULLET"> <li>If the transponder is faulty, the entire vehicle key must be replaced.</li> </ul> <ul class="clsDASH"> <li>Order a replacement key through distributor or importer with vehicle-specific lock number using VIN.</li> </ul> <ul class="clsDASH"> <li>Perform the adaptation on all vehicle keys using Vehicle Diagnosis, Testing info. System VAS 5051B (or other VAS 505X class tester) in operating mode "Guided Fault Finding".</li> </ul><a name="S03304153952008020700000"></a><h2 class="clsHeadThree">Induction Coil, Replacing</h2><a name="S11789197052008020700000"></a><h2 class="clsHeadFour">Induction Coil, Replacing</h2> <ul class="clsBULLET"> <li>The induction coil is integrated in the lock cylinder and cannot be replaced separately.</li> </ul> <ul class="clsBULLET"> <li>If the induction coil is faulty, the entire lock cylinder must be replaced.</li> </ul> <ul class="clsDASH"> <li>Order a new lock cylinder through distributor or importer with vehicle-specific lock number using VIN.</li> </ul><a name="S16880356632008020700000"></a><h2 class="clsHeadThree">Lock Set, Replacement Procedure</h2><a name="S13044659722008020700000"></a><h2 class="clsHeadFour">Lock Set, Replacement Procedure</h2> <p>After replacement of lock set, adapt all vehicle keys can only be adapted using Vehicle Diagnosis, Testing info. System VAS 5051B in operating mode "Guided Fault Finding".</p><a name="S27590587672008020700000"></a><h2 class="clsHeadTwo">Anti-Theft Immobilizer, with Access/Start Control Module</h2><a name="S41323354522008020700000"></a><h2 class="clsHeadThree">Anti-Theft Immobilizer, with Access/Start Control Module</h2> <p>Immobilizer control is integrated in Access/Start Control Module J518. Component location: Integrated in steering column, removing and installing --> <a class="clsExtHyperlink" id="A00278916_S32803510402008020700000">48 - STEERING</a> .</p> <p>The following components are also part of the immobilizer:</p> <ul class="clsBULLET"> <li>Vehicle key with integrated transponder.</li> </ul> <ul class="clsBULLET"> <li>Induction coil in Access/Start Authorization Switch E415 (electronic ignition lock).</li> </ul> <ul class="clsBULLET"> <li>Engine Control Module (ECM).</li> </ul> <ul class="clsBULLET"> <li>Transmission Control Module (TCM).</li> </ul> <ul class="clsDASH"> <li>If the control module is replaced, use Vehicle Diagnosis, Testing info. System VAS 5051B (or other VAS 505X class tester) in operating mode "Guided Functions" and select the "Replace" function for the respective control module.</li> </ul><a name="S27639566922008020700000"></a><h2 class="clsHeadTwo">Heated Steering Wheel</h2><a name="S16969411062008020700000"></a><h2 class="clsHeadThree">Heated Steering Wheel</h2> <ul class="clsDASH"> <li>Remove airbag unit for fault finding --> Body Interior - <a class="clsExtHyperlink" id="A00278922_S12872913122008020700000">69 - PASSENGER PROTECTION - AIRBAGS, SEAT BELTS</a> .</li> </ul> <ul class="clsDASH"> <li>Remove steering wheel --> <a class="clsExtHyperlink" id="A00278916_S32803510402008020700000">48 - STEERING</a> .</li> </ul> <ul class="clsDASH"> <li>Check wire connections --> Electrical Wiring Diagrams, Troubleshooting and Component Locations.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Complete heated steering wheel must be replaced if faulty.</li> </ul> </td> </tr> </table></span></p><a name="S16202540862008020700000"></a><h2 class="clsHeadTwo">Trailer Hitch Wiring Socket</h2><a name="S38997361432008020700000"></a><h2 class="clsHeadThree">Trailer Hitch Wiring Socket</h2> <p>--> <a class="clsHyperlink" href="#S22337296792008020700000">Trailer Hitch Wiring Socket, Removing and Installing</a></p> <p>--> <a class="clsHyperlink" href="#S40573218162008020700000">Trailer Hitch Wiring Socket, Multi-Pin Connector Assignments</a></p><a name="S22337296792008020700000"></a><h2 class="clsHeadThree">Trailer Hitch Wiring Socket, Removing and Installing</h2><a name="S28841061172008020700000"></a><h2 class="clsHeadFour">Trailer Hitch Wiring Socket, Removing and Installing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017200" name="S00376183742008020700000">Fig. 46: Trailer Hitch Wiring Socket Components</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Switch off ignition and remove ignition key.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Switch off ignition.</li> <li>Switch off all electrical consumers and remove ignition key</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Remove screws - <span class="clsEmphBOLD">arrows</span> -.</li> </ul> <ul class="clsDASH"> <li>Remove socket assembly from mounting plate.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017201" name="S16843608682008020700000">Fig. 47: Switch Connector And Connector At Socket</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Wiring socket with Switchable Rear Fog Lamp Shut-Off Contact Switch F216 :</span> </p> <ul class="clsDASH"> <li>Disconnect switch connector - <span class="clsEmphBOLD">2</span> - and connector - <span class="clsEmphBOLD">1</span> - from socket.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017202" name="S14761710042008020700000">Fig. 48: Pressing Multi-Pin Connector Out Of Socket</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Wiring socket without Switchable Rear Fog Lamp Shut-Off Contact Switch F216 :</span> </p> <ul class="clsDASH"> <li>Press multi-pin connector - <span class="clsEmphBOLD">2</span> - in - <span class="clsEmphBOLD">direction of arrow</span> - out of socket - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017203" name="S29840421702008020700000">Fig. 49: Releasing Securing Tabs And Then Releasing Retainer Clips</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Version 1:</span> </p> <ul class="clsDASH"> <li>Release securing tabs - <span class="clsEmphBOLD">arrows</span> - and then release retainer clips - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">3 through 5</span> -.</li> </ul> <ul class="clsDASH"> <li>Remove retainer from harness connectors - <span class="clsEmphBOLD">2</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017204" name="S14972579202008020700000">Fig. 50: Releasing Securing Tabs And Then Retaining Clips</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Version 2:</span> </p> <ul class="clsDASH"> <li>First release securing tabs - <span class="clsEmphBOLD">arrows</span> - and then retaining clips - <span class="clsEmphBOLD">1, 2, 3, 4, 6, 7</span> -.</li> </ul> <ul class="clsDASH"> <li>Remove retaining cage from multi-pin electrical connector - <span class="clsEmphBOLD">5</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017205" name="S21218575272008020700000">Fig. 51: O-Rings, Harness Connectors And Retainer</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, noting the following:</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Ensure O-rings - <span class="clsEmphBOLD">1</span> - and - <span class="clsEmphBOLD">3</span> - are not damaged.</li> <li>Slide harness connectors - <span class="clsEmphBOLD">4</span> - into retainer - <span class="clsEmphBOLD">2</span> - until they audibly engage.</li> </ul> </td> </tr> </table></span></p><a name="S40573218162008020700000"></a><h2 class="clsHeadThree">Trailer Hitch Wiring Socket, Multi-Pin Connector Assignments</h2><a name="S01573538642008020700000"></a><h2 class="clsHeadFour">Trailer Hitch Wiring Socket, Multi-Pin Connector Assignments</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017206" name="S26719508012008020700000">Fig. 52: Trailer Hitch Wiring Socket, Multi-Pin Connector Assignments</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ol class="clsARABICNUM"> <li>Terminal BL (left turn signal)</li> <li>Terminal NSL (rear fog lamp)</li> <li>Terminal 31, ground (GND)</li> <li>Terminal BR (right turn signal)</li> <li>Terminal 58 R (right tail lamp)</li> <li>Terminal 54 (brake light)</li> <li>Terminal 58 L (left tail lamp)</li> <li>Terminal RF (back-up light)</li> <li>Where applicable</li> <li>Where applicable</li> <li>Where applicable</li> <li>Where applicable</li> <li>Where applicable</li> </ol> <p><span class="clsEmphBOLD">Trailer wiring socket with Switchable Rear Fog Lamp Shut-Off Contact Switch F216 :</span> </p> <p>Multi-pin connector assignments for Switchable Rear Fog Lamp Shut-Off Contact Switch F216 (where applicable) --> Electrical Wiring Diagrams, Troubleshooting and Component Locations</p><a name="S05966597062008020700000"></a><h2 class="clsHeadOne">97 - Wiring</h2><a name="S07055434552008020700000"></a><h2 class="clsHeadTwo">Wiring Harnesses and Connectors, Repairing</h2><a name="S23432094132008020700000"></a><h2 class="clsHeadThree">Wiring Harnesses and Connectors, Repairing</h2> <p>--> <a class="clsHyperlink" href="#S26459495402008020700000">Vehicle Electrical System, General Information</a></p> <p>--> <a class="clsHyperlink" href="#S12676479202008020700000">Wiring Harness and Connector Repairs, General Information</a></p> <p>--> <a class="clsHyperlink" href="#S07007497642008020700000">Airbag and Safety Belt Tensioner Wiring, Repairing</a></p> <p>--> <a class="clsHyperlink" href="#S04430893552008020700000">CAN-Bus Wiring, Repairing</a></p> <p>--> <a class="clsHyperlink" href="#S06986864642008020700000">Wire, 0.25 mm with Individual Crimp Connector, Repairing</a></p> <p>--> <a class="clsHyperlink" href="#S42251432412008020700000">Wire, 0.35 mm and Larger with Individual Crimp Connector, Repairing</a></p> <p>--> <a class="clsHyperlink" href="#S16195994622008020700000">Wire, 0.25 mm with Intermediate Wire Section, Repairing</a></p> <p>--> <a class="clsHyperlink" href="#S19270210972008020700000">Wire, 0.35 mm or Larger with Intermediate Wire Section, Repairing</a></p> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00002540" name="S25689220942008020700000">Fig. 53: Wiring Harness Repair Kit V.A.S 1978</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Wiring Harness Repair Kit VAS 1978 with</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004284" name="S06439156102008020700000">Fig. 54: Upgrade Kit For VAS1978 (VAS1978/50)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Upgrade kit VAS 1978/50</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004285" name="S30638986442008020700000">Fig. 55: Wiring Harness Repair Set VAS 1978A</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>or Wiring Harness Repair Set VAS 1978A</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>The Upgrade Kit VAS 1978/50 is required to bring the "old" Wiring Harness Repair Kit VAS 1978 up to the new standard of the Wiring Harness Repair Set VAS 1978A.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Wiring harness and socket repairs may only be carried out with the Wiring Harness Repair Kit VAS 1978 or Wiring Harness Repair Set VAS 1978A.</li> <li>Observe the country-specific requirements.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017141" name="S16000096432008020700000">Fig. 56: Opened Wiring Harness Repair Kit VAS 1978</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Usage of the Wiring Harness Repair Kit VAS 1978 or Wiring Harness Repair Set VAS 1978A is described extensively in the accompanying usage instructions.</li> <li>Repairs on open circuits and faulty connectors are also explained using examples.</li> </ul> </td> </tr> </table></span></p><a name="S26459495402008020700000"></a><h2 class="clsHeadThree">Vehicle Electrical System, General Information</h2><a name="S38080877362008020700000"></a><h2 class="clsHeadFour">Vehicle Electrical System, General Information</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Risk of injury.<ul class="clsBULLET"> <li>Pay attention to stickers designating high voltage components. Prior to performing repairs, residual voltage must first be discharged.</li> <li>Some tools are supplied with a tool safety clip, which is slid over the tool points after using the tool, in order to protect other workers from injuries and tool points from damage.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Observe country-specific requirements.</li> <li>By disconnecting battery ground (GND) wire, safe work on vehicle electrical system is guaranteed. With the ignition switched off, disconnect battery ground cable --> <a class="clsExtHyperlink" id="A00278929_S42401837392008020700000">27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL</a> .</li> <li>Before starting a repair, the cause of the damage must be eliminated first, i.e. sharp edges on chassis parts, faulty consumers, corrosion etc.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>If possible, do not loosen ground (GND) straps from body (danger of corrosion).</li> <li>Further information, e.g. installing and removing the individual components, is described in the appropriate repair manual.</li> </ul> </td> </tr> </table></span></p><a name="S12676479202008020700000"></a><h2 class="clsHeadThree">Wiring Harness and Connector Repairs, General Information</h2><a name="S18321048642008020700000"></a><h2 class="clsHeadFour">Wiring Harness and Connector Repairs, General Information</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Observe general notes for repairs on the vehicle electrical system --> <a class="clsHyperlink" href="#S26459495402008020700000">Vehicle Electrical System, General Information</a>.</li> <li>Not all of the wire cross sections contained in the vehicle are in the Wiring Harness Repair Kit VAS 1978 or Wiring Harness Repair Set VAS 1978A. If the required wire cross-section is not present, the next greater cross-section must be used.</li> <li>For repairs on vehicle electrical system, soldering is not permitted.</li> <li>Do not repair crimp connectors. If necessary, lay a wire parallel to the faulty wire.</li> <li>After crimping, crimp connections must be heat-shrunk using hot air gun to prevent moisture penetration.</li> <li>Shielded wires, such as RPM sensors and knock sensors, may not be repaired. If faulty, the entire harness must be replaced.</li> <li>Exclusive use is to be made of yellow wires for wiring harness repairs.</li> <li>Wiring harness repairs should not be made again in the wrapping on the vehicle-specific wiring harness.</li> <li>Mark repaired areas using yellow adhesive tape.</li> <li>Yellow wires and areas in the wiring harness wrapped with yellow adhesive tape mark a previously performed repair.</li> <li>Perform a function test after each repair. If necessary, check DTC memory, erase and/or bring systems into basic setting.</li> </ul> </td> </tr> </table></span></p><a name="S07007497642008020700000"></a><h2 class="clsHeadThree">Airbag and Safety Belt Tensioner Wiring, Repairing</h2><a name="S03299878542008020700000"></a><h2 class="clsHeadFour">Airbag and Safety Belt Tensioner Wiring, Repairing</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Observe general notes for repairs on the vehicle electrical system --> <a class="clsHyperlink" href="#S26459495402008020700000">Vehicle Electrical System, General Information</a>.</li> <li>Observe the notes on wiring harness and connector repairs --> <a class="clsHyperlink" href="#S12676479202008020700000">Wiring Harness and Connector Repairs, General Information</a> including identifying repair locations.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Passenger protection malfunction due to faulty repairs to the airbag and belt tensioner wiring harness<ul class="clsBULLET"> <li>Repairs on the airbag and seat belt wiring must only be performed on the vehicle using the Wiring Harness Repair Kit VAS 1978 or Repair Manual Wiring Set VAS 1978A and original replacement parts (connector housing, terminals, wires) in order to guarantee the repair quality required by Audi AG.</li> <li>Wires at individual airbag modules may not be repaired.</li> <li>If the wires or connectors on the airbag modules are damaged, the respective airbag module must be replaced for safety reasons.</li> </ul> </td> </tr> </table></span></p> <ul class="clsBULLET"> <li>A maximum of two repairs may be performed when repairing wires of airbag- and seat belt tensioner system. Repairs increase the electrical resistance in the wire and may trigger malfunctions in the system On Board Diagnostic (OBD).</li> </ul> <ul class="clsBULLET"> <li>Repairs in the area of the airbag or seat belt tensioner should be performed a maximum of 30 cm from the next terminal housing. Together with the identification using yellow adhesive tape, this procedure makes it possible to obtain a quick overview of previously performed repairs.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004273" name="S38309771022008020700000">Fig. 57: Repairing Twisted Wire Pairs</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Both wires to the airbag igniter have a twist with 20 5 mm routing length. This routing length must be maintained when repairing the twisted wires.</li> </ul> <ul class="clsBULLET"> <li>When repairing, both wires to the airbag igniters must be the same length. When twisting the wires - <span class="clsEmphBOLD">1 and 2</span> - together, the - <span class="clsEmphBOLD">A</span> - = 20 mm routing length must be maintained.</li> </ul> <ul class="clsBULLET"> <li>While doing so, no section of wire must be greater than - <span class="clsEmphBOLD">B</span> - = 100 mm without twisting of wires, e.g. in area of welded connectors - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <ul class="clsBULLET"> <li>Repairs are to be documented in the Audi Service Plan under "Space for workshop entries" with a short commentary of scope of repairs, workshop stamp and signature.</li> </ul> <ul class="clsBULLET"> <li>Any warranty claims to Audi AG are voided if airbag wiring harness repairs were not performed using original replacement parts and the Wiring Harness Repair Kit VAS 1978 or Wiring Harness Repair Set VAS 1978A.</li> </ul><a name="S04430893552008020700000"></a><h2 class="clsHeadThree">CAN-Bus Wiring, Repairing</h2><a name="S03968706142008020700000"></a><h2 class="clsHeadFour">CAN-Bus Wiring, Repairing</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Observe general notes for repairs on the vehicle electrical system --> <a class="clsHyperlink" href="#S26459495402008020700000">Vehicle Electrical System, General Information</a>.</li> <li>Observe the notes on wiring harness and connector repairs --> <a class="clsHyperlink" href="#S12676479202008020700000">Wiring Harness and Connector Repairs, General Information</a> including identifying repair locations.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004273" name="S12773404002008020700000">Fig. 58: Repairing Twisted Wire Pairs</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>An unshielded two-strand wire - <span class="clsEmphBOLD">1 and 2</span> - with a cross section of 0.35 mm <sup>2</sup> or 0.5 mm <sup>2</sup> can be used as CAN-Bus wiring.</p> <ul class="clsBULLET"> <li>CAN bus wires have the following color coding:</li> </ul> <p><span class="clsArticleTable"><a name="S039687061420080207000001"></a><table cellspacing="0" class="clsArticleTable58"> <colgroup> <col span="1" id="COL1" width="198px"> <col span="1" id="COL2" width="198px"> </colgroup> <tbody> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Powertrain CAN Bus High</td> <td valign="TOP" align="LEFT" class="clsCellNormal">orange/black</td> </tr> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Comfort CAN Bus High</td> <td valign="TOP" align="LEFT" class="clsCellNormal">orange/green</td> </tr> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">Infotainment CAN Bus High</td> <td valign="TOP" align="LEFT" class="clsCellNormal">orange/violet</td> </tr> <tr> <td valign="TOP" align="LEFT" class="clsCellNormal">CAN Bus Wiring Low</td> <td valign="TOP" align="LEFT" class="clsCellNormal">orange/brown</td> </tr> </tbody> </table></span></p> <ul class="clsBULLET"> <li>During repair work, both bus wires must have the same length. When twisting the wires - <span class="clsEmphBOLD">1 and 2</span> - together, the - <span class="clsEmphBOLD">A</span> - = 20 mm routing length must be maintained.</li> </ul> <ul class="clsBULLET"> <li>While doing so, no section of wire must be greater than - <span class="clsEmphBOLD">B</span> - = 50 mm without twisting of wires, e.g. in area of welded connectors - <span class="clsEmphBOLD">arrow</span> -.</li> </ul><a name="S06986864642008020700000"></a><h2 class="clsHeadThree">Wire, 0.25 mm with Individual Crimp Connector, Repairing</h2><a name="S18883987272008020700000"></a><h2 class="clsHeadFour">Wire, 0.25 mm with Individual Crimp Connector, Repairing</h2> <p><span class="clsEmphBOLD">Procedure</span> </p> <ul class="clsDASH"> <li>Free up the wire to be repaired approximately 20 cm on both sides of the repair point.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Risk of damaging the electrical wires.<ul class="clsBULLET"> <li>Free up wrapped wiring harnesses carefully.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>If necessary, removing the wiring harness wrapping using a knife.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004291" name="S00408587092008020700000">Fig. 59: Cutting Wire Using Side-Cutter Function Of Wire Stripper</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Cut out the damaged wire section using wire stripper VAS 1978/3.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>If, by cutting out the damaged wire section, both ends of the vehicle-specific single wire are too short for a repair using a single crimp connector, insert a repair wire section of matching length with two crimp connections --> <a class="clsHyperlink" href="#S16195994622008020700000">Wire, 0.25 mm with Intermediate Wire Section, Repairing</a>.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00002550" name="S00864034262008020700000">Fig. 60: Stripping Insulation At Wiring Using Stripping Pliers</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Adjust the sliding stop in the Wire Stripper VAS 1978/3 pliers jaws to 12 to 14 mm for the wire to be stripped.</li> </ul> <ul class="clsDASH"> <li>Insert wire end from front up to stop into jaws of pliers and squeeze the pliers completely.</li> </ul> <ul class="clsDASH"> <li>Open pliers again and remove the stripped wire end.</li> </ul> <ul class="clsDASH"> <li>Twist bare strands one-half turn.</li> </ul> <ul class="clsDASH"> <li>For the repair of a 0.25 mm <sup>2</sup> wire, use a small yellow crimp connector from the Wiring Harness Repair Set VAS 1978A.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004293" name="S34977385252008020700000">Fig. 61: Crimping Pliers</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>To press the crimp connector, use the Crimping Pliers (Base Tool) VAS 1978/1-2 with Exchangeable Head, 0.35-2.5mm<sup>2</sup> VAS 1978/1-1.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004307" name="S31222363932008020700000">Fig. 62: Crimping Single Break Point</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Slide the small yellow crimp connector onto both stripped, uninsulated wire ends on the vehicle-specific single wire and crimp them using crimp pliers.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Do not crimp wire insulation.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004308" name="S24169711942008020700000">Fig. 63: Heating Crimp Connection Using Hot Air Gun</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>After crimping, crimp connections must be heat-shrunk using hot air gun to prevent moisture penetration.</p> <ul class="clsDASH"> <li>Put Shrink Tip For Hot Air Gun VAS 1978/15 on to Hot Air Gun, 220 V/ 50 Hz VAS 1978/14.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Risk of damaging surrounding components.<ul class="clsBULLET"> <li>When heat-shrinking crimp connections, be careful not to damage any other wiring, plastic parts or insulating material with the hot nozzle of the hot air gun.</li> <li>Always observe operating instructions of heat gun.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004306" name="S40184313672008020700000">Fig. 64: Single Repair Point</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Heat crimp connection using hot air gun lengthwise from center outward until it is sealed completely and adhesive comes out the ends.</li> </ul> <ul class="clsBULLET"> <li>This is how the completed repair location with individual crimp connector should appear.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004309" name="S02174522992008020700000">Fig. 65: Offsetting Crimp Connections</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Make sure that crimp connections do not lie directly next to each other when several wires need to be repaired. Arrange the crimp connectors at a slight offset so that the circumference of the wiring harness does not become too large.</li> <li>If the repair point was previous taped, this point must be taped again with yellow insulating tape after repairs.</li> <li>Secure the repaired wiring harness if necessary with a cable tie to prevent flapping noises while driving.</li> </ul> </td> </tr> </table></span></p><a name="S42251432412008020700000"></a><h2 class="clsHeadThree">Wire, 0.35 mm and Larger with Individual Crimp Connector, Repairing</h2><a name="S11697195272008020700000"></a><h2 class="clsHeadFour">Wire, 0.35 mm and Larger with Individual Crimp Connector, Repairing</h2> <p><span class="clsEmphBOLD">Procedure</span> </p> <ul class="clsDASH"> <li>Free up the wire to be repaired approximately 20 cm on both sides of the repair point.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Risk of damaging the electrical wires.<ul class="clsBULLET"> <li>Free up wrapped wiring harnesses carefully.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>If necessary, removing the wiring harness wrapping using a knife.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004291" name="S38418469672008020700000">Fig. 66: Cutting Wire Using Side-Cutter Function Of Wire Stripper</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Cut out the damaged wire section using wire stripper VAS 1978/3.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>If, by cutting out the damaged wire section, both ends of the vehicle-specific single wire are too short for a repair using a single crimp connector, insert a repair wire section of matching length with two crimp connections --> <a class="clsHyperlink" href="#S19270210972008020700000">Wire, 0.35 mm or Larger with Intermediate Wire Section, Repairing</a>.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00002550" name="S09299919612008020700000">Fig. 67: Stripping Insulation At Wiring Using Stripping Pliers</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Adjust the sliding stop in the Wire Stripper VAS 1978/3 pliers jaws to 6 to 7 mm for the wire to be stripped.</li> </ul> <ul class="clsDASH"> <li>Insert wire end from front up to stop into jaws of pliers and squeeze the pliers completely.</li> </ul> <ul class="clsDASH"> <li>Open pliers again and remove the stripped wire end.</li> </ul> <ul class="clsDASH"> <li>For the repair, use a suitable crimp connector form the Wiring Harness Repair Set VAS 1978A.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004293" name="S01993509742008020700000">Fig. 68: Crimping Pliers</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Use the Crimping Pliers (Base Tool) VAS 1978/1-2 to press the crimp connector.</li> </ul> <p>The following exchangeable heads are available for the Crimping Pliers (Base Tool) VAS 1978/1-2 :</p> <ul class="clsBULLET"> <li>Exchangeable Head, 0.35-2.5mm VAS 1978/1-1</li> </ul> <ul class="clsBULLET"> <li>Exchangeable head, 4.0-6.0 mm<sup>2</sup> VAS 1978/2 A</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004307" name="S04039130742008020700000">Fig. 69: Crimping Single Break Point</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Slide crimp connection on to both stripped wire ends of vehicle-specific single wire and crimp them using crimp pliers.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Do not crimp wire insulation.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004308" name="S36419363252008020700000">Fig. 70: Heating Crimp Connection Using Hot Air Gun</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>After crimping, crimp connections must be heat-shrunk using hot air gun to prevent moisture penetration.</p> <ul class="clsDASH"> <li>Put Shrink Tip For Hot Air Gun VAS 1978/15 on to Hot Air Gun, 220 V/ 50 Hz VAS 1978/14.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Risk of damaging surrounding components.<ul class="clsBULLET"> <li>When heat-shrinking crimp connections, be careful not to damage any other wiring, plastic parts or insulating material with the hot nozzle of the hot air gun.</li> <li>Always observe operating instructions of heat gun.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004306" name="S36412499232008020700000">Fig. 71: Single Repair Point</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Heat crimp connection using hot air gun lengthwise from center outward until it is sealed completely and adhesive comes out the ends.</li> </ul> <ul class="clsBULLET"> <li>This is how the completed repair location with individual crimp connector should appear.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004309" name="S31392776502008020700000">Fig. 72: Offsetting Crimp Connections</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Make sure that crimp connections do not lie directly next to each other when several wires need to be repaired. Arrange the crimp connectors at a slight offset so that the circumference of the wiring harness does not become too large.</li> <li>If the repair point was previous taped, this point must be taped again with yellow insulating tape after repairs.</li> <li>Secure the repaired wiring harness if necessary with a cable tie to prevent flapping noises while driving.</li> </ul> </td> </tr> </table></span></p><a name="S16195994622008020700000"></a><h2 class="clsHeadThree">Wire, 0.25 mm with Intermediate Wire Section, Repairing</h2><a name="S23915912572008020700000"></a><h2 class="clsHeadFour">Wire, 0.25 mm with Intermediate Wire Section, Repairing</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Only 0.5 mm <sup>2</sup> repair wires are available for repairing a 0.25 mm <sup>2</sup> wire.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Procedure</span> </p> <ul class="clsDASH"> <li>Free up the wire to be repaired at two places approximately 20 cm on both sides of the repair point.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Risk of damaging the electrical wires.<ul class="clsBULLET"> <li>Free up wrapped wiring harnesses carefully.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>If necessary, removing the wiring harness wrapping using a knife.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004291" name="S18114254632008020700000">Fig. 73: Cutting Wire Using Side-Cutter Function Of Wire Stripper</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Route yellow repair wire next to damaged wiring harness and cut repair wire to the required length using wire stripper VAS 1978/3.</li> </ul> <ul class="clsDASH"> <li>Cut damaged wire section from the vehicle-specific single wire.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00002550" name="S29948537332008020700000">Fig. 74: Stripping Insulation At Wiring Using Stripping Pliers</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Adjust the sliding stop in the Wire Stripper VAS 1978/3 pliers jaws to 12 to 14 mm for the wire to be stripped.</li> </ul> <ul class="clsDASH"> <li>Insert the vehicle-specific single wire end from the front into the pliers jaws as far as the stop and squeeze the pliers together completely.</li> </ul> <ul class="clsDASH"> <li>Open pliers again and remove the stripped wire end.</li> </ul> <ul class="clsDASH"> <li>Twist bare strands one-half turn.</li> </ul> <ul class="clsDASH"> <li>Repeat the procedure on the other end of the vehicle-specific individual wire.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00002550" name="S22641130792008020700000">Fig. 75: Stripping Insulation At Wiring Using Stripping Pliers</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Adjust the sliding stop in the Wire Stripper VAS 1978/3 pliers jaws to 6 to 7 mm for the wire to be stripped.</li> </ul> <ul class="clsDASH"> <li>Insert the yellow repair wire end from the front into the pliers jaws as far as the stop and squeeze the pliers together completely.</li> </ul> <ul class="clsDASH"> <li>Open pliers again and remove the stripped wire end.</li> </ul> <ul class="clsDASH"> <li>Repeat this procedure on the other repair wire end.</li> </ul> <ul class="clsDASH"> <li>For the repair of a 0.25 mm <sup>2</sup> wire, use a small yellow crimp connector from the Wiring Harness Repair Set VAS 1978A.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004293" name="S17137647632008020700000">Fig. 76: Crimping Pliers</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>To press the crimp connector, use the Crimping Pliers (Base Tool) VAS 1978/1-2 from the Wiring Harness Repair Set VAS 1978A with the Exchangeable Head, 0.35 mm-2.5 mm VAS 1978/1-1.</li> </ul> <ul class="clsDASH"> <li>Slide the small yellow crimp connector onto the vehicle-specific single wire at one side and onto the repair wire at the other side.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004307" name="S38406977932008020700000">Fig. 77: Crimping Single Break Point</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Crimp the crimp connection at both wire ends using crimp pliers.</li> </ul> <ul class="clsDASH"> <li>Repeat this procedure at the other repair wire end.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Do not crimp wire insulation.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004308" name="S16362830082008020700000">Fig. 78: Heating Crimp Connection Using Hot Air Gun</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>After crimping, crimp connections must be heat-shrunk using hot air gun to prevent moisture penetration.</p> <ul class="clsDASH"> <li>Put Shrink Tip For Hot Air Gun VAS 1978/15 on to Hot Air Gun, 220 V/ 50 Hz VAS 1978/14.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Risk of damaging surrounding components.<ul class="clsBULLET"> <li>When heat-shrinking crimp connections, be careful not to damage any other wiring, plastic parts or insulating material with the hot nozzle of the hot air gun.</li> <li>Always observe operating instructions of heat gun.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004310" name="S22878260152008020700000">Fig. 79: Wire Break With Dual Repair Point</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Heat crimp connection using hot air gun lengthwise from center outward until it is sealed completely and adhesive comes out the ends.</li> </ul> <ul class="clsBULLET"> <li>This is how the completed repair location with the inserted wire and two crimp connectors should look.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004309" name="S34362965812008020700000">Fig. 80: Offsetting Crimp Connections</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Make sure that crimp connections do not lie directly next to each other when several wires need to be repaired. Arrange the crimp connectors at a slight offset so that the circumference of the wiring harness does not become too large.</li> <li>If the repair point was previous taped, this point must be taped again with yellow insulating tape after repairs.</li> <li>Secure the repaired wiring harness if necessary with a cable tie to prevent flapping noises while driving.</li> </ul> </td> </tr> </table></span></p><a name="S19270210972008020700000"></a><h2 class="clsHeadThree">Wire, 0.35 mm or Larger with Intermediate Wire Section, Repairing</h2><a name="S08113168262008020700000"></a><h2 class="clsHeadFour">Wire, 0.35 mm or Larger with Intermediate Wire Section, Repairing</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Only 0.5 mm <sup>2</sup> repair wires are available for repairing a 0.35 mm <sup>2</sup> wire.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Procedure</span> </p> <ul class="clsDASH"> <li>Free up the wire to be repaired at two places approximately 20 cm on both sides of the repair point.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Risk of damaging the electrical wires.<ul class="clsBULLET"> <li>Free up wrapped wiring harnesses carefully.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>If necessary, removing the wiring harness wrapping using a knife.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004291" name="S37834740632008020700000">Fig. 81: Cutting Wire Using Side-Cutter Function Of Wire Stripper</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Route yellow repair wire next to damaged wiring harness and cut repair wire to the required length using wire stripper VAS 1978/3.</li> </ul> <ul class="clsDASH"> <li>Cut damaged wire section from the vehicle-specific single wire.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00002550" name="S37236566942008020700000">Fig. 82: Stripping Insulation At Wiring Using Stripping Pliers</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Adjust the sliding stop in the Wire Stripper VAS 1978/3 pliers jaws to 6 to 7 mm for the wire to be stripped.</li> </ul> <ul class="clsDASH"> <li>Insert the vehicle-specific single wire end from the front into the pliers jaws as far as the stop and squeeze the pliers together completely.</li> </ul> <ul class="clsDASH"> <li>Open pliers again and remove the stripped wire end.</li> </ul> <ul class="clsDASH"> <li>Repeat the procedure on the other end of the vehicle-specific individual wire.</li> </ul> <ul class="clsDASH"> <li>For the repair, use two suitable crimp connectors form the Wiring Harness Repair Set VAS 1978A.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004293" name="S38422356942008020700000">Fig. 83: Crimping Pliers</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Use the Crimping Pliers (Base Tool) VAS 1978/1-2 to press the crimp connector.</li> </ul> <p>The following exchangeable heads are available for the Crimping Pliers (Base Tool) VAS 1978/1-2 :</p> <ul class="clsBULLET"> <li>Exchangeable Head, 0.35-2.5mm VAS 1978/1-1</li> </ul> <ul class="clsBULLET"> <li>Exchangeable head, 4.0-6.0 mm<sup>2</sup> VAS 1978/2 A</li> </ul> <ul class="clsDASH"> <li>Slide the crimp connector onto the vehicle-specific single wire at one side and onto repair wire at the other side.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004307" name="S39133395962008020700000">Fig. 84: Crimping Single Break Point</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Crimp the crimp connection at both wire ends using crimp pliers.</li> </ul> <ul class="clsDASH"> <li>Repeat this procedure on the other wire ends.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Do not crimp wire insulation.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004308" name="S14300113192008020700000">Fig. 85: Heating Crimp Connection Using Hot Air Gun</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p>After crimping, crimp connections must be heat-shrunk using hot air gun to prevent moisture penetration.</p> <ul class="clsDASH"> <li>Put Shrink Tip For Hot Air Gun VAS 1978/15 on to Hot Air Gun, 220 V/ 50 Hz VAS 1978/14.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Risk of damaging surrounding components.<ul class="clsBULLET"> <li>When heat-shrinking crimp connections, be careful not to damage any other wiring, plastic parts or insulating material with the hot nozzle of the hot air gun.</li> <li>Always observe operating instructions of heat gun.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004310" name="S16444671652008020700000">Fig. 86: Wire Break With Dual Repair Point</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Heat crimp connection using hot air gun lengthwise from center outward until it is sealed completely and adhesive comes out the ends.</li> </ul> <ul class="clsBULLET"> <li>This is how the completed repair location with the inserted wire and two crimp connectors should look.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004309" name="S21219483532008020700000">Fig. 87: Offsetting Crimp Connections</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Make sure that crimp connections do not lie directly next to each other when several wires need to be repaired. Arrange the crimp connectors at a slight offset so that the circumference of the wiring harness does not become too large.</li> <li>If the repair point was previous taped, this point must be taped again with yellow insulating tape after repairs.</li> <li>Secure the repaired wiring harness if necessary with a cable tie to prevent flapping noises while driving.</li> </ul> </td> </tr> </table></span></p><a name="S27404784302008020700000"></a><h2 class="clsHeadTwo">Terminal Housings and Connectors, Repairing</h2><a name="S16501639072008020700000"></a><h2 class="clsHeadThree">Terminal Housings and Connectors, Repairing</h2> <p>--> <a class="clsHyperlink" href="#S40541031382008020700000">Terminal Housing and Harness Connector Repairs, General Information</a></p> <p>--> <a class="clsHyperlink" href="#S16244097552008020700000">Contacts in Terminal Housing, Repairing</a></p> <p>--> <a class="clsHyperlink" href="#S19603113652008020700000">Single Wire Seals, Assembly</a></p> <p>--> <a class="clsHyperlink" href="#S31350585472008020700000">Terminal Housings with Insulation Displacement Terminal, Repairing</a></p><a name="S40541031382008020700000"></a><h2 class="clsHeadThree">Terminal Housing and Harness Connector Repairs, General Information</h2><a name="S13393044962008020700000"></a><h2 class="clsHeadFour">Terminal Housing and Harness Connector Repairs, General Information</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Observe general notes for repairs on the vehicle electrical system --> <a class="clsHyperlink" href="#S26459495402008020700000">Vehicle Electrical System, General Information</a>.</li> <li>Allocation of crimp contacts with correct fit to contact housing is performed according to the part number stamped in on the contact housing. Terminal housing part numbers in conjunction with the appropriate crimp contacts; <a class="clsExtHyperlink" id="A00278922_S33794234522008020700000">70 - INTERIOR TRIM</a> , chart 970-00.</li> <li>Damaged contact housings must always be replaced.</li> </ul> </td> </tr> </table></span></p><a name="S16244097552008020700000"></a><h2 class="clsHeadThree">Contacts in Terminal Housing, Repairing</h2><a name="S38603556192008020700000"></a><h2 class="clsHeadFour">Contacts in Terminal Housing, Repairing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004313" name="S15555147252008020700000">Fig. 88: Releasing Terminal Lock And Pulling Wire With Single Wire Seal Toward Rear Out Of Terminal Housing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Procedure</span> </p> <ul class="clsDASH"> <li>First, open or release secondary lock of the contact housing (where applicable) --> <a class="clsHyperlink" href="#S15765947182008020700000">Terminal Housings, Releasing and Disassembling</a>.</li> </ul> <ul class="clsDASH"> <li>Release contact (primary lock) using appropriate release tool - <span class="clsEmphBOLD">A</span> - --> <a class="clsHyperlink" href="#S15765947182008020700000">Terminal Housings, Releasing and Disassembling</a>.</li> </ul> <ul class="clsDASH"> <li>Pull contact back out of housing - <span class="clsEmphBOLD">arrow</span> - at single wire (with single wire seal if necessary).</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004314" name="S33420053382008020700000">Fig. 89: Cutting Off Old Terminal With Single Wire Seal</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Cut off old contact (with the single wire seal) from vehicle-specific wiring harness.</li> </ul> <ul class="clsDASH"> <li>Determine yellow repair wire with correct contact from Wiring Harness Repair Set VAS 1978A.</li> </ul> <ul class="clsDASH"> <li>Free up wire to be repaired approximately 20 cm on both sides of the repair point.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Risk of damaging the electrical wires.<ul class="clsBULLET"> <li>Free up wrapped wiring harnesses carefully.</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>If necessary, remove wiring harness wrapping using knife.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004315" name="S28289755652008020700000">Fig. 90: Inserting New Terminal Into Terminal Housing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Slide new repair wire contact into corresponding contact housing compartment until it engages.</li> </ul> <ul class="clsDASH"> <li>If necessary, install single wire seal on repair wire --> <a class="clsHyperlink" href="#S19603113652008020700000">Single Wire Seals, Assembly</a>.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004291" name="S01125973422008020700000">Fig. 91: Cutting Wire Using Side-Cutter Function Of Wire Stripper</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Shorten repair wire and vehicle-specific wiring harness single wire as needed using the Wire Stripper VAS 1978/3.</li> </ul> <ul class="clsDASH"> <li>Remove insulation from ends of repair wire and vehicle-specific single wire and crimp ends with crimping wires and a crimp connector --> <a class="clsHyperlink" href="#S06986864642008020700000">Wire, 0.25 mm with Individual Crimp Connector, Repairing</a> or --> <a class="clsHyperlink" href="#S19270210972008020700000">Wire, 0.35 mm or Larger with Intermediate Wire Section, Repairing</a>.</li> </ul><a name="S19603113652008020700000"></a><h2 class="clsHeadThree">Single Wire Seals, Assembly</h2><a name="S11552592982008020700000"></a><h2 class="clsHeadFour">Single Wire Seals, Assembly</h2> <p><span class="clsEmphBOLD">Procedure</span> </p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Single wire seals prevent the penetration of water and dirt into the contact housing. They are installed e.g. in the engine compartment and must be reinstalled after a repair.</li> <li>Single wire seal is crimped on at the factory together with contact on the wire, this is not the case for repair wires. The single wire seal must be slid onto the wire before crimping the repair wire.</li> <li>Single wire seals must always fit with the repair wire cross-section. Outer circumference of single wire seal is aligned according to chamber circumference of the contact housing. Perform assembly using only the assembly tool with correct fit.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004316" name="S00271117632008020700000">Fig. 92: Sliding On Single Wire Seal</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Put single wire seal - <span class="clsEmphBOLD">A</span> - on to free end of repair wire.</li> </ul> <ul class="clsBULLET"> <li>When doing this, the single wire seal small diameter must point toward the contact housing.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004312" name="S13640012722008020700000">Fig. 93: Inserting New Terminal With Wire Seal</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Slide the single wire seal - <span class="clsEmphBOLD">A</span> - onto the repair wire up to the contact housing and then into the housing as far as the stop using the appropriate assembly tool - <span class="clsEmphBOLD">B</span> -.</li> </ul><a name="S31350585472008020700000"></a><h2 class="clsHeadThree">Terminal Housings with Insulation Displacement Terminal, Repairing</h2><a name="S40287011812008020700000"></a><h2 class="clsHeadFour">Terminal Housings with Insulation Displacement Terminal, Repairing</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004317" name="S26150667412008020700000">Fig. 94: Identifying Terminal Housings With Insulation Displacement Terminal</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>For technical reasons, contact housings for insulation displacement application can be supplied only with insulation displacement contacts slid on.</li> <li>If these contacts are not needed, they can be removed as on any other contact housing.</li> <li>Repair wires that already have the corresponding contacts crimped on are available.</li> </ul> </td> </tr> </table></span></p><a name="S15765947182008020700000"></a><h2 class="clsHeadTwo">Terminal Housings, Releasing and Disassembling</h2><a name="S25206006892008020700000"></a><h2 class="clsHeadThree">Terminal Housings, Releasing and Disassembling</h2><a name="S21491173532008020700000"></a><h2 class="clsHeadFour">Terminal Housings, Releasing and Disassembling</h2> <p>--> <a class="clsHyperlink" href="#S40862487362008020700000">Terminal Housings, Release and Disassembly, General Information</a></p> <p>--> <a class="clsHyperlink" href="#S35717914242008020700000">Secondary Lock</a></p> <p>--> <a class="clsHyperlink" href="#S31190937832008020700000">Primary Lock</a></p> <p>--> <a class="clsHyperlink" href="#S04712482182008020700000">Primary Connector with Round Terminal Connector Systems</a></p> <p>--> <a class="clsHyperlink" href="#S29903608432008020700000">Primary Connector with Flat Terminal Connector Systems</a></p> <p>--> <a class="clsHyperlink" href="#S29903608432008020700000">Primary Connector with Flat Terminal Connector Systems</a></p><a name="S40862487362008020700000"></a><h2 class="clsHeadThree">Terminal Housings, Release and Disassembly, General Information</h2><a name="S39508583342008020700000"></a><h2 class="clsHeadFour">Terminal Housings, Release and Disassembly, General Information</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Risk of injury.<ul class="clsBULLET"> <li>Some tools are supplied with a tool safety clip, which is slid over the tool points after using the tool, in order to protect other workers from injuries and tool points from damage.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Observe general notes for repairs on the vehicle electrical system --> <a class="clsHyperlink" href="#S26459495402008020700000">Vehicle Electrical System, General Information</a>.</li> <li>Always use the release tools intended for the releasing process. Under no circumstances may terminals be pulled forcefully out of terminal housings.</li> <li>Damaged contact housings must always be replaced.</li> <li>Small screwdrivers may be used as an aid to release the secondary locks.</li> <li>Chamber/pin assignment is located partially stamped in on secondary lock or rear side of terminal housing.</li> <li>Detailed information on component locations of harness connectors --> Electrical Wiring Diagrams, Troubleshooting and Component Locations.</li> <li>Allocation of the correct release tool to the respective retainers --> VAS 1978/35 instructions.</li> </ul> </td> </tr> </table></span></p><a name="S35717914242008020700000"></a><h2 class="clsHeadThree">Secondary Lock</h2><a name="S38720087492008020700000"></a><h2 class="clsHeadFour">Secondary Lock</h2> <ul class="clsBULLET"> <li>The secondary lock is a housing securing mechanism (second locking mechanism) that secures all wires in one terminal housing. If a secondary lock is installed at a terminal housing, it must always be opened or removed using specified tool before releasing and pulling out individual crimp contacts.</li> </ul> <ul class="clsBULLET"> <li>Secondary lock is distinguished by a different color from the rest of the contact housing. It simplifies recognizing the secondary lock and clarifies its function.</li> </ul> <ul class="clsBULLET"> <li>The shapes of the terminal housings depicted here are only a selection which, as an example, should make clear the various functions of the secondary lock.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004318" name="S12652288782008020700000">Fig. 95: Secondary Lock (Comb Type)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Example 1:</span> </p> <ul class="clsDASH"> <li>Release housing lock by removing "cam" - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004319" name="S36106441712008020700000">Fig. 96: Secondary Lock (Flap Type)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Example 2:</span> </p> <ul class="clsDASH"> <li>Release housing lock by opening "lid" - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004320" name="S25944049042008020700000">Fig. 97: Secondary Lock (Slider Type)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Example 3:</span> </p> <ul class="clsDASH"> <li>Release housing lock by disengaging "slider" - <span class="clsEmphBOLD">arrow</span> -.</li> </ul><a name="S31190937832008020700000"></a><h2 class="clsHeadThree">Primary Lock</h2><a name="S34628532182008020700000"></a><h2 class="clsHeadFour">Primary Lock</h2> <ul class="clsBULLET"> <li>The primary lock is the locking mechanism of an individual crimp contact in the terminal housing.</li> </ul> <ul class="clsBULLET"> <li>If necessary, housing securing mechanisms (secondary locks) must be released or removed using specified tool before releasing the contacts --> <a class="clsHyperlink" href="#S35717914242008020700000">Secondary Lock</a>.</li> </ul> <ul class="clsBULLET"> <li>The shapes of the primary locks depicted in the following are only a selection which, as an example, should make clear the various functions of the secondary lock.</li> </ul> <ul class="clsBULLET"> <li>Allocation of the correct release tool to the respective locking mechanism --> VAS 1978/35 operating instructions.</li> </ul><a name="S04712482182008020700000"></a><h2 class="clsHeadThree">Primary Connector with Round Terminal Connector Systems</h2><a name="S19144014592008020700000"></a><h2 class="clsHeadFour">Primary Connector with Round Terminal Connector Systems</h2> <p><span class="clsEmphBOLD">Procedure</span> </p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>If necessary, housing securing mechanisms (secondary locks) must be released or removed using specified tool before releasing the contacts --> <a class="clsHyperlink" href="#S35717914242008020700000">Secondary Lock</a>.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004321" name="S42103389332008020700000">Fig. 98: Removing Round Connector Terminal (1 of 2)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Guide release tool (which fits terminal housing) into release channel on terminal housing as illustrated.</li> </ul> <ul class="clsDASH"> <li>Grasp contact at wire and gently push into terminal housing - <span class="clsEmphBOLD">left arrow</span> -.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>By pushing contact in direction of terminal housing, contact retaining tabs are lifted off the housing shoulder and can be released using release tool.</li> <li>At the same time, push release tool in direction of the terminal housing - <span class="clsEmphBOLD">right arrow</span> - and pull the released contact out of the terminal housing.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004322" name="S05300140712008020700000">Fig. 99: Removing Round Connector Terminal (2 of 2)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Remove the release tool after removing the contact from the housing.</li> </ul><a name="S29903608432008020700000"></a><h2 class="clsHeadThree">Primary Connector with Flat Terminal Connector Systems</h2><a name="S39279326712008020700000"></a><h2 class="clsHeadFour">Primary Connector with Flat Terminal Connector Systems</h2> <p><span class="clsEmphBOLD">Procedure</span> </p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>If necessary, housing securing mechanisms (secondary locks) must be released or removed using specified tool before releasing contacts --> <a class="clsHyperlink" href="#S35717914242008020700000">Secondary Lock</a>.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004323" name="S38070226642008020700000">Fig. 100: Removing Flat Connector Terminal With One Retaining Tab (1 Of 2)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Flat connector system with one retaining tab:</span> </p> <ul class="clsDASH"> <li>Guide release tool (which fits terminal housing) into release channel on terminal housing.</li> </ul> <ul class="clsDASH"> <li>Grasp contact at wire and push gently into terminal housing - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>By pushing contact in direction of terminal housing, contact retaining tab is lifted off the housing shoulder and can be released using release tool.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004324" name="S42038847992008020700000">Fig. 101: Removing Flat Connector Terminal With One Retaining Tab (2 Of 2)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>At the same time, push release tool in direction of terminal housing and pull released contact out of terminal housing - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <ul class="clsDASH"> <li>Remove release tool after removing contact from housing.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004325" name="S19450001022008020700000">Fig. 102: Removing Flat Connector Terminal With Two Retaining Tab (1 Of 2)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Flat connector system with two retaining tabs:</span> </p> <ul class="clsDASH"> <li>Guide release tool (which fits terminal housing) into release channel on terminal housing.</li> </ul> <ul class="clsDASH"> <li>Grasp contact at wire and push gently into terminal housing until it stops - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>By pushing contact in direction of terminal housing, contact retaining tabs are lifted off the housing shoulder and can be released using release tool.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004326" name="S01250377682008020700000">Fig. 103: Removing Flat Connector Terminal With Two Retaining Tab (2 Of 2)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>At the same time, push release tool in direction of terminal housing and pull released contact out of terminal housing - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <ul class="clsDASH"> <li>Remove release tool after removing contact from housing.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004327" name="S08380134472008020700000">Fig. 104: Removing Asymmetrical Flat Connector Terminal (1 of 2)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Asymmetrical:</span> </p> <ul class="clsDASH"> <li>Guide release tool (which fits terminal housing) into release channel on terminal housing.</li> </ul> <ul class="clsDASH"> <li>Grasp contact at wire and push gently into terminal housing - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>By pushing contact in direction of terminal housing, contact retaining tabs are lifted off the housing shoulder and can be released using release tool.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004328" name="S19666391362008020700000">Fig. 105: Removing Asymmetrical Flat Connector Terminal (2 of 2)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>At the same time, push release tool in the direction of terminal housing and pull released contact out of terminal housing - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <ul class="clsDASH"> <li>Remove the release tool after removing the contact from the housing.</li> </ul><a name="S24467625412008020700000"></a><h2 class="clsHeadThree">Primary Connector with Special Connector Systems</h2> <p><span class="clsEmphBOLD">Procedure</span> </p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>If necessary, housing securing mechanisms (secondary locks) must be released or removed using specified tool before releasing the contacts --> <a class="clsHyperlink" href="#S35717914242008020700000">Secondary Lock</a>.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004288" name="S16273703302008020700000">Fig. 106: Removing Fasten Connector Terminal (1 Of 2)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Fasten contacts:</span> </p> <ul class="clsDASH"> <li>Guide release tool (that fits terminal housing) into release channel on terminal housing - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <ul class="clsDASH"> <li>Grasp contact at wire and push gently into terminal housing.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>By pushing contact in direction of terminal housing, contact retaining tabs are lifted off the housing shoulder and can be released using release tool.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004329" name="S37102879422008020700000">Fig. 107: Removing Fasten Connector Terminal (2 Of 2)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>At the same time, push release tool in direction of terminal housing and pull released contact out of terminal housing - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <ul class="clsDASH"> <li>Remove release tool after removing contact from housing.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004330" name="S12327588282008020700000">Fig. 108: Removing GT 150/280 Connector Terminal (1 Of 2)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">GT 150/280 contacts:</span> </p> <ul class="clsDASH"> <li>Guide release tool (which fits terminal housing) under retaining tab into terminal housing.</li> </ul> <ul class="clsDASH"> <li>Push tool into terminal housing until it stops - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004331" name="S38610000102008020700000">Fig. 109: Removing GT 150/280 Connector Terminal (2 Of 2)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Contact is ejected from the terminal housing.</li> </ul> <ul class="clsDASH"> <li>Remove release tool after removing contact from housing.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004332" name="S28958553622008020700000">Fig. 110: Removing Connector Terminal Without Releasing Tabs (1 Of 2)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Contacts without retaining tabs:</span> </p> <ul class="clsDASH"> <li>Insert release tool under retaining tab of terminal housing.</li> </ul> <ul class="clsDASH"> <li>Push release tool through until it stops by gently lifting - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004333" name="S25804452922008020700000">Fig. 111: Removing Connector Terminal Without Releasing Tabs (2 Of 2)</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Contact is ejected from terminal housing.</li> </ul> <ul class="clsDASH"> <li>Remove release tool after removing the contact from housing.</li> </ul><a name="S32146184082008020700000"></a><h2 class="clsHeadTwo">Antenna Wires, Repairing</h2><a name="S15304892012008020700000"></a><h2 class="clsHeadThree">Antenna Wires, Repairing</h2> <p>A repair procedure has been developed for repairing antenna wires. Instead of a complete antenna wire, connecting wires of different lengths and various adapter leads are now available as replacement parts.</p> <p>Replacement parts; Special Catalog Electrical Connection Elements ; Accessories; Sub 35 chart 035-20.</p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Do not repair antenna wires. Replace them using connector and adapter wires available as original replacement parts.</li> <li>These original replacement parts are suitable for all antenna wires and wire cross sections that need to be replaced.</li> <li>Individual antenna connectors are not designed to be replaced.</li> <li>The wires must be used retroactively for all Audi models, for all installed antenna wire diameters.</li> <li>All adapter leads and connecting wires are suitable for various transmission and reception signals.</li> <li>The repair concept can also be used as a testing or retrofitting solution.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004274" name="S16091934732008020700000">Fig. 112: Assembly Overview Of Antenna Wire</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>- <span class="clsEmphBOLD">1</span> - Adapter wire, for connection to radio; length: approximately 30 cm</li> </ul> <ul class="clsBULLET"> <li>- <span class="clsEmphBOLD">2</span> - Connecting wire, available in various lengths</li> </ul> <ul class="clsBULLET"> <li>- <span class="clsEmphBOLD">3</span> - Adapter wire, for connection to antenna; length: approximately 30 cm</li> </ul> <p><span class="clsEmphBOLD">Procedure</span> </p> <p>Example: Antenna wire from radio to antenna is faulty.</p> <ul class="clsDASH"> <li>Separate connectors of the faulty antenna wiring from associated components.</li> </ul> <ul class="clsDASH"> <li>Determine path of faulty antenna wire in vehicle and measure total length of antenna wire to be replaced.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004274" name="S23618432572008020700000">Fig. 113: Assembly Overview Of Antenna Wire</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>The entire length of antenna wire consists of the length of required adapter wires - <span class="clsEmphBOLD">1 and 3</span> - and connecting wire - <span class="clsEmphBOLD">2</span> -.</li> </ul> <ul class="clsDASH"> <li>Subtract 60 cm from the total length of antenna wire measured, to receive the length of connecting wire required.</li> </ul> <ul class="clsDASH"> <li>Obtain the correct length of the required adapter wires and connecting wires as an original replacement part according.</li> </ul> <ul class="clsDASH"> <li>Cut the connectors off of the faulty antenna wiring.</li> </ul> <ul class="clsBULLET"> <li>Leave the remaining antenna wire in vehicle.</li> </ul> <ul class="clsDASH"> <li>Connect adapter wires to associated components in the vehicle.</li> </ul> <ul class="clsDASH"> <li>Provide harness connectors with piece of foam hose to avoid rattle.</li> </ul> <ul class="clsDASH"> <li>Route and secure connecting wire parallel to old antenna wire.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Antenna wires must not be kinked or excessively bent! The bending radius must never be below 50 mm.</li> <li>Connect the connecting wire with the adapter leads.</li> <li>To avoid rattle, slide on suitable piece of foam hose onto antenna connector.</li> <li>Perform function test.</li> </ul> </td> </tr> </table></span></p><a name="S16170276852008020700000"></a><h2 class="clsHeadTwo">Fiber Optic Cable</h2><a name="S36803575372008020700000"></a><h2 class="clsHeadThree">Fiber Optic Cable</h2> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Do not excessively bend or kink fiber optic cables. (min. bending radius 25 mm).</td> </tr> </table></span></p> <p>--> <a class="clsHyperlink" href="#S41488099042008020700000">Fiber Optic Cables, Repairing</a></p> <p>--> <a class="clsHyperlink" href="#S02284033952008020700000">Fiber Optic Cable, Separating from Wiring Harness Connector</a></p><a name="S41488099042008020700000"></a><h2 class="clsHeadThree">Fiber Optic Cables, Repairing</h2><a name="S35664167462008020700000"></a><h2 class="clsHeadFour">Fiber Optic Cables, Repairing</h2> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017207" name="S21131377832008020700000">Fig. 114: Fiber Optic Plier Repair Set VAS 6223</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Fiber Optic Plier Repair Set VAS 6223</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017198" name="S18381616762008020700000">Fig. 115: Air Hose Pliers VAS 6228</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Air Hose Pliers VAS 6228</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017208" name="S12409113292008020700000">Fig. 116: Pliers For Fiber-Optic Conductor VAS 6223/1 Cutting Device</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Checking remaining cut indicator</span> </p> <ul class="clsDASH"> <li>Start by checking remaining cut indicator:</li> </ul> <ul class="clsBULLET"> <li>The Pliers For Fiber-optic Conductor VAS 6223/1 cutting device can perform approx. 1260 cuts. The blade is rotated for each further cut.</li> </ul> <ul class="clsBULLET"> <li>The remaining cut indicator - <span class="clsEmphBOLD">arrow</span> - displays the last 150 cuts available.</li> </ul> <ul class="clsBULLET"> <li>Once no further cuts are available, the blade is blocked. It must then be replaced --> Pliers For Fiber-optic Conductor VAS 6223/1 instructions.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017209" name="S35625864952008020700000">Fig. 117: Preparing Pliers For Fiber Optic Conductor VAS 6223/1</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Preparing Pliers For Fiber Optic Conductor VAS 6223/1</span> </p> <ul class="clsDASH"> <li>Release transportation safeguard at cutter by loosening Allen bolt - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017210" name="S02828958742008020700000">Fig. 118: Fiber Optic Cable, Cutting To Length</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Fiber optic cable, cutting to length</span> </p> <ul class="clsDASH"> <li>Establish length of fiber optic cable required.</li> </ul> <ul class="clsDASH"> <li>Open Pliers For Fiber Optic Conductor VAS 6223/1 and insert fiber-optic cable - <span class="clsEmphBOLD">1</span> - into trimming station.</li> </ul> <ul class="clsDASH"> <li>Close cutting tool to cut fiber optic cable to length.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017211" name="S27800437352008020700000">Fig. 119: Opening Pliers For Fiber Optic Conductor VAS 6223/1</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Stripping</span> </p> <ul class="clsDASH"> <li>Open Pliers For Fiber Optic Conductor VAS 6223/1.</li> </ul> <ul class="clsBULLET"> <li>Stripping lever must be in lower position - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <ul class="clsDASH"> <li>Place fiber optic cable - <span class="clsEmphBOLD">1</span> - in stripping point.</li> </ul> <ul class="clsBULLET"> <li>Fiber-optic cable must terminate flush to rear side of cutting pliers.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017212" name="S40515787712008020700000">Fig. 120: Closing Pliers For Fiber Optic Conductor VAS 6223/1 Until Stop And Keep Closed</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Close Pliers For Fiber Optic Conductor VAS 6223/1 until stop and keep closed.</li> </ul> <ul class="clsDASH"> <li>Lift up stripping lever - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <ul class="clsDASH"> <li>Open cutting tool and remove fiber optic cable - <span class="clsEmphBOLD">1</span> -.</li> </ul> <ul class="clsDASH"> <li>Detach separated section of insulation from fiber optic cable.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017213" name="S07899483682008020700000">Fig. 121: Sliding Fiber Optic Cable Into Cutting Point</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Precision cutting (production of optical end face)</span> </p> <ul class="clsDASH"> <li>Slide fiber optic cable - <span class="clsEmphBOLD">1</span> - into cutting point.</li> </ul> <ul class="clsBULLET"> <li>Insulation must make contact with cutting point stop - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <ul class="clsDASH"> <li>Close Pliers For Fiber Optic Conductor VAS 6223/1.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017214" name="S15925925292008020700000">Fig. 122: Pressing Cutting Unit Down</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Press cutting unit - <span class="clsEmphBOLD">arrow</span> - down.</li> </ul> <ul class="clsDASH"> <li>Open Pliers For Fiber Optic Conductor VAS 6223/1 and remove fiber-optic cable - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Fiber optic cable is only to be placed on an absolutely clean surface.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017209" name="S17260226142008020700000">Fig. 123: Preparing Pliers For Fiber Optic Conductor VAS 6223/1</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Activating transportation safeguard</span> </p> <ul class="clsDASH"> <li>Close Pliers For Fiber Optic Conductor VAS 6223/1.</li> </ul> <ul class="clsDASH"> <li>Secure hex socket screw - <span class="clsEmphBOLD">arrow</span> - for transportation safeguard on blade.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017215" name="S23882965722008020700000">Fig. 124: Opening Securing Lever On Crimping Pliers For Fiber-Optic Cable VAS 6223/2</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Attaching brass pin contact to fiber optic cable</span> </p> <ul class="clsDASH"> <li>Open securing lever on Crimping Pliers For Fiber-optic Cable VAS 6223/2 - <span class="clsEmphBOLD">arrow 1</span> - and - <span class="clsEmphBOLD">arrow 2</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017216" name="S41452480222008020700000">Fig. 125: Closing Securing Lever On Crimping Pliers For Fiber-Optic Cable VAS 6223/2</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Insert brass pin contact - <span class="clsEmphBOLD">1</span> - in mount.</li> </ul> <ul class="clsDASH"> <li>Close securing lever on Crimping Pliers For Fiber-optic Cable VAS 6223/2 - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017217" name="S03145135012008020700000">Fig. 126: Sliding Fiber Optic Cable Into Brass Pin Contact As Far As Spring-Loaded Stop</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Slide fiber optic cable - <span class="clsEmphBOLD">2</span> - into brass pin contact - <span class="clsEmphBOLD">1</span> - as far as spring-loaded stop.</li> </ul> <ul class="clsDASH"> <li>Slide fiber-optic cable further in up to fixed stop and close Crimping Pliers For Fiber-optic Cable VAS 6223/2.</li> </ul> <ul class="clsDASH"> <li>Open Crimping Pliers For Fiber-optic Cable and remove fiber-optic cable with brass pin contact.</li> </ul> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td>Do not excessively bend or kink fiber optic cables. (min. bending radius 25 mm).</td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017218" name="S35055802902008020700000">Fig. 127: Checking Proper Attachment Of Brass Pin Contact To Fiber Optic Cable</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Check proper attachment of brass pin contact - <span class="clsEmphBOLD">2</span> - to fiber optic cable - <span class="clsEmphBOLD">1</span> -.</li> </ul> <ul class="clsBULLET"> <li>4 crimp points must be visible at brass connection pin.</li> </ul> <ul class="clsBULLET"> <li>The brass pin contact must not be able to be removed by hand from fiber-optic cable.</li> </ul> <ul class="clsBULLET"> <li>End face of fiber optic cable is located 0.01 to 0.1 mm behind brass pin contact (visual inspection).</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Plug-in couplings are available for connecting fiber optic cables.</li> <li>For installing new fiber optic cable in wiring harness connector, refer to --> <a class="clsHyperlink" href="#S02284033952008020700000">Fiber Optic Cable, Separating from Wiring Harness Connector</a>.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017219" name="S02535084482008020700000">Fig. 128: Cutting Corrugated Tube To Appropriate Length Using Air Hose Pliers VAS 6228 Or A Sharp Knife</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Installing corrugated tube on fiber-optic cable</span> </p> <ul class="clsDASH"> <li>Cut corrugated tube to appropriate length.</li> </ul> <ul class="clsBULLET"> <li>Use air hose pliers VAS 6228 or a sharp knife for cutting.</li> </ul> <ul class="clsBULLET"> <li>The corrugated tube must not be cut through using a side cutter under any circumstances</li> </ul> <ul class="clsBULLET"> <li>The corrugated tube must be cut on the wave peak - <span class="clsEmphBOLD">arrow</span> - , not in the wave trough.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017220" name="S15928718772008020700000">Fig. 129: Guiding Fiber-Optic Cable Into Crimping Pliers For Fiber-Optic Cable VAS 6223/10</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Guide fiber-optic cable into Crimping Pliers For Fiber-optic Cable VAS 6223/10 as shown in illustration.</li> </ul> <ul class="clsDASH"> <li>Position Crimping Pliers For Fiber-optic Cable at slot of corrugated tube.</li> </ul> <ul class="clsDASH"> <li>Position Crimping Pliers For Fiber-optic Cable at slot of corrugated tube. By doing this, fiber-optic cable is fed in corrugated tube.</li> </ul><a name="S02284033952008020700000"></a><h2 class="clsHeadThree">Fiber Optic Cable, Separating from Wiring Harness Connector</h2><a name="S12801193702008020700000"></a><h2 class="clsHeadFour">Fiber Optic Cable, Separating from Wiring Harness Connector</h2> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017221" name="S16400637682008020700000">Fig. 130: Releasing Catch In Fiber Optic Cable Connector Using Small Screw Driver</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Removing</span> </p> <ul class="clsDASH"> <li>Unplug fiber-optic cable connection from control module or device.</li> </ul> <ul class="clsDASH"> <li>Use small screw driver to release catch in fiber optic cable connector - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017222" name="S23913958782008020700000">Fig. 131: Pulling Fiber Optic Cable Basic Module Out Of Connector Housing</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>Pull fiber optic cable basic module - <span class="clsEmphBOLD">2</span> - out of connector housing - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017223" name="S18406021822008020700000">Fig. 132: Making Colored Dots To Mark Assignment Of Fiber Optic Cable To Corresponding Sockets In Basic Module</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>Make colored dots to mark assignment of fiber optic cable - <span class="clsEmphBOLD">5</span> - to corresponding sockets in basic module - <span class="clsEmphBOLD">1</span> -.</li> <li>Note the arrows - <span class="clsEmphBOLD">3</span> - for allocation on the base module "IN" and "OUT".</li> </ul> </td> </tr> </table></span></p> <ul class="clsDASH"> <li>Release secondary catch - <span class="clsEmphBOLD">6</span> - (blue pin) using a small screwdriver - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <ul class="clsDASH"> <li>Release retaining tab - <span class="clsEmphBOLD">2</span> - and remove fiber optic cable - <span class="clsEmphBOLD">5</span> - with brass connector pin - <span class="clsEmphBOLD">4</span> - from basic module - <span class="clsEmphBOLD">1</span> -.</li> </ul> <p><span class="clsEmphBOLD">Installing</span> </p> <p>Install in reverse order of removal, observing the following:</p> <ul class="clsDASH"> <li>Install fiber optic cable in line with markings.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017224" name="S16788979132008020700000">Fig. 133: Fiber-Optic Cable Harness Connector And Protective Cap For Cable Connector VAS 6223/9</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Seal open harness connector - <span class="clsEmphBOLD">2</span> - for fiber-optic cable using Protective Cap For Cable Connector VAS 6223/9 - <span class="clsEmphBOLD">1</span> -.</li> <li>Protective cap prevents contamination of or mechanical damage to end face of fiber optic cable which would impair signal transmission.</li> </ul> </td> </tr> </table></span></p><a name="S25674678292008020700000"></a><h2 class="clsHeadTwo">Vehicle Diagnosis, Testing and Information Systems</h2><a name="S34676021992008020700000"></a><h2 class="clsHeadThree">Vehicle Diagnosis, Testing and Information Systems</h2> <p>--> <a class="clsHyperlink" href="#S01607505372008020700000">Safety Precautions</a></p> <p>--> <a class="clsHyperlink" href="#S11317004502008020700000">Vehicle Diagnosis, Testing and Information System VAS 5051B, Connecting</a></p><a name="S28544342402008020700000"></a><h2 class="clsHeadThree">Safety Precautions</h2><a name="S40147632932008020700000"></a><h2 class="clsHeadFour">Safety Precautions</h2> <p><span class="clsEmphBOLD">Audi A3, Audi A4, Audi A4 Cabriolet, Audi A5, Audi A6, Audi A8 Audi Q7</span> </p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>During road tests using a vehicle diagnostic and information system, there is the hazard of extreme to lethal injuries!</li> <li>If vehicle diagnostic and information system is deposited in the action area of an airbag during a road test, here is the hazard of extreme to lethal injuries in the event the airbag deploys!</li> <li>During road tests, have a second person sitting in the rear seat to operate the vehicle diagnostic and information system.</li> <li>Due to weight, size and need for manual operation of diagnostic tester while vehicle is driven on public roads, diagnostic tester must be used only with a Driver operating the vehicle and an Diagnostic Tester Operator operating the test equipment.</li> </ul> <ul class="clsBULLET"> <li>Do not use Diagnostic Tester with Driver only. Always use two persons to conduct test.</li> <li>Do not place Diagnostic Tester on lap of Driver or front seat passenger because emergency stop may dislodge diagnostic tester and cause airbag deployment with risk of injury to Diagnostic Tester Operator.</li> <li>Place diagnostic tester in rear seating area and secure by available safety belt.</li> <li>Diagnostic Tester Operator must be seated in the other rear seating position, after sliding front passenger seat and moving the seat back as far forward as possible. Do not activate the seat back release lever.</li> </ul> <ul class="clsBULLET"> <li>Diagnostic Tester Operator must wear safety belt.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00017225" name="S17843739972008020700000">Fig. 134: Diagnostic Tester Operator Wearing Safety Belt</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <p><span class="clsEmphBOLD">Audi TT and Audi R8</span> </p> <p><span class="clsCaution"><table> <tr> <td class="clsCautionLabel"><span>CAUTION:</span></td> <td> <ul class="clsBULLET"> <li>During road tests using a vehicle diagnostic and information system, there is the hazard of extreme to lethal injuries!</li> <li>If vehicle diagnostic and information system is deposited in the action area of an airbag during a road test, here is the hazard of extreme to lethal injuries in the event the airbag deploys!</li> <li>During road tests, have a second person sitting in the passengers seat to operate the vehicle diagnostic and information system.</li> <li>Only use the Vehicle Diagnosis And Service System VAS 5052 or Diagnostic System VAS 5053.</li> </ul> <ul class="clsBULLET"> <li>Due to weight, size and need for manual operation of diagnostic tester while vehicle is driven on public roads, diagnostic tester must be used only with a Driver operating the vehicle and an Diagnostic Tester Operator operating the test equipment.</li> <li>Do not use Diagnostic Tester with Driver only. Always use two persons to conduct test.</li> <li>Position the passengers seat as far back as possible.</li> <li>Diagnostic Tester Operator must wear safety belt.</li> </ul> <ul class="clsBULLET"> <li>Diagnostic tester - <span class="clsEmphBOLD">1</span> - must lie flat on the Tester Operators legs and be operated only by that person, as shown in the illustration.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>All adaptations, coding, etc. can be performed with the Vehicle Diagnosis, Testing and Information System VAS 5051B and the Vehicle Diagnosis And Service System VAS 5052.</li> <li>All work instructions can be reached in the operating modes "Guided Fault Finding" and "Guided Functions".</li> <li>Additional information:</li> </ul> </td> </tr> </table></span></p> <p>911203 VAS 5052 Design and Function</p><a name="S11317004502008020700000"></a><h2 class="clsHeadThree">Vehicle Diagnosis, Testing and Information System VAS 5051B, Connecting</h2><a name="S08539151792008020700000"></a><h2 class="clsHeadFour">Vehicle Diagnosis, Testing and Information System VAS 5051B, Connecting</h2> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Follow the current operating instructions for the Vehicle Diagnosis, Testing and Information System VAS 5051B , which can be displayed by selecting the "Administration" and "operators handbook" buttons.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Special tools, testers and auxiliary items required</span> </p> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00002349" name="S11012218602008020700000">Fig. 135: Identifying Vehicle Diagnosis, Testing And Information System VAS 5051B</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsBULLET"> <li>Vehicle Diagnosis, Testing and Information System VAS 5051B</li> </ul> <ul class="clsBULLET"> <li>Diagnostic Cable 5 Meters VAS 5051/6B or</li> </ul> <ul class="clsBULLET"> <li>Diagnostic cable VAS 5051/5A (3m)</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>Only use the diagnostic cables listed for diagnosis because they are equipped with CAN cables and allow CAN diagnosis or CAN communication.</li> </ul> </td> </tr> </table></span></p> <p><span class="clsEmphBOLD">Procedure</span> </p> <ul class="clsDASH"> <li>Engage the parking brake.</li> </ul> <ul class="clsDASH"> <li>Move manual shift lever into neutral or place automatic transmission selector lever in "P" or "N" position.</li> </ul> <p><span class="clsFig"><a class="clsExtGraphicLink" onclick="ajaxModalImg($(this).attr('id'))" id="GW00004283" name="S38802353762008020700000">Fig. 136: Locating Data Link Connector</a><br><span class="clsCourtesyNote">Courtesy of VOLKSWAGEN UNITED STATES, INC.</span></span></p> <ul class="clsDASH"> <li>With the ignition switched off, connect the Vehicle Diagnosis, Testing and Information System VAS 5051B with the diagnostic cable to the vehicle Data Link Connector (DLC) - <span class="clsEmphBOLD">arrow</span> -.</li> </ul> <ul class="clsDASH"> <li>Switch on ignition.</li> </ul> <ul class="clsDASH"> <li>Turn off all electrical consumers.</li> </ul> <p><span class="clsNote"><table> <tr> <td class="clsNoteLabel"><span>NOTE:</span></td> <td> <ul class="clsBULLET"> <li>If a malfunction is displayed --> VAS 5051B operating instructions.</li> <li>The Vehicle Diagnosis And Service System VAS 5052 or Diagnostic System VAS 5053 is connected the same way.</li> </ul> </td> </tr> </table></span></p> </body> </html>

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ELECTRICAL EQUIPMENT - GENERAL INFORMATION
  • HEADINGS
    • 27 - Battery, Starter, Generator, Cruise control
      • Battery, General Information
        • Battery, General Information
        • Safety Precautions
          • Safety Precautions
        • Lead-Acid Battery, Safety Precautions
          • Lead-Acid Battery, Safety Precautions
      • Lead-Acid Battery without Visual Indicator
        • Lead-Acid Battery without Visual Indicator
        • Central Venting System
          • Central Venting System
        • Battery Post and Terminal, Handling Instructions
          • Battery Post and Terminal, Handling Instructions
        • Lead-Acid Battery without Visual Indicator, Checking
          • Lead-Acid Battery without Visual Indicator, Checking
        • Battery, Visual Inspection
          • Battery, Visual Inspection
        • Battery Electrolyte Level, Checking
          • Battery Electrolyte Level, Checking
        • Battery Specific Gravity, Measuring in All Cells
          • Battery Specific Gravity, Measuring in All Cells
      • Maintenance-Free Batteries
        • Maintenance-Free Batteries
        • Maintenance-Free Battery with Visual Indicator
          • Maintenance-Free Battery with Visual Indicator
        • Maintenance-Free Battery with Visual Indicator, Checking
          • Maintenance-Free Battery with Visual Indicator, Checking
        • Absorbent Glass Mat Battery without Visual Indicator
          • Absorbent Glass Mat Battery without Visual Indicator
        • Absorbent Glass Mat Battery, Checking
          • Absorbent Glass Mat Battery, Checking
        • Central Venting System
          • Central Venting System
        • Battery Post and Terminal, Handling Instructions
          • Battery Post and Terminal, Handling Instructions
        • Battery, Visual Inspection
          • Battery, Visual Inspection
        • Maintenance-Free Battery with Visual Indicator, Checking Color Display
          • Maintenance-Free Battery with Visual Indicator, Checking Color Display
        • Battery Electrolyte Level, Checking
          • Battery Electrolyte Level, Checking
      • Battery, Testing
        • Battery, Testing
        • Battery, Testing with Midtronics Battery/Starting/Charging System Analyzer MCR340A
          • Battery, Testing with Midtronics Battery/Starting/Charging System Analyzer MCR340A
        • Battery - Vehicles with Energy Management Control Module, Testing with Vehicle Diagnosis, Testing and Information System VAS 5051B
          • Battery - Vehicles with Energy Management Control Module, Testing with Vehicle Diagnosis, Testing and Information System VAS 5051B
        • Battery No-Load Voltage - Vehicles without Energy Management Control Module, Checking
          • Battery No-Load Voltage - Vehicles without Energy Management Control Module, Checking
        • Battery No-Load Voltage - Vehicles with Energy Management Control Module, Checking
          • Battery No-Load Voltage - Vehicles with Energy Management Control Module, Checking
        • Battery, Load Testing with Midtronics Diagnostic Conductance Charging Station INC-940
          • Battery, Load Testing with Midtronics Diagnostic Conductance Charging Station INC-940
      • Battery, Charging
        • Battery, Charging
          • Battery, Charging
        • Battery, Charging with Midtronics Diagnostic Conductance Charging Station INC-940
          • Battery, Charging with Midtronics Diagnostic Conductance Charging Station INC-940
        • Totally Discharged Batteries, Charging
          • Totally Discharged Batteries, Charging
        • Battery, Quick Charging
          • Battery, Quick Charging
        • Battery, Support Mode with Midtronics Battery Maintainer PSC-550 or Midtronics Battery Maintainer CXC-2115
          • Battery, Support Mode with Midtronics Battery Maintainer PSC-550 or Midtronics Battery Maintainer CXC-2115
      • Generator, Testing and Servicing
        • Generator, Testing and Servicing
        • Generator, Testing
          • Generator, Testing
        • Bosch Generator, through MY 2000, Assembly Overview
          • Bosch Generator, through MY 2000, Assembly Overview
        • Bosch Generator, from MY 2001, Assembly Overview
          • Bosch Generator, from MY 2001, Assembly Overview
        • Voltage Regulator, Bosch Generator from MY 2001, Removing and Installing
          • Voltage Regulator, Bosch Generator from MY 2001, Removing and Installing
        • Carbon Brushes, Bosch Generator from MY 2001, Checking
          • Carbon Brushes, Bosch Generator from MY 2001, Checking
        • Valeo Generator, through MY 2000, Assembly Overview
          • Valeo Generator, through MY 2000, Assembly Overview
        • Valeo Generator, from MY 2001, Assembly Overview
          • Valeo Generator, from MY 2001, Assembly Overview
        • Voltage Regulator, Valeo Generator from MY 2001, Removing and Installing
          • Voltage Regulator, Valeo Generator from MY 2001, Removing and Installing
        • Carbon Brushes, Valeo Generator from MY 2001, Checking
          • Carbon Brushes, Valeo Generator from MY 2001, Checking
        • Ribbed Belt Pulley without Freewheel, Removing and Installing
          • Ribbed Belt Pulley without Freewheel, Removing and Installing
        • Ribbed Belt Pulley with Freewheel, Removing and Installing
          • Ribbed Belt Pulley with Freewheel, Removing and Installing
      • Cruise Control System, with Electronic Power Control
        • Cruise Control System, with Electronic Power Control
        • General Information
          • General Information
        • Cruise Control System, Activating and Deactivating
          • Cruise Control System, Activating and Deactivating
    • 92 - Windshield wiper and washer system
      • Washer Hose Couplings
      • Washer Hoses, Repairing
        • Washer Hoses, Repairing
        • Smooth Hoses, Repairing
          • Smooth Hoses, Repairing
        • Corrugated Hoses, Repairing
          • Corrugated Hoses, Repairing
    • 94 - Lights, Switches - Exterior
      • HID Headlamps, Safety Precautions
    • 96 - Lights, Switches - Interior, Anti-theft
      • Anti-Theft Immobilizer, without Access/Start Control Module
        • Anti-Theft Immobilizer, without Access/Start Control Module
        • General Information
          • General Information
        • Faulty Transponder or Lost Key
          • Faulty Transponder or Lost Key
        • Induction Coil, Replacing
          • Induction Coil, Replacing
        • Lock Set, Replacement Procedure
          • Lock Set, Replacement Procedure
      • Anti-Theft Immobilizer, with Access/Start Control Module
        • Anti-Theft Immobilizer, with Access/Start Control Module
      • Heated Steering Wheel
        • Heated Steering Wheel
      • Trailer Hitch Wiring Socket
        • Trailer Hitch Wiring Socket
        • Trailer Hitch Wiring Socket, Removing and Installing
          • Trailer Hitch Wiring Socket, Removing and Installing
        • Trailer Hitch Wiring Socket, Multi-Pin Connector Assignments
          • Trailer Hitch Wiring Socket, Multi-Pin Connector Assignments
    • 97 - Wiring
      • Wiring Harnesses and Connectors, Repairing
        • Wiring Harnesses and Connectors, Repairing
        • Vehicle Electrical System, General Information
          • Vehicle Electrical System, General Information
        • Wiring Harness and Connector Repairs, General Information
          • Wiring Harness and Connector Repairs, General Information
        • Airbag and Safety Belt Tensioner Wiring, Repairing
          • Airbag and Safety Belt Tensioner Wiring, Repairing
        • CAN-Bus Wiring, Repairing
          • CAN-Bus Wiring, Repairing
        • Wire, 0.25 mm with Individual Crimp Connector, Repairing
          • Wire, 0.25 mm with Individual Crimp Connector, Repairing
        • Wire, 0.35 mm and Larger with Individual Crimp Connector, Repairing
          • Wire, 0.35 mm and Larger with Individual Crimp Connector, Repairing
        • Wire, 0.25 mm with Intermediate Wire Section, Repairing
          • Wire, 0.25 mm with Intermediate Wire Section, Repairing
        • Wire, 0.35 mm or Larger with Intermediate Wire Section, Repairing
          • Wire, 0.35 mm or Larger with Intermediate Wire Section, Repairing
      • Terminal Housings and Connectors, Repairing
        • Terminal Housings and Connectors, Repairing
        • Terminal Housing and Harness Connector Repairs, General Information
          • Terminal Housing and Harness Connector Repairs, General Information
        • Contacts in Terminal Housing, Repairing
          • Contacts in Terminal Housing, Repairing
        • Single Wire Seals, Assembly
          • Single Wire Seals, Assembly
        • Terminal Housings with Insulation Displacement Terminal, Repairing
          • Terminal Housings with Insulation Displacement Terminal, Repairing
      • Terminal Housings, Releasing and Disassembling
        • Terminal Housings, Releasing and Disassembling
          • Terminal Housings, Releasing and Disassembling
        • Terminal Housings, Release and Disassembly, General Information
          • Terminal Housings, Release and Disassembly, General Information
        • Secondary Lock
          • Secondary Lock
        • Primary Lock
          • Primary Lock
        • Primary Connector with Round Terminal Connector Systems
          • Primary Connector with Round Terminal Connector Systems
        • Primary Connector with Flat Terminal Connector Systems
          • Primary Connector with Flat Terminal Connector Systems
        • Primary Connector with Special Connector Systems
      • Antenna Wires, Repairing
        • Antenna Wires, Repairing
      • Fiber Optic Cable
        • Fiber Optic Cable
        • Fiber Optic Cables, Repairing
          • Fiber Optic Cables, Repairing
        • Fiber Optic Cable, Separating from Wiring Harness Connector
          • Fiber Optic Cable, Separating from Wiring Harness Connector
      • Vehicle Diagnosis, Testing and Information Systems
        • Vehicle Diagnosis, Testing and Information Systems
        • Safety Precautions
          • Safety Precautions
        • Vehicle Diagnosis, Testing and Information System VAS 5051B, Connecting
          • Vehicle Diagnosis, Testing and Information System VAS 5051B, Connecting
  • FIGURES
    • Fig. 1: Battery Safety Label
    • Fig. 2: Identifying Battery Posts
    • Fig. 3: Battery fill bottle VAS 5045
    • Fig. 4: VAS 5045 Battery Filling Bottle
    • Fig. 5: Identifying Refractometer T10007
    • Fig. 6: Identifying Commercially Available Hydrometer
    • Fig. 7: Hydrometer Specific Gravity Reading
    • Fig. 8: Locating Magic Eye
    • Fig. 9: Identifying Battery Posts
    • Fig. 10: Locating Magic Eye
    • Fig. 11: Battery VAS Tester
    • Fig. 12: Display On VAS 5051 - (1st Control Element In Test & Evaporative Emission (EVAP) Canister Purge Regulator Valve-N80-)
    • Fig. 13: Portable Multimeter V.A.G 1526C
    • Fig. 14: Portable Multimeter V.A.G 1526C
    • Fig. 15: Battery charging unit VAS 5900
    • Fig. 16: Battery charging unit VAS 5900
    • Fig. 17: Battery charging unit VAS 5095 A
    • Fig. 18: Bosch Generator, Through MY 2000, Assembly Overview
    • Fig. 19: Bosch Generator, From MY 2001, Assembly Overview
    • Fig. 20: Generator Cover And Screws
    • Fig. 21: Voltage Regulator Screws
    • Fig. 22: Carbon Brushes Wear Limit
    • Fig. 23: Valeo Generator, Through MY 2000, Assembly Overview
    • Fig. 24: Valeo Generator, From MY 2001, Assembly Overview
    • Fig. 25: Identifying Cover And Threaded Pins At Rear Side Of Generator
    • Fig. 26: Generator Bolts And Combination Bolt
    • Fig. 27: Voltage Regulator And Protective Cap
    • Fig. 28: Carbon Brushes, Valeo Generator From MY 2001, Checking
    • Fig. 29: Identifying Multi-Point Socket 3310
    • Fig. 30: Loosen/Tighten Nut At Pulley With Wrench And Adapter 3310
    • Fig. 31: Identifying Multi-Point Socket 3400
    • Fig. 32: Tightening/Loosening Nut At Pulley With Wrench And Adapter 3400
    • Fig. 33: Display On VAS 5051 - (1st Control Element In Test & Evaporative Emission (EVAP) Canister Purge Regulator Valve-N80-)
    • Fig. 34: Identifying Washer Hose Coupling
    • Fig. 35: Connecting/Disconnecting Washer Hose Coupling (Type 1)
    • Fig. 36: Connecting/Disconnecting Washer Hose Coupling (Type 2)
    • Fig. 37: Connecting/Disconnecting Washer Hose Coupling (Type 3)
    • Fig. 38: Connecting/Disconnecting Washer Hose Coupling (Headlight Cleaning System)
    • Fig. 39: Headlamp Washer System Hose Connection With Hose Clamp
    • Fig. 40: Headlamp Washer System Hose Coupling With Spring Clamp
    • Fig. 41: Repairing Smooth Washer Hose
    • Fig. 42: Securing Hose With Cable Ties
    • Fig. 43: Wiring Harness Repair Set VAS 1978A
    • Fig. 44: Air Hose Pliers VAS 6228
    • Fig. 45: Connecting Ends Of The Washer Fluid Line With Connector Pieces
    • Fig. 46: Trailer Hitch Wiring Socket Components
    • Fig. 47: Switch Connector And Connector At Socket
    • Fig. 48: Pressing Multi-Pin Connector Out Of Socket
    • Fig. 49: Releasing Securing Tabs And Then Releasing Retainer Clips
    • Fig. 50: Releasing Securing Tabs And Then Retaining Clips
    • Fig. 51: O-Rings, Harness Connectors And Retainer
    • Fig. 52: Trailer Hitch Wiring Socket, Multi-Pin Connector Assignments
    • Fig. 53: Wiring Harness Repair Kit V.A.S 1978
    • Fig. 54: Upgrade Kit For VAS1978 (VAS1978/50)
    • Fig. 55: Wiring Harness Repair Set VAS 1978A
    • Fig. 56: Opened Wiring Harness Repair Kit VAS 1978
    • Fig. 57: Repairing Twisted Wire Pairs
    • Fig. 58: Repairing Twisted Wire Pairs
    • Fig. 59: Cutting Wire Using Side-Cutter Function Of Wire Stripper
    • Fig. 60: Stripping Insulation At Wiring Using Stripping Pliers
    • Fig. 61: Crimping Pliers
    • Fig. 62: Crimping Single Break Point
    • Fig. 63: Heating Crimp Connection Using Hot Air Gun
    • Fig. 64: Single Repair Point
    • Fig. 65: Offsetting Crimp Connections
    • Fig. 66: Cutting Wire Using Side-Cutter Function Of Wire Stripper
    • Fig. 67: Stripping Insulation At Wiring Using Stripping Pliers
    • Fig. 68: Crimping Pliers
    • Fig. 69: Crimping Single Break Point
    • Fig. 70: Heating Crimp Connection Using Hot Air Gun
    • Fig. 71: Single Repair Point
    • Fig. 72: Offsetting Crimp Connections
    • Fig. 73: Cutting Wire Using Side-Cutter Function Of Wire Stripper
    • Fig. 74: Stripping Insulation At Wiring Using Stripping Pliers
    • Fig. 75: Stripping Insulation At Wiring Using Stripping Pliers
    • Fig. 76: Crimping Pliers
    • Fig. 77: Crimping Single Break Point
    • Fig. 78: Heating Crimp Connection Using Hot Air Gun
    • Fig. 79: Wire Break With Dual Repair Point
    • Fig. 80: Offsetting Crimp Connections
    • Fig. 81: Cutting Wire Using Side-Cutter Function Of Wire Stripper
    • Fig. 82: Stripping Insulation At Wiring Using Stripping Pliers
    • Fig. 83: Crimping Pliers
    • Fig. 84: Crimping Single Break Point
    • Fig. 85: Heating Crimp Connection Using Hot Air Gun
    • Fig. 86: Wire Break With Dual Repair Point
    • Fig. 87: Offsetting Crimp Connections
    • Fig. 88: Releasing Terminal Lock And Pulling Wire With Single Wire Seal Toward Rear Out Of Terminal Housing
    • Fig. 89: Cutting Off Old Terminal With Single Wire Seal
    • Fig. 90: Inserting New Terminal Into Terminal Housing
    • Fig. 91: Cutting Wire Using Side-Cutter Function Of Wire Stripper
    • Fig. 92: Sliding On Single Wire Seal
    • Fig. 93: Inserting New Terminal With Wire Seal
    • Fig. 94: Identifying Terminal Housings With Insulation Displacement Terminal
    • Fig. 95: Secondary Lock (Comb Type)
    • Fig. 96: Secondary Lock (Flap Type)
    • Fig. 97: Secondary Lock (Slider Type)
    • Fig. 98: Removing Round Connector Terminal (1 of 2)
    • Fig. 99: Removing Round Connector Terminal (2 of 2)
    • Fig. 100: Removing Flat Connector Terminal With One Retaining Tab (1 Of 2)
    • Fig. 101: Removing Flat Connector Terminal With One Retaining Tab (2 Of 2)
    • Fig. 102: Removing Flat Connector Terminal With Two Retaining Tab (1 Of 2)
    • Fig. 103: Removing Flat Connector Terminal With Two Retaining Tab (2 Of 2)
    • Fig. 104: Removing Asymmetrical Flat Connector Terminal (1 of 2)
    • Fig. 105: Removing Asymmetrical Flat Connector Terminal (2 of 2)
    • Fig. 106: Removing Fasten Connector Terminal (1 Of 2)
    • Fig. 107: Removing Fasten Connector Terminal (2 Of 2)
    • Fig. 108: Removing GT 150/280 Connector Terminal (1 Of 2)
    • Fig. 109: Removing GT 150/280 Connector Terminal (2 Of 2)
    • Fig. 110: Removing Connector Terminal Without Releasing Tabs (1 Of 2)
    • Fig. 111: Removing Connector Terminal Without Releasing Tabs (2 Of 2)
    • Fig. 112: Assembly Overview Of Antenna Wire
    • Fig. 113: Assembly Overview Of Antenna Wire
    • Fig. 114: Fiber Optic Plier Repair Set VAS 6223
    • Fig. 115: Air Hose Pliers VAS 6228
    • Fig. 116: Pliers For Fiber-Optic Conductor VAS 6223/1 Cutting Device
    • Fig. 117: Preparing Pliers For Fiber Optic Conductor VAS 6223/1
    • Fig. 118: Fiber Optic Cable, Cutting To Length
    • Fig. 119: Opening Pliers For Fiber Optic Conductor VAS 6223/1
    • Fig. 120: Closing Pliers For Fiber Optic Conductor VAS 6223/1 Until Stop And Keep Closed
    • Fig. 121: Sliding Fiber Optic Cable Into Cutting Point
    • Fig. 122: Pressing Cutting Unit Down
    • Fig. 123: Preparing Pliers For Fiber Optic Conductor VAS 6223/1
    • Fig. 124: Opening Securing Lever On Crimping Pliers For Fiber-Optic Cable VAS 6223/2
    • Fig. 125: Closing Securing Lever On Crimping Pliers For Fiber-Optic Cable VAS 6223/2
    • Fig. 126: Sliding Fiber Optic Cable Into Brass Pin Contact As Far As Spring-Loaded Stop
    • Fig. 127: Checking Proper Attachment Of Brass Pin Contact To Fiber Optic Cable
    • Fig. 128: Cutting Corrugated Tube To Appropriate Length Using Air Hose Pliers VAS 6228 Or A Sharp Knife
    • Fig. 129: Guiding Fiber-Optic Cable Into Crimping Pliers For Fiber-Optic Cable VAS 6223/10
    • Fig. 130: Releasing Catch In Fiber Optic Cable Connector Using Small Screw Driver
    • Fig. 131: Pulling Fiber Optic Cable Basic Module Out Of Connector Housing
    • Fig. 132: Making Colored Dots To Mark Assignment Of Fiber Optic Cable To Corresponding Sockets In Basic Module
    • Fig. 133: Fiber-Optic Cable Harness Connector And Protective Cap For Cable Connector VAS 6223/9
    • Fig. 134: Diagnostic Tester Operator Wearing Safety Belt
    • Fig. 135: Identifying Vehicle Diagnosis, Testing And Information System VAS 5051B
    • Fig. 136: Locating Data Link Connector
  • TABLES

ELECTRICAL

Electrical Equipment - General Information

27 - Battery, Starter, Generator, Cruise control

Battery, General Information

Battery, General Information

CAUTION: Danger of injury!

CAUTION: Risk of damage to battery or vehicle.

The battery is one of the most important electrical components in the modern automobile. A battery that provides trouble-free service has a great influence on customer satisfaction. To ensure trouble-free service and optimum service life, batteries must be checked, serviced and maintained as per the instructions in this information.

Apart from starting the engine, the battery has other tasks. It acts as a buffer and also supplies electrical energy to the complete vehicle electrical system. In addition, the cyclical and capacity demands on the battery have increased due to additional safety and convenience features (electrical consumers) being installed.

The automobile battery has undergone many technical changes and improvements, and development of new battery technologies continues.

A new generation of maintenance free batteries uses physically and constructively optimized, lead-calcium coated positive electrodes. Advantages include minimal electrolyte consumption and servicing requirements, as well as improved charge stability over a longer period of time. Simplified checking of these batteries is also achieved with the "Magic Eye" charge indicator.

--> Safety Precautions

--> Lead-Acid Battery, Safety Precautions

Safety Precautions

Safety Precautions

Before beginning work, technicians must be acquainted with the possible risks when handling batteries.

CAUTION:
  • Personnel instructed in protection, such as e. g. a trainee or apprentice, may only perform work on vehicle batteries under supervision of technical personnel such as e. g. a master automotive mechanic or a master automotive electrician.
  • Acid has strong corrosive properties. If batteries are handled inappropriately, there is a risk that personal injury may result from exposure to harmful electrolyte influences. Therefore, suitable remedies for acid damage must be kept readily available. Suitable remedy is e.g. soap solution.
  • If electrolyte drips out from the battery, skin can be acid-burned, and the vehicle may be affected by acid erosion and corrosion. It is a possibility that safety-related vehicle components can be damaged.
  • When charging and when resting after charging, explosive gas is present. In extreme cases, if battery is handled inappropriately, the emitted gases may cause the battery to explode.
  • Batteries with a colorless or light yellow "Magic Eye" charge indicator must be replaced. They may not be tested or charged and jump starting may not be used. There is a risk of explosion during testing, charging or jump starting.
  • Generating sparks by sanding, welding, separating work and open flame, e.g. smoking in vicinity of the battery, is prohibited. Producing sparks through electrostatic discharge must also be avoided. Always touch the vehicle body before touching the battery.
  • Only perform battery procedures in suitable and well-ventilated rooms.

Lead-Acid Battery, Safety Precautions

Lead-Acid Battery, Safety Precautions

Recognizing and preventing risks

Working with batteries can be hazardous. Danger can be avoided if the warnings on the battery, in the owners manual and in the repair information are heeded.

Fig. 1: Battery Safety Label
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Explanation of battery symbols

CAUTION: 1 - Keep open flames and sparks away and DO NOT smoke near batteries! Avoid sparks when working with cables and electrical units. Always reinstall battery positive (B+) or negative (-) terminal covers if removed during servicing.
  • Avoid sparks when working with cables and electrical units.
  • Always reinstall battery positive (B+) or negative (-) terminal covers if removed during servicing.

2 - Always wear eye protection when working with electrolyte!

  • If electrolyte gets into eyes, flush with large quantities of water. Seek medical attention immediately!

3 - Keep children away from batteries!

4 - Dispose of batteries properly!

  • Waste batteries must only be disposed of in appropriate waste disposal sites. Refer to local regulations pertaining to battery disposal.

5 - Never dispose of batteries in household waste!

6 - Danger of explosion!

  • Batteries produce explosive gasses while being charged.
  • Keep open flames and sparks away and DO NOT smoke near batteries.
  • The battery charger MUST be turned off when connecting or disconnecting the cables at the battery.
  • Battery cell caps must NOT be removed while charging.
  • Ensure that battery is charged in a well ventilated area.
  • Avoid short circuits. Always reinstall battery positive (B+) or negative (-) terminal covers if removed during servicing.

7 - Read and follow all instructions on battery, contained in Repair Information, Electrical Equipment, and in Owners Manual!

8 - Battery acid can cause severe burns!

  • When working with electrolyte always wear eye protection, rubber gloves and a suitable apron. If electrolyte is spilled on eyes, skin, clothing (or painted surfaces), flush at once with large quantities of water.
  • Never tip a battery on edge. Electrolyte can spill from the ventilation openings.

CAUTION: There is a risk of injury from the battery acid.
  • Can cause severe injury to the eyes, skin and mucous membranes.
  • Inhalation can damage the respiratory system.
  • Swallowing is harmful to the digestive system.
  • First Aid: Rinse eyes and immediately consult first aid station or inform doctor.
  • Never tilt battery. Electrolyte may leak out of vents.
  • Soak up spilled electrolyte with appropriate absorbent material and neutralize remaining electrolyte with commercial acid neutralizer (or water and baking soda). A soapy solution, for example, is a suitable remedy.
  • Never allow electrolyte to come into contact with bare hands.
  • Avoid contact with skin.
  • Never touch mouth, nose or eyes with soiled hands.
  • Immediately remove electrolyte-contaminated clothing and place in water.
  • Do not eat, drink or store food in work areas.
  • Wash thoroughly before breaks and on completion of work.

CAUTION: Protect against injury by using protective eyewear and clothing.
  • Wear safety goggles and an acid-resistant apron or alternatively electrolyte-proof overalls.
  • Wear electrolyte-proof gloves.

CAUTION: Risk of explosion due to the explosive gas that forms during battery charging.
  • The gas resulting from charging and partially when resting after charging is explosive. In extreme cases, if battery is handled inappropriately, the emitted gases may cause the battery to explode.
  • Smoking, open flame, fire and sparks (from sanding, welding or separating work) are prohibited when working near the battery.
  • Avoid short circuits when working with electrical wires and devices. Do not place any tools on the battery.
  • To prevent sparks from forming due to electrostatic discharge, always touch the vehicle body before touching the battery.

CAUTION: Protect against explosion.
  • On batteries with a "magic eye" , the battery must not be tested or charged if the indicator has no color or is light yellow. Jump starting must not be used! There is a risk of explosion during testing, charging or jump starting. The battery must be replaced.
  • Used batteries (lengthy period of use over 6 months) must be treated with an anti-static spray "Neostatic Antistatikum HB 155" (or equivalent) prior to handling.
  • On batteries that are not maintenance-free, the sealing plugs must be securely installed when charging the battery.
  • Charging of batteries removed from the vehicle is only permitted in vented cubicles with extraction system.
  • After charging, battery must be left in charging area with extraction system for an appropriate length of time.
  • Only perform battery procedures in suitable and well-ventilated rooms.
  • Batteries are always to be transported in conductive metal containers.
  • Electrostatically chargeable materials are not to be used for securing purposes.

CAUTION: Risk of damage to vehicle.
  • Safety-related vehicle components could be damaged by acid burns and corrosion due to escaping battery acid.

CAUTION: Personal injury and environmental risk.
  • Old batteries require special disposal. They contain poisonous lead (Pb) and sulfuric acid.
  • Follow disposal requirements, only dispose of used batteries in suitable containers at an authorized collection site.

Lead-Acid Battery without Visual Indicator

Lead-Acid Battery without Visual Indicator

Lead acid batteries with removable battery cell sealing caps, without charge indicator "Magic Eye" and filled with fluid electrolyte (wet battery) require regular maintenance. The removable sealing caps allow for topping off with distilled water.

CAUTION: Risk of injury from direct exposure to battery acid!

Risk of explosion due to the explosive gas that forms during battery charging.

--> Central Venting System

--> Battery Post and Terminal, Handling Instructions

--> Lead-Acid Battery without Visual Indicator, Checking

--> Battery, Visual Inspection

--> Battery Electrolyte Level, Checking

--> Battery Specific Gravity, Measuring in All Cells

Central Venting System

Central Venting System

To prevent vapors produced by the battery during charging from causing damage or posing a health at risk, vapors are discharged centrally through an opening on the top cover side of the battery.

  • Ensure the central venting hose or tube is always secured on the battery.
  • Ensure the central venting hose or tube is not pinched. Only then can battery be properly vented.

NOTE:
  • Newer generation batteries have a fine mesh flame trap at the central venting exit point. The "flame trap" is a round fiberglass matt approximately 15 mm wide and 2 mm thick that works like a valve. On the one hand, it allows the gas formed during battery charging to flow out and on the other hand, prevents the explosive gas in the battery from igniting.

Battery Post and Terminal, Handling Instructions

Battery Post and Terminal, Handling Instructions

Fig. 2: Identifying Battery Posts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

CAUTION: In order to prevent damage to the battery terminals and battery posts, observe the following:
  • Battery terminals must only be placed on battery posts - arrows - without using force (by hand only).
  • Do not apply grease to battery terminals or posts.
  • Battery terminals must be securely and fully seated on the battery post before tightening (battery post flush with terminal or protruding slightly from terminal).
  • Battery terminals that are torqued to specification must NOT be tightened any further. Terminal damage will result.

Lead-Acid Battery without Visual Indicator, Checking

Lead-Acid Battery without Visual Indicator, Checking

CAUTION: Risk of injury and explosion!

Perform battery checks in the following sequence:

Battery, Visual Inspection

Battery, Visual Inspection

  • Before performing extensive measurements, inspect visually.
  • External battery condition;
  • Battery connections;
  • Secure battery seating.

CAUTION: Risk of explosion, inadequate crash safety, risk of corrosion, shortened service life.
  • A lose battery retaining bracket can damage the battery housing and allow battery acid to leak.
  • A battery that is mounted incorrectly can sustain vibration damage resulting in damage to the battery plates.
  • Battery retaining bracket bolt tightening torque depends on model and application. Refer to appropriate model Electrical Equipment Repair Manual.

Risk of malfunction in the electrical system or wiring burn.

  • Wiring connection contact is not guaranteed if the battery terminals are damaged or the battery clamps are loose. Check the condition of the battery terminals; battery terminal clamp and auxiliary clamp tightening torque --> 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL .
  • Risk of corrosion due to leaking battery acid.
  • To ensure the various battery connection systems are free of leaks, the batterys original sealing plugs must be installed in the battery openings. Only replace missing or damaged sealing plugs with the same type of original plugs.
  • The sealing plugs must be equipped with an O-ring.

Battery Electrolyte Level, Checking

Battery Electrolyte Level, Checking

Special tools, testers and auxiliary items required

Fig. 3: Battery fill bottle VAS 5045
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Battery filler VAS 5045

Procedure

Maintaining the correct electrolyte level in the battery is an important factor affecting the length of the batterys service life.

CAUTION: Risk of injury from direct exposure to battery acid.

Risk of explosion due to open flame, fire and smoking.

  • Only illuminate the inside of the battery housing with a flashlight.
  • Never illuminate the inside of the battery housing with an open flame.
  • Never handle open flame or burning cigarettes near batteries.

  • If the "min" and "max" marking on the outside of the battery can be seen, simply inspect by sight.
  • The electrolyte level must be above the "min" marking but must only go as high as the "max" marking.
  • If it is difficult to see the "min" and "max" markings on the outside of the battery or they cannot be seen because the battery housing is opaque, remove the sealing plugs.
  • Check electrolyte level by visually checking the inside of the battery.
  • The electrolyte level must coincide with the internal level mark (plastic web). This corresponds to the outer "max" marking.

CAUTION: Risk of corrosion due to leaking battery acid.
  • To ensure the various battery connection systems are free of leaks, the batterys original sealing plugs must be installed in the battery openings. Only replace missing or damaged sealing plugs with the same type of original plugs.
  • The sealing plugs must be equipped with an O-ring.

  • Thread in battery cell sealing plugs.

Electrolyte level too low

If the electrolyte level is too low, a loss of battery capacity (power) occurs due to cell plates drying out. If the cell plates are not surrounded by electrolyte (sulfuric acid-water mixture), the plates, plate straps, and cell connectors will corrode. The corrosion damages battery operation, the battery can no longer be used.

Fig. 4: VAS 5045 Battery Filling Bottle
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • If electrolyte level is too low, use battery filler VAS 5045 to add distilled water until max mark is reached.

NOTE:
  • The filler neck of the Battery filler VAS 5045 is designed to prevent over-filling of the battery cell and electrolyte leakage. The flow of distilled water into the battery cell is interrupted on reaching the max. level.
  • Always use distilled water for topping up to prevent electrolyte contamination which results in increased self-discharge.

Battery Specific Gravity, Measuring in All Cells

Battery Specific Gravity, Measuring in All Cells

Special tools, testers and auxiliary items required

Fig. 5: Identifying Refractometer T10007
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Refractometer T10007 or

Fig. 6: Identifying Commercially Available Hydrometer
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Commercially available hydrometer

Prerequisites

  • The temperature of the battery acid must be at least +10 C.

Procedure

In conjunction with battery test --> Battery, Testing with Midtronics Battery/Starting/Charging System Analyzer MCR340A , the specific gravity measurement gives information about the condition of the battery.

CAUTION: Risk of injury from direct exposure to battery acid.

NOTE:
  • Specific gravity of electrolyte can be checked immediately after charging battery.
  • Remove all battery cell sealing plugs.

Fig. 7: Hydrometer Specific Gravity Reading
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Dip hydrometer into battery cell and siphon off enough electrolyte until float floats freely in electrolyte.
  • The higher the specified weight of the siphoned battery acid, the higher the float will float.
  • The acid density of the electrolyte can be read off in kg/dm 3 on the hydrometer scale (specified density of the battery acid).
  • Compare hydrometer reading to values given in table.

Charge condition Electrolyte density in kg/dm 3
  in normal climates in the tropics
Discharged 1.12 1.08
Partial charge 1.20 1.16
Fully charged 1.28 1.23

Specified acid density must be at least 1.24 kg/dm 3 in moderate climate zones. If the acid density in all battery cells is too low:

  • Charge battery and repeat acid density test.

Example 1            
Battery cell 1 2 3 4 5 6
Electrolyte density per cell in kg/dm 3 1.24 1.25 1.25 1.10 1) 1.24 1.25
1) Acid density in cell 4 is too low (deviation greater than 0.03 kg/dm 3 ).

Example 2            
Battery cell 1 2 3 4 5 6
Electrolyte density per cell in kg/dm 3 1.26 1.26 1.25 1.14 1) 1.18 1) 1.24
1) Acid density in cells 4 and 5 too low (deviation greater than 0.03 kg/dm 3 ).

  • If the specified values are not reached, replace battery.

NOTE:
  • The measured values for the specific gravity of the individual battery cells must not deviate by more than 0.03 kg/dm 3 , otherwise the battery should be replaced.

CAUTION: Risk due to leaking battery acid.
  • To ensure the various battery connection systems are free of leaks, the batterys original sealing plugs must be installed in the battery openings. Only replace missing or damaged sealing plugs with the same type of original plugs.
  • The sealing plugs must be equipped with an O-ring.

  • If the specified values are reached, reinstall battery cell sealing plugs.

NOTE:

Maintenance-Free Batteries

Maintenance-Free Batteries

Only maintenance-free batteries conforming to standards "TL82506" (as of December 1997) and "VW75073" (as of August 2001) may be installed.

CAUTION: Risk of injury due to contact with battery acid!

Risk of explosion due to the explosive gas that forms during battery charging.

--> Maintenance-Free Battery with Visual Indicator

--> Maintenance-Free Battery with Visual Indicator, Checking

--> Absorbent Glass Mat Battery without Visual Indicator

--> Absorbent Glass Mat Battery, Checking

--> Central Venting System

--> Battery Post and Terminal, Handling Instructions

--> Battery, Visual Inspection

--> Maintenance-Free Battery with Visual Indicator, Checking Color Display

--> Battery Electrolyte Level, Checking

Maintenance-Free Battery with Visual Indicator

Maintenance-Free Battery with Visual Indicator

Lead acid batteries with non-removable battery cell sealing caps, with charge indicator "Magic Eye" and filled with fluid electrolyte (wet battery) are considered maintenance-free. Sealing caps are not removable for topping off with distilled water.

NOTE:
  • If batteries with a "magic eye" are equipped with sealing plugs for production reasons only, the plugs are covered with plastic sheeting.
  • The covering must not be removed and distilled water must not be added.
  • Only perform a visual inspection.

Fig. 8: Locating Magic Eye
Courtesy of VOLKSWAGEN UNITED STATES, INC.

The "magic eye" - arrow - gives information about the electrolyte level and charge condition of the battery by means of a color display. Possible color displays --> Maintenance-Free Battery with Visual Indicator, Checking Color Display.

CAUTION: Risk of explosion on discharged battery with magic eye.
  • If the magic eye has no color or is light yellow, the battery may not be tested or charged. Jump starting must not be used! There is a risk of explosion during testing, charging or jump starting. The battery must be replaced.

Maintenance-Free Battery with Visual Indicator, Checking

Maintenance-Free Battery with Visual Indicator, Checking

CAUTION: Risk of injury and explosion!

Perform battery checks in the following sequence:

Absorbent Glass Mat Battery without Visual Indicator

Absorbent Glass Mat Battery without Visual Indicator

  • AGM batteries are deep cycle-resistant and leak-proof.
  • Lead acid AGM (Absorbent Glass Mat) batteries are filled with electrolyte contained in an absorbent glass mat. The battery is closed and equipped with breather valves.
  • These batteries do not utilize a "Magic Eye" due to the fixed electrolyte. AGM batteries are marked with "AGM" on the battery.

NOTE:
  • AGM batteries cannot and must not be opened and distilled water must not be added.
  • Only perform a visual inspection.

CAUTION: Crash safety is inadequate if the incorrect battery is installed.
  • If the vehicle was originally equipped with an AGM battery, another AGM battery must be installed when replacing.

Absorbent Glass Mat Battery, Checking

Absorbent Glass Mat Battery, Checking

CAUTION: Risk of injury and explosion!

Perform battery checks in the following sequence:

Central Venting System

Central Venting System

To prevent vapors produced by the battery during charging from causing damage or posing a health at risk, vapors are discharged centrally through an opening on the top cover side of the battery.

  • Ensure that the central venting hose or tube is always secured on the battery.
  • Ensure that the central venting hose or tube is not pinched. Only then can battery be properly vented.

NOTE:
  • Newer generation batteries have a fine mesh flame trap at the central venting exit point. The "flame trap" is a round fiberglass matt approximately 15 mm wide and 2 mm thick that works like a valve. On the one hand, it allows the gas formed during battery charging to flow out and on the other hand, prevents the explosive gas in the battery from igniting.

Battery Post and Terminal, Handling Instructions

Battery Post and Terminal, Handling Instructions

Fig. 9: Identifying Battery Posts
Courtesy of VOLKSWAGEN UNITED STATES, INC.

CAUTION: In order to prevent damage to the battery terminals and battery posts, observe the following:
  • Battery terminals must only be placed on battery posts - arrows - without using force (by hand only).
  • Do not apply grease to battery terminals or posts.
  • Battery terminals must be securely and fully seated on the battery post before tightening (battery post flush with terminal or protruding slightly from terminal).
  • Battery terminals that are torqued to specification must NOT be tightened any further. Terminal damage will result.

Battery, Visual Inspection

Battery, Visual Inspection

  • Before performing extensive measurements, inspect visually.
  • External battery condition;
  • Battery connections;
  • Secure battery seating.

CAUTION: Risk of explosion, inadequate crash safety, risk of corrosion, shortened service life.
  • A lose battery retaining bracket can damage the battery housing and allow battery acid to leak.
  • A battery that is mounted incorrectly can sustain vibration damage resulting in damage to the battery plates.
  • Tighten retaining bracket bolt; tightening torque --> 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL .

Risk of malfunction in the electrical system or wiring burn.

  • Wiring connection contact is not guaranteed if the battery terminals are damaged or the battery clamps are loose. Check the condition of the battery terminals; battery terminal clamp and auxiliary clamp tightening torque --> 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL .

Maintenance-Free Battery with Visual Indicator, Checking Color Display

Maintenance-Free Battery with Visual Indicator, Checking Color Display

Fig. 10: Locating Magic Eye
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Procedure

  • To obtain an accurate reading, gently tap the magic eye - arrow - with a screwdriver handle or rock the vehicle slightly.

NOTE:
  • When recharging the battery and while driving, air bubbles can form below the "magic eye" and result in an incorrect color display. Tapping releases the air bubbles under the "magic eye".
  • The "magic eye" can be installed at various locations on top of battery.
  • Because the "magic eye" is located in a single cell, the indication is only valid for that cell. The procedure for making an accurate assessment of the battery condition depends on the vehicle: on vehicles without the Energy Management Control Module J644 --> Battery, Testing with Midtronics Battery/Starting/Charging System Analyzer MCR340A , on vehicles with the Energy Management Control Module J644 --> Battery - Vehicles with Energy Management Control Module, Testing with Vehicle Diagnosis, Testing and Information System VAS 5051B .
  • If no diagnostic system is available, the battery test can be performed on vehicles with the Energy Management Control Module J644 using the Battery Tester With Printer VAS 5097A --> Battery, Testing with Midtronics Battery/Starting/Charging System Analyzer MCR340A.
  • Check the battery condition using the color indicator. There are three possible color indications:

Color indicator Battery status
Green Battery adequately charged for testing
Black No charge or charge too low.
Colorless or yellow Risk of explosion, the battery must not be tested or charged.

CAUTION: Risk of explosion on discharged battery with magic eye.
  • If the magic eye has no color or is light yellow, the battery may not be tested or charged. Jump starting must not be used! There is a risk of explosion during testing, charging or jump starting. The battery must be replaced.

NOTE:

Battery Electrolyte Level, Checking

Battery Electrolyte Level, Checking

Procedure

Maintaining the correct electrolyte level in the battery is an important factor affecting the length of the batterys service life.

CAUTION: Risk of injury due to contact with battery acid.

Risk of explosion due to open flame, fire and smoking.

  • Never handle open flame or burning cigarettes near batteries.

  • If the "min" and "max" marking on the outside of the battery can be seen, inspect by sight.
  • The electrolyte level must be above the "min" marking but must only go as high as the "max" marking.

Battery, Testing

Battery, Testing

Maintenance-free batteries must not be opened. Otherwise, the warranty is void.

--> Battery, Testing with Midtronics Battery/Starting/Charging System Analyzer MCR340A

--> Battery - Vehicles with Energy Management Control Module, Testing with Vehicle Diagnosis, Testing and Information System VAS 5051B

--> Battery No-Load Voltage - Vehicles without Energy Management Control Module, Checking under

--> Battery No-Load Voltage - Vehicles with Energy Management Control Module, Checking

--> Battery, Load Testing with Midtronics Diagnostic Conductance Charging Station INC-940

Battery, Testing with Midtronics Battery/Starting/Charging System Analyzer MCR340A

Battery, Testing with Midtronics Battery/Starting/Charging System Analyzer MCR340A

CAUTION: Risk of injury from battery acid.
  • Prior to handling or servicing batteries, read, understand and observe the Warnings and Safety Measures for lead-acid batteries for lead-acid batteries --> Safety Precautions !
  • Wear protective eyewear and clothing --> 27 - Battery, Starter, Generator, Cruise control .
  • If the magic eye has no color or is light yellow, the battery may not be tested or charged. Jump starting must not be used! There is a risk of explosion during testing, charging or jump starting. The battery must be replaced.
  • DO NOT battery test batteries which are gassing. Otherwise there is a risk of explosion.
  • Dispose of electrolyte (sulfuric acid/water mixture) properly! Waste electrolyte must only be disposed of in appropriate waste disposal sites. Refer to local regulations pertaining to electrolyte disposal.
  • The following notes and procedures must be followed to ensure correct measurements.

Special tools, testers and auxiliary items required

Fig. 11: Battery VAS Tester
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Midtronics Battery/Starting/Charging System Analyzer MCR340A (VAS tester illustrated here for reference only)

Procedure

CAUTION:
  • Switch off all electrical consumers.
  • Switch ignition off and remove ignition key.
  • Refer to Midtronics Battery/Starting/Charging System Analyzer MCR340A Instruction Manual.

  • Check no-load voltage --> Battery No-Load Voltage - Vehicles without Energy Management Control Module, Checking .
  • Connect tester cable clamps to battery terminal --> MCR340A Instruction Manual. Tester leads must be securely fastened and make proper contact with battery posts.
  • Select test mode "IN-VEHICLE" or "OUT-OF-VEHICLE" as appropriate --> MCR340A Instruction Manual.
  • Select battery type (AGM or conventional) --> MCR340A Instruction Manual
  • Set tester to "Warranty Test" --> MCR340A Instruction Manual.
  • Perform battery test by setting load current on tester according to battery (DIN) capacity --> MCR340A Instruction Manual.

NOTE:
  • Use print function of MCR340A in event test results are required for warranty claims.

Battery test results:

Battery Tester Display / Printout Required action
Good Battery None
Good - Recharge Charge battery where necessary
Use inCHARGE Charge battery
Replace Battery Replace battery. Electrical Equipment 27 Battery.
Bad Cell - Replace Replace battery. Electrical Equipment 27 Battery.

NOTE:

Battery - Vehicles with Energy Management Control Module, Testing with Vehicle Diagnosis, Testing and Information System VAS 5051B

Battery - Vehicles with Energy Management Control Module, Testing with Vehicle Diagnosis, Testing and Information System VAS 5051B

Special tools, testers and auxiliary items required

  • e.g. Vehicle Diagnosis, Testing and Information System VAS 5051B (or any of the VAS 505X class testers) with diagnostic cable

Prerequisites

  • Battery must not be in process of being charged.
  • Engine must not be running.
  • Battery temperature must be at least -10 C.
  • Diagnostic system temperature must be between +5 and 45 C.

Procedure

NOTE:
  • If an error message appears on the display --> , VAS 5051B operating instructions.
  • Press Guided Functions button on operating mode selection screen.

Fig. 12: Display On VAS 5051 - (1st Control Element In Test & Evaporative Emission (EVAP) Canister Purge Regulator Valve-N80-)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Display:

  • Enter vehicle identification number (VIN) in field - 1 - in selection - A -.

The Vehicle Diagnosis, Testing and Information System VAS 5051B then switches to the next selection level. The following example shows how vehicle type, engine and vehicle system of function could be selected (some steps may be skipped):

The following information is given as an example only. Always enter required information as it pertains to vehicle being serviced.

Selection Text lines to be selected
Select brand Audi
Select model (example) Audi A6 2005 >
Select model year (example) 2006 (6)
Select version (example) Sedan
Select engine code (example) BXA 5.2L FSI / 320 kW
If vehicle identification was performed correctly, then press button to confirm  
Select vehicle system or function 61 - Battery control
Select vehicle system or function A - Battery, test (27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL )

  • Follow VAS 5051B instructions and prompts. Depending on results, the following will be displayed:
  • Battery is OK.
  • Charge battery.
  • Replace battery.

After battery test:

  • Tap button Go to.
  • Select function "Exit".
  • Where applicable, follow tester prompts regarding warranty requirements.
  • Switch ignition off and disconnect tester from Data Link Connector (DLC).
  • If necessary, charge battery --> Battery, Charging with Midtronics Diagnostic Conductance Charging Station INC-940

NOTE:

Battery No-Load Voltage - Vehicles without Energy Management Control Module, Checking

Battery No-Load Voltage - Vehicles without Energy Management Control Module, Checking

NOTE:
  • Measuring the no-load voltage, e.g. within the prescribed maintenance and service work on vehicles in storage, determines if the battery must be recharged --> Maintenance Tables.

Special tools, testers and auxiliary items required

Fig. 13: Portable Multimeter V.A.G 1526C
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Multimeter VAG 1526C , Multimeter Fluke 83 or equivalent (VAG tester illustrated here for reference only).

To ensure correct measurements, follow prerequisites and procedure exactly as given:

Prerequisites

  • If no-load voltage on battery installed in vehicle is measured, disconnect ground cable.
  • Battery must not be discharged by electrical consumers within 2 hours prior to measurement.
  • Battery must not be charged within 12 hours prior to measurement.
  • Battery temperature must be at least -10 C.

Procedure

After a holding time of at least 12 hours:

  • Use multimeter to measure voltage between battery terminals.
  • Specified value: 12.5 Volts or above = Battery OK.
  • If no-load voltage is under 12.5 Volts, charge battery --> Battery, Charging with Midtronics Diagnostic Conductance Charging Station INC-940 .
  • If battery no-load voltage is below 11.7 Volts, battery is severely discharged.
  • If no-load voltage is OK, reconnect battery.

Battery No-Load Voltage - Vehicles with Energy Management Control Module, Checking

Battery No-Load Voltage - Vehicles with Energy Management Control Module, Checking

NOTE:
  • No-load voltage measurement for assessment of battery condition is only appropriate if it is not possible to test battery with any of the VAS 505X class testers.
  • Measuring the no-load voltage, e.g. within the prescribed maintenance and service work on vehicles in storage, determines if the battery must be recharged --> Maintenance Tables.

Special tools, testers and auxiliary items required

Fig. 14: Portable Multimeter V.A.G 1526C
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Multimeter VAG 1526C , Multimeter Fluke 83 or equivalent (VAG tester illustrated here for reference only).

To ensure correct measurements, follow prerequisites and procedure exactly as given:

Prerequisites

  • Battery remains installed in vehicle. DO NOT disconnect battery ground cable.
  • Open front hood or rear lid as appropriate for access to battery terminals.
  • Manually place rear lid lock in "Closed" position to prevent illumination of luggage compartment lamp
  • Manually close front hood switch where applicable to prevent activation of front hood alarm.
  • Lock vehicle with remote control.
  • Battery must not be discharged by electrical consumers within 2 hours prior to measurement.
  • Battery must not be charged within 12 hours prior to measurement.
  • Battery temperature must be at least -10 C.

Procedure

After a holding time of at least 2 hours:

  • Use multimeter to measure voltage between battery terminals or between battery jump-start terminals as applicable.
  • Specified value: 12.5 Volts or above = Battery OK.
  • If no-load voltage is under 12.5 Volts, charge battery --> Battery, Charging with Midtronics Diagnostic Conductance Charging Station INC-940 .
  • If battery no-load voltage is below 11.7 Volts, battery is severely discharged.
  • If no-load voltage is OK, reconnect battery.

Battery, Load Testing with Midtronics Diagnostic Conductance Charging Station INC-940

Battery, Load Testing with Midtronics Diagnostic Conductance Charging Station INC-940

The Midtronics Diagnostic Conductance Charging Station INC-940 (also known as "inCHARGE 940" ) integrates battery conductance and load testing with charging.

By checking a batterys current draw capacity during charging, a decision can be made as to whether a severely discharged battery --> Totally Discharged Batteries, Charging can be made usable again by recharging, or if it must be replaced.

CAUTION: Risk of injury from battery acid.
  • Prior to handling or servicing batteries, read, understand and observe the Warnings and Safety Measures for lead-acid batteries for lead-acid batteries --> Safety Precautions !
  • Wear protective eyewear and clothing --> 27 - Battery, Starter, Generator, Cruise control .
  • On non-maintenance-free batteries, the sealing plugs must be installed tightly.
  • Provide sufficient ventilation.
  • If the magic eye has no color or is light yellow, the battery may not be tested or charged. Jump starting must not be used! There is a risk of explosion during testing, charging or jump starting. The battery must be replaced.
  • DO NOT battery test batteries which are gassing. Otherwise there is a risk of explosion.
  • Rapid-charging batteries --> Battery, Quick Charging.
  • Dispose of electrolyte (sulfuric acid/water mixture) properly! Waste electrolyte must only be disposed of in appropriate waste disposal sites. Refer to local regulations pertaining to electrolyte disposal.
  • The following notes and procedures must be followed to ensure correct measurements.

CAUTION: Risk of damaging AGM batteries.
  • Specific charging procedures are required for AGM batteries.

Special tools, testers and auxiliary items required

Fig. 15: Battery charging unit VAS 5900
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Midtronics Diagnostic Conductance Charging Station INC-940 (VAS tester illustrated here for reference only)

Prerequisite

Battery temperature must be at least +10 C.

Procedure

CAUTION:
  • Switch off all electrical consumers.
  • Switch ignition off and remove ignition key.
  • Refer to Midtronics Diagnostic Conductance Charging Station INC-940 Instruction Manual.

  • Connect tester cable clamps to battery terminals --> INC-940 Instruction Manual. Tester leads must be securely fastened and make proper contact with battery posts.
  • Select charge mode "Automatic" --> INC-940 Instruction Manual
  • Select test mode "IN-VEHICLE" or "OUT-OF-VEHICLE" as appropriate --> INC-940 Instruction Manual.
  • Select battery type (AGM or conventional) --> INC-940 Instruction Manual
  • Set tester to "Warranty Test" --> INC-940 Instruction Manual.
  • Select battery DIN rating value as appropriate --> INC-940 Instruction Manual.

NOTE:
  • Use the "Generate Test Code" function of INC-940 in event test results are required for warranty claims.

Battery load test results:

Battery Tester Display / Printout Required action
GOOD BATTERY None (reinstall where necessary)
CHARGING REQUIRED Analysis finds that the battery has a low state of charge. The inCHARGE 940 will display an approximate charge time and begin fast charging. The accumulated CCA (Cold Cranking Amps) and remaining charging time are displayed and updated at intervals.
REPLACE BATTERY Replace battery. Electrical Equipment 27 Battery

NOTE:

Battery, Charging

Battery, Charging

Battery, Charging

--> Battery, Charging with Midtronics Diagnostic Conductance Charging Station INC-940

--> Totally Discharged Batteries, Charging

--> Battery, Quick Charging

--> Battery, Support Mode with Midtronics Battery Maintainer PSC-550 or Midtronics Battery Maintainer CXC-2115

Battery, Charging with Midtronics Diagnostic Conductance Charging Station INC-940

Battery, Charging with Midtronics Diagnostic Conductance Charging Station INC-940

The Midtronics Diagnostic Conductance Charging Station INC-940 (also known as "inCHARGE 940" ) integrates battery conductance and load testing with charging.

NOTE:
  • Battery charger Midtronics Diagnostic Conductance Charging Station INC-940 charges without current and voltage peaks. Batteries can therefore be charged when installed. When doing this, heed all safety precautions.
  • When performing electrical troubleshooting or otherwise working on the electrical system with consumers temporarily switched on, and for working with any of the VAS 505X class testers in operating mode "Guided Fault Finding" , the battery must be charged during these procedures with a battery maintainer in battery support mode to prevent damage to the battery --> Battery, Support Mode with Midtronics Battery Maintainer PSC-550 or Midtronics Battery Maintainer CXC-2115.

CAUTION: Risk of injury from battery acid.
  • Prior to handling or servicing batteries, read, understand and observe the Warnings and Safety Measures for lead-acid batteries for lead-acid batteries --> Safety Precautions !
  • Wear protective eyewear and clothing --> 27 - Battery, Starter, Generator, Cruise control .
  • On non-maintenance-free batteries, the sealing plugs must be installed tightly.
  • Provide sufficient ventilation.
  • If the magic eye has no color or is light yellow, the battery may not be tested or charged. Jump starting must not be used! There is a risk of explosion during testing, charging or jump starting. The battery must be replaced.
  • DO NOT battery test batteries which are gassing. Otherwise there is a risk of explosion.
  • Rapid-charging batteries --> Battery, Quick Charging.
  • Dispose of electrolyte (sulfuric acid/water mixture) properly! Waste electrolyte must only be disposed of in appropriate waste disposal sites. Refer to local regulations pertaining to electrolyte disposal.
  • The following notes and procedures must be followed to ensure correct charging.

CAUTION: Risk of damaging AGM batteries.
  • Specific charging procedures are required for AGM batteries.

Special tools, testers and auxiliary items required

Fig. 16: Battery charging unit VAS 5900
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Midtronics Diagnostic Conductance Charging Station INC-940 (VAS tester illustrated here for reference only)

Prerequisite

Battery temperature must be at least +10 C.

Procedure

CAUTION:
  • Switch off all electrical consumers.
  • Switch ignition off and remove ignition key.
  • Refer to Midtronics Diagnostic Conductance Charging Station INC-940 Instruction Manual.

  • Connect tester cable clamps to battery terminals or battery jump-start terminals --> INC-940 Instruction Manual. Tester leads must be securely fastened and make proper contact with battery posts or jumper terminals.
  • Select charge mode "Automatic" or "Manual" --> INC-940 Instruction Manual
  • Select test mode "IN-VEHICLE" or "OUT-OF-VEHICLE" as appropriate --> INC-940 Instruction Manual.
  • Select battery type (AGM or conventional) --> INC-940 Instruction Manual
  • Set tester to "Warranty Test" --> INC-940 Instruction Manual.
  • Select battery DIN rating value as appropriate --> INC-940 Instruction Manual.

NOTE:
  • Use the "Generate Test Code" function of INC-940 (available in "Automatic" mode only) in event test results are required for warranty claims.

  • When the battery is completely charged --> MCR340A Instruction Manual
  • Disconnect battery charger clamps.

Totally Discharged Batteries, Charging

Totally Discharged Batteries, Charging

  • Batteries which have not been used for lengthy periods, e.g. in vehicles which have not been driven, are subject to self-discharge.
  • Batteries are considered to be severely discharged if open-circuit voltage drops below 11.6 V. With voltage between 12.2 and 11.6 V, the battery is pre-damaged. Measure no-load voltage:
  • Vehicles without Energy Management Control Module J644 --> Battery No-Load Voltage - Vehicles without Energy Management Control Module, Checking .
  • With severely discharged batteries, the electrolyte (mixture of sulfuric acid and water) is mostly water, with a greatly reduced sulfuric acid content.
  • Severely discharged batteries become sulfated, i.e. all the plate surfaces of such batteries become hardened. Instead of being transparent, the electrolyte has a slightly milky appearance.
  • The sulfating process may be reversed if a severely discharged battery is recharged immediately.
  • If battery is not recharged, plates will continue to harden, and ability to accept a charge will diminish. This results in reduction of battery performance.

CAUTION: Risk of injury from battery acid.
  • Prior to handling or servicing batteries, read, understand and observe the Warnings and Safety Measures for lead-acid batteries for lead-acid batteries --> Safety Precautions !
  • Wear protective eyewear and clothing --> 27 - Battery, Starter, Generator, Cruise control .
  • On non-maintenance-free batteries, the sealing plugs must be installed tightly.
  • Provide sufficient ventilation.
  • If the magic eye has no color or is light yellow, the battery may not be tested or charged. Jump starting must not be used! There is a risk of explosion during testing, charging or jump starting. The battery must be replaced.
  • DO NOT battery test batteries which are gassing. Otherwise there is a risk of explosion.
  • Rapid-charging batteries --> Battery, Quick Charging.
  • Dispose of electrolyte (sulfuric acid/water mixture) properly! Waste electrolyte must only be disposed of in appropriate waste disposal sites. Refer to local regulations pertaining to electrolyte disposal.
  • The following notes and procedures must be followed to ensure correct charging.

CAUTION: Risk of severely discharged batteries freezing.
  • Severely discharged batteries freeze at low temperatures, the housing can crack.
  • Batteries that have frozen must no longer be used.

Prerequisite

  • Battery temperature must be at least +10 C.

Procedure

Severely discharged (sulfated) batteries must be charged using a low charging current:

NOTE:
  • The Midtronics Diagnostic Conductance Charging Station INC-940 automatically detects severely discharged batteries and carefully starts the charging procedure with a low charging current. The charge current is automatically adjusted to the battery charge state.
  • In order to initiate charging procedure, battery voltage must be at least 0.6 V!

CAUTION: Risk of damaging severely discharged batteries.
  • Do not quick charge severely discharged batteries.

  • Charge battery --> Battery, Charging with Midtronics Diagnostic Conductance Charging Station INC-940 .
  • The charging voltage may be a maximum of 14.4 V.

NOTE:

Battery, Quick Charging

Battery, Quick Charging

CAUTION: Risk of injury from battery acid.
  • Prior to handling or servicing batteries, read, understand and observe the Warnings and Safety Measures for lead-acid batteries for lead-acid batteries --> Safety Precautions !
  • Wear protective eyewear and clothing --> 27 - Battery, Starter, Generator, Cruise control .
  • On non-maintenance-free batteries, the sealing plugs must be installed tightly.
  • Provide sufficient ventilation.
  • If the magic eye has no color or is light yellow, the battery may not be tested or charged. Jump starting must not be used! There is a risk of explosion during testing, charging or jump starting. The battery must be replaced.
  • DO NOT battery test batteries which are gassing. Otherwise there is a risk of explosion.
  • Rapid-charging batteries --> Battery, Quick Charging.
  • Dispose of electrolyte (sulfuric acid/water mixture) properly! Waste electrolyte must only be disposed of in appropriate waste disposal sites. Refer to local regulations pertaining to electrolyte disposal.
  • The following notes and procedures must be followed to ensure correct charging.

Prerequisite

  • Battery temperature must be at least +10 C.

Procedure

CAUTION: Risk of damaging the battery and vehicle electronic components.
  • DO NOT quick charge AGM batteries!
  • Batteries in vehicles with Energy Management Control Module J644 must not be quick charged.
  • Do not quick charge severely discharged batteries.
  • Quick charging of batteries should only be performed in exceptional circumstances (e.g. boost starting) as Quick charging may cause damage.
  • Battery must not be connected to vehicle electrical system when performing Quick charging. Disconnect the positive and negative cables from battery terminals. Refer to applicable model 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL .
  • Do not exceed maximum charging voltage of 14.8 Volts.

NOTE:

Battery, Support Mode with Midtronics Battery Maintainer PSC-550 or Midtronics Battery Maintainer CXC-2115

Battery, Support Mode with Midtronics Battery Maintainer PSC-550 or Midtronics Battery Maintainer CXC-2115

During electrical troubleshooting or otherwise working on the electrical system where consumers are temporarily switched on, and for working with any of the VAS 505X class testers in operating mode "Guided Fault Finding" and during software flashing, battery voltage must be must maintained. Use Midtronics Battery Maintainer PSC-550 to prevent excessive battery discharge during servicing as described above.

Where it is necessary to maintain battery charge in showroom vehicles for demonstration of electrical features, use Midtronics Battery Maintainer CXC-2115.

Special tools, testers and auxiliary items required

  • Midtronics Battery Maintainer PSC 550 or

Fig. 17: Battery charging unit VAS 5095 A
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Midtronics Battery Maintainer CXC-2115 (VAS charger illustrated here for reference only)

Procedure

CAUTION:
  • Switch off all electrical consumers.
  • Switch ignition off and remove ignition key.
  • Depending on use for temporary power supply or voltage maintainer for showroom use, refer to Midtronics Battery Maintainer PSC 550 or Midtronics Battery Maintainer CXC-2115 Instruction Manuals as necessary.

  • Connect battery maintainer cable clamps to battery terminals or battery jump-start terminals as applicable --> PSC 550 or CXC-2115 Instruction Manual. Tester leads must be securely fastened and make proper contact with battery posts or jumper terminals.
  • Plug battery maintainer into 120V AC supply to initiate charging --> PSC 550 or CXC-2115 Instruction Manual.

Generator, Testing and Servicing

Generator, Testing and Servicing

--> Generator, Testing

--> Bosch Generator, through MY 2000, Assembly Overview

--> Bosch Generator, from MY 2001, Assembly Overview

--> Voltage Regulator, Bosch Generator from MY 2001, Removing and Installing

--> Carbon Brushes, Bosch Generator from MY 2001, Checking

--> Valeo Generator, through MY 2000, Assembly Overview

--> Valeo Generator, from MY 2001, Assembly Overview

--> Voltage Regulator, Valeo Generator from MY 2001, Removing and Installing

--> Carbon Brushes, Valeo Generator from MY 2001, Checking

--> Ribbed Belt Pulley without Freewheel, Removing and Installing

--> Ribbed Belt Pulley with Freewheel, Removing and Installing

Generator, Testing

Generator, Testing

  • Test generator using Vehicle Diagnosis, Testing info. System VAS 5051B (or other VAS 505X class tester) in operating mode "Guided Fault Finding".

After tester has established communication with vehicle and interrogated all vehicle systems

  • Select operating mode "Guided Fault Finding"
  • Press Go to button
  • Select "Function / Component Selection"
  • Select "27 - Battery, Starter, Generator, Cruise Control"
  • Select "Electrical components"
  • Select "C - Generator (GEN), testing (RG 27)"
  • Follow testers prompts

Bosch Generator, through MY 2000, Assembly Overview

Bosch Generator, through MY 2000, Assembly Overview

Fig. 18: Bosch Generator, Through MY 2000, Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Screws

  • 1 Nm

2 - Cover

  • with 3 retaining tabs

3 - Screws

  • 2 Nm

4 - Voltage Regulator (VR)

  • Removing:
  • Remove screws - 1 - and remove protective cap - 2 -.
  • Remove screws - 3 - and remove voltage regulator.
  • Carbon brush wear limit: 5 mm

5 - Generator (GEN)

Bosch Generator, from MY 2001, Assembly Overview

Bosch Generator, from MY 2001, Assembly Overview

NOTE:
  • The new generators are installed as a running change.

Fig. 19: Bosch Generator, From MY 2001, Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Generator (GEN)

2 - Voltage Regulator (VR)

3 - Screw

  • 2.5 Nm

4 - Cover

5 - Nut

  • 12 Nm

6 - Nut

  • 30 Nm

7 - Screw

  • 3 Nm

8 - Screw

  • 1.5 Nm

Voltage Regulator, Bosch Generator from MY 2001, Removing and Installing

Voltage Regulator, Bosch Generator from MY 2001, Removing and Installing

Fig. 20: Generator Cover And Screws
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing

  • Remove screw - 1 - and nuts - 3 - and - 4 -.
  • Remove cover - 2 - at rear side of generator.

Fig. 21: Voltage Regulator Screws
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove screws - arrows -.
  • Remove voltage regulator.

Installing

  • When positioning voltage regulator, ensure carbon brushes rest correctly on slides.

Further installation is in reverse order of removal.

Carbon Brushes, Bosch Generator from MY 2001, Checking

Carbon Brushes, Bosch Generator from MY 2001, Checking

Fig. 22: Carbon Brushes Wear Limit
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Procedure

  • Check carbon brushes for length - a -.
  • Wear limit: - a - = 5 mm.

Valeo Generator, through MY 2000, Assembly Overview

Valeo Generator, through MY 2000, Assembly Overview

Fig. 23: Valeo Generator, Through MY 2000, Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Generator (GEN)

2 - Voltage Regulator (VR)

  • Removing:
  • Remove nuts - 5 - and cover - 4 -.
  • Remove screw - 6 - and nuts - 7 - and remove voltage regulator.
  • Carbon brush wear limit: 5 mm

3 - Protective cap

4 - Cover

5 - Nut

  • 2 Nm

6 - Screw

  • 2 Nm

7 - Nut

  • Qty. 2
  • 3.5 Nm

Valeo Generator, from MY 2001, Assembly Overview

Valeo Generator, from MY 2001, Assembly Overview

NOTE:
  • The new generators are installed as a running change.

Fig. 24: Valeo Generator, From MY 2001, Assembly Overview
Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Generator (GEN)

2 - Voltage Regulator (VR)

3 - Screw

  • 2 Nm

4 - Cover

5 - Protective cap

6 - Screw

  • 2 Nm

Voltage Regulator, Valeo Generator from MY 2001, Removing and Installing

Voltage Regulator, Valeo Generator from MY 2001, Removing and Installing

Fig. 25: Identifying Cover And Threaded Pins At Rear Side Of Generator
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing

  • Press out cover from threaded pins at rear side of generator - arrows -.

Fig. 26: Generator Bolts And Combination Bolt
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove bolts - 1 - and combination bolt - 2 -.
  • Remove voltage regulator.

Fig. 27: Voltage Regulator And Protective Cap
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Installing

  • Press off protective cap - 2 - from voltage regulator - 1 - in - direction of arrow -.
  • When positioning voltage regulator, ensure carbon brushes rest correctly on slides.
  • Attach protective cap with voltage regulator installed.

Further installation is in reverse order of removal.

Carbon Brushes, Valeo Generator from MY 2001, Checking

Carbon Brushes, Valeo Generator from MY 2001, Checking

Fig. 28: Carbon Brushes, Valeo Generator From MY 2001, Checking
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Procedure

  • Check carbon brushes for length - a -.
  • Wear limit: - a - = 5 mm.

Ribbed Belt Pulley without Freewheel, Removing and Installing

Ribbed Belt Pulley without Freewheel, Removing and Installing

Special tools, testers and auxiliary items required

Fig. 29: Identifying Multi-Point Socket 3310
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Socket 3310
  • 8 mm hex socket or TORX T50

Fig. 30: Loosen/Tighten Nut At Pulley With Wrench And Adapter 3310
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing

  • If present, press the protective cap off the generator pulley.
  • Counterhold mounting nut using socket 3310 and rotate generator shaft clockwise to loosen it.
  • Remove ribbed belt pulley.

Installing

Install in reverse order of removal, observing the following:

  • Turn the generator shaft counterclockwise to tighten.
  • Clip protective cap onto generator pulley.

Tightening torque

Component Nm
Ribbed belt pulley to generator 65

Ribbed Belt Pulley with Freewheel, Removing and Installing

Ribbed Belt Pulley with Freewheel, Removing and Installing

Special tools, testers and auxiliary items required

Fig. 31: Identifying Multi-Point Socket 3400
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Multi-point adapter 3400
  • 8 mm hex socket or TORX T50

Fig. 32: Tightening/Loosening Nut At Pulley With Wrench And Adapter 3400
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing

  • If present, press the protective cap off the generator pulley.
  • Counter pulley with Multi-Tooth Adapter 3400 and turn generator shaft clockwise to loosen.

Installing

Install in reverse order of removal, observing the following:

  • Turn the generator shaft counterclockwise to tighten.
  • Clip protective cap onto generator pulley.

Tightening torque

Component Nm
Ribbed belt pulley with freewheel to generator 80

Cruise Control System, with Electronic Power Control

Cruise Control System, with Electronic Power Control

--> General Information

--> Cruise Control System, Activating and Deactivating

General Information

General Information

All cruise control system functions are controlled by the applicable Engine Control Module (ECM). The processing of electronic engine controls and cruise control functions are integrated in the ECM. Other than the cruise control switches on the steering column/multifunction steering wheel, the clutch and brake pedal switches and related wiring, there are no separate cruise control components to be serviced.

As all electronic throttle control (EPC) operations are monitored by On Board Diagnostic (OBD), Diagnostic Trouble Codes (DTC) pertaining to engine electronics that are stored in DTC memory may be relevant to cruise control function. Always check DTC memory first before troubleshooting.

All CCS troubleshooting and OBD program functions are performed using the Vehicle Diagnosis, Testing info. System VAS 5051B (or other VAS 505X class tester) in operating mode "Guided Fault Finding" or "Vehicle Self Diagnosis".

Cruise Control System, Activating and Deactivating

Cruise Control System, Activating and Deactivating

Special tools, testers and auxiliary items required

  • e.g. Vehicle Diagnosis, Testing and Information System VAS 5051B (or any of the VAS 505X class testers) with diagnostic cable

Procedure

NOTE:
  • If an error message appears on the display --> , VAS 5051B operating instructions.
  • Press Guided Functions button on operating mode selection screen.

Fig. 33: Display On VAS 5051 - (1st Control Element In Test & Evaporative Emission (EVAP) Canister Purge Regulator Valve-N80-)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Display:

  • Enter vehicle identification number (VIN) in field - 1 - in selection - A -.

The Vehicle Diagnosis, Testing and Information System VAS 5051B then switches to the next selection level. The following example shows how vehicle type, engine and vehicle system of function could be selected (some steps may be skipped):

The following information is given as an example only. Always enter required information as it pertains to vehicle being serviced.

Selection Text lines to be selected
Select brand Audi
Select model (example) Audi A3 2004 >
Select model year (example) 2006 (6)
Select version (example) 5-door vehicles
Select engine code (example) BAG 1.6L FSI / 85 kW
If vehicle identification was performed correctly, then press button to confirm  
Select vehicle system or function 01 - Engine electronics
Select vehicle system or function J220 - Cruise control, activating or deactivating

  • Follow VAS 5051B instructions and prompts.

After successful activation/deactivation:

  • Tap button Go to.
  • Select function "Exit".
  • Switch ignition off and disconnect tester from Data Link Connector (DLC).

NOTE:
  • If it is not possible to activate/deactivate the CCS using "Guided Fault Finding" , e.g.: with older Engine Control Module (ECM) generations, CCS function (or lack of CCS function) are hard-programmed into the ECM version. In these cases, ECMs with and without CCS function are identified via different ECM part numbers.

92 - Windshield wiper and washer system

Washer Hose Couplings

Disconnecting and Connecting

The following hose coupling types are used for connecting hoses to pumps and washer nozzles or as separating points.

Fig. 34: Identifying Washer Hose Coupling
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unsecured hose coupling

  • Disconnect by pulling apart both parts of coupling.
  • Reconnect by pushing both halves of coupling together until felt and heard to engage.

Fig. 35: Connecting/Disconnecting Washer Hose Coupling (Type 1)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Secured hose coupling with circlip

  • Disconnect by turning lock ring - 1 - through 90 - arrow - and then pulling apart both halves of coupling.
  • Reconnect by pushing both halves of coupling together and rotating locking ring - 1 - - arrow - until it engages.

Fig. 36: Connecting/Disconnecting Washer Hose Coupling (Type 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Secured hose coupling with circlip, version 1

  • To disconnect the connection, pull the circlip - 1 - up approximately 1 mm - arrow - and remove the hose connection.
  • To connect, position the hose connection and press the circlip in until it engages.

Fig. 37: Connecting/Disconnecting Washer Hose Coupling (Type 3)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Secured hose coupling with circlip, version 2

  • Disconnect by lifting lock ring - 1 - approx. 1 mm - arrow - and then pulling apart both halves of coupling.
  • Reconnect by pushing both halves of coupling together and clipping locking ring - 1 - until it engages.

Fig. 38: Connecting/Disconnecting Washer Hose Coupling (Headlight Cleaning System)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Headlamp washer system hose connection with circlip

  • Disconnect by depressing clip - 1 - - arrow - and then separating coupling from jet.
  • Reconnect by keeping clip - arrow - depressed while pushing coupling onto jet until it engages. Check securing clip for secure locking by attempting to pull it off without depressing clip.

Fig. 39: Headlamp Washer System Hose Connection With Hose Clamp
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Headlamp washer system hose connection with hose clamp

  • Disconnect by removing clamp - 1 - (cut with side cutters) and remove hose.
  • Reconnect by slide new hose clamp onto hose, position hose connection and install the hose clamp with Hose Clamp Pliers VAG 1275.

Fig. 40: Headlamp Washer System Hose Coupling With Spring Clamp
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Headlamp washer system hose coupling with spring clamp

  • Disconnect opening spring clamp - 1 - with Hose Clip Pliers VAG 1921 and remove hose connection.
  • Reconnect by opening spring clamp with Hose Clip Pliers VAG 1921 and repositioning hose on connection.

Washer Hoses, Repairing

Washer Hoses, Repairing

--> Smooth Hoses, Repairing

--> Corrugated Hoses, Repairing

Smooth Hoses, Repairing

Smooth Hoses, Repairing

NOTE:
  • Smooth hoses with a 5x1mm or 6x1 mm diameter can be replaced with EPDM (Ethylene Propylene Diene Monomer) hose.

Fig. 41: Repairing Smooth Washer Hose
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Trim and remove damaged sections of hose.
  • Select the appropriate EPDM hose - 2 - and cable tie.
  • Cut a length of EPDM hose - 2 - so that the ends of the smooth hose - 1 - and - 3 - can be pushed approximately 10 mm into the EPDM hose - 2 -.

Fig. 42: Securing Hose With Cable Ties
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Secure with cable ties as illustrated - 1 -.
  • Check for function and leaks.

Corrugated Hoses, Repairing

Corrugated Hoses, Repairing

NOTE:
  • Corrugated hoses can be replaced with heat-shrink sleeves.

Special tools, testers and auxiliary items required

Fig. 43: Wiring Harness Repair Set VAS 1978A
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Hot Air Gun VAS 1978/14 from Wiring Harness Repair Set VAS 1978A.

Fig. 44: Air Hose Pliers VAS 6228
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Air Hose Pliers VAS 6228
  • Connecting piece 1J0 955 875 R
  • Connecting piece 1J0 955 875

Fig. 45: Connecting Ends Of The Washer Fluid Line With Connector Pieces
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Procedure

  • Disconnect damaged part of washer fluid hose with the Air Hose Pliers VAS 6228.
  • Connect ends - 1 and 4 - of the washer fluid line with connector pieces - 2 and 3 -.
  • Slide the heat-shrink sleeve - 5 - over an end of the washer fluid line and connect the connector pieces with each other.
  • Slide the heat-shrink sleeve over the washer fluid connector pieces.
  • After sliding on, the heat-shrink sleeve must be shrunk with the Hot Air Gun VAS 1978/14.
  • The heat-shrink sleeve must be heated from the center outward until it seals completely.
  • Set the hot air gun to the correct temperature according to the operating instructions.
  • When shrinking, ensure no other lines, plastic parts or insulation material is damaged by the hot nozzle.
  • Check for function and leaks.

94 - Lights, Switches - Exterior

HID Headlamps, Safety Precautions

Prior to servicing vehicles with HID headlamps, technicians must read, understand and heed the following safety precautions:

CAUTION: HIGH VOLTAGE!
  • Switch off the ignition, switch off all electrical consumers and remove ignition key.
  • Disconnect battery prior to servicing HID headlamp components marked with yellow HIGH VOLTAGE! symbols.
  • After disconnecting battery, switch low beam on and off again in order to discharge any residual voltage.
  • Do not operate HID lamp control module without gas-discharge lamp installed.
  • Due to high voltage (over 28000 V when igniting the lamp), do not operate HID lamp outside the headlamp housing.

CAUTION: Risk of injury due to burning, UV rays, blinding and explosion.
  • When removing and installing HID bulbs, always wear safety glasses and gloves.
  • Due the high temperatures, absorption of UV rays, and the risk of blinding, the gas-discharge lamp should only be operated inside the headlamp housing.
  • Do not look into the beam of light. It may interfere with the ability to see for a significant period of time.
  • Gas-discharge lamps are under pressure and can crack when bulbs are replaced.

CAUTION: Environmental risk.
  • Gas-discharge bulbs require special disposal. They contain metallic mercury (Hg) and traces of thallium.
  • Do not destroy gas-discharge lamps. Avoid contact with burst glass bulbs.
  • Follow disposal requirements, only dispose of gas-discharge lamps in suitable containers at an authorized collection site.

CAUTION:
  • Do not touch gas-discharge bulbs with bare hands. The remaining fingerprint would evaporate due to the heat of the operated bulb and condense on the reflector which would impair headlamp luminosity. Use clean cloth gloves to insert the gas-discharge lamp.
  • Only replace faulty gas-discharge lamps with the same type of bulbs. Bulb identification can be found on bulb socket or glass cone.
  • Harness connectors must engage correctly when installed and must be checked for proper connection.

96 - Lights, Switches - Interior, Anti-theft

Anti-Theft Immobilizer, without Access/Start Control Module

Anti-Theft Immobilizer, without Access/Start Control Module

--> General Information

--> Faulty Transponder or Lost Key

--> Induction Coil, Replacing

--> Lock Set, Replacement Procedure

General Information

General Information

The immobilizer control module is integrated in the instrument cluster. The immobilizer control module is replaced together with the instrument cluster.

  • If the control module is replaced, use Vehicle Diagnosis, Testing info. System VAS 5051B (or other VAS 505X class tester) in operating mode "Guided Functions" and select the "Replace" function for the respective control module.

Faulty Transponder or Lost Key

Faulty Transponder or Lost Key

  • The transponder is integrated in the vehicle key and cannot be replaced separately.
  • If the transponder is faulty, the entire vehicle key must be replaced.
  • Order a replacement key through distributor or importer with vehicle-specific lock number using VIN.
  • Perform the adaptation on all vehicle keys using Vehicle Diagnosis, Testing info. System VAS 5051B (or other VAS 505X class tester) in operating mode "Guided Fault Finding".

Induction Coil, Replacing

Induction Coil, Replacing

  • The induction coil is integrated in the lock cylinder and cannot be replaced separately.
  • If the induction coil is faulty, the entire lock cylinder must be replaced.
  • Order a new lock cylinder through distributor or importer with vehicle-specific lock number using VIN.

Lock Set, Replacement Procedure

Lock Set, Replacement Procedure

After replacement of lock set, adapt all vehicle keys can only be adapted using Vehicle Diagnosis, Testing info. System VAS 5051B in operating mode "Guided Fault Finding".

Anti-Theft Immobilizer, with Access/Start Control Module

Anti-Theft Immobilizer, with Access/Start Control Module

Immobilizer control is integrated in Access/Start Control Module J518. Component location: Integrated in steering column, removing and installing --> 48 - STEERING .

The following components are also part of the immobilizer:

  • Vehicle key with integrated transponder.
  • Induction coil in Access/Start Authorization Switch E415 (electronic ignition lock).
  • Engine Control Module (ECM).
  • Transmission Control Module (TCM).
  • If the control module is replaced, use Vehicle Diagnosis, Testing info. System VAS 5051B (or other VAS 505X class tester) in operating mode "Guided Functions" and select the "Replace" function for the respective control module.

Heated Steering Wheel

Heated Steering Wheel

  • Check wire connections --> Electrical Wiring Diagrams, Troubleshooting and Component Locations.

NOTE:
  • Complete heated steering wheel must be replaced if faulty.

Trailer Hitch Wiring Socket

Trailer Hitch Wiring Socket

--> Trailer Hitch Wiring Socket, Removing and Installing

--> Trailer Hitch Wiring Socket, Multi-Pin Connector Assignments

Trailer Hitch Wiring Socket, Removing and Installing

Trailer Hitch Wiring Socket, Removing and Installing

Fig. 46: Trailer Hitch Wiring Socket Components
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing

  • Switch off ignition and remove ignition key.

CAUTION:
  • Switch off ignition.
  • Switch off all electrical consumers and remove ignition key

  • Remove screws - arrows -.
  • Remove socket assembly from mounting plate.

Fig. 47: Switch Connector And Connector At Socket
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Wiring socket with Switchable Rear Fog Lamp Shut-Off Contact Switch F216 :

  • Disconnect switch connector - 2 - and connector - 1 - from socket.

Fig. 48: Pressing Multi-Pin Connector Out Of Socket
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Wiring socket without Switchable Rear Fog Lamp Shut-Off Contact Switch F216 :

  • Press multi-pin connector - 2 - in - direction of arrow - out of socket - 1 -.

Fig. 49: Releasing Securing Tabs And Then Releasing Retainer Clips
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Version 1:

  • Release securing tabs - arrows - and then release retainer clips - 1 - and - 3 through 5 -.
  • Remove retainer from harness connectors - 2 -.

Fig. 50: Releasing Securing Tabs And Then Retaining Clips
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Version 2:

  • First release securing tabs - arrows - and then retaining clips - 1, 2, 3, 4, 6, 7 -.
  • Remove retaining cage from multi-pin electrical connector - 5 -.

Fig. 51: O-Rings, Harness Connectors And Retainer
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Installing

Install in reverse order of removal, noting the following:

NOTE:
  • Ensure O-rings - 1 - and - 3 - are not damaged.
  • Slide harness connectors - 4 - into retainer - 2 - until they audibly engage.

Trailer Hitch Wiring Socket, Multi-Pin Connector Assignments

Trailer Hitch Wiring Socket, Multi-Pin Connector Assignments

Fig. 52: Trailer Hitch Wiring Socket, Multi-Pin Connector Assignments
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  1. Terminal BL (left turn signal)
  2. Terminal NSL (rear fog lamp)
  3. Terminal 31, ground (GND)
  4. Terminal BR (right turn signal)
  5. Terminal 58 R (right tail lamp)
  6. Terminal 54 (brake light)
  7. Terminal 58 L (left tail lamp)
  8. Terminal RF (back-up light)
  9. Where applicable
  10. Where applicable
  11. Where applicable
  12. Where applicable
  13. Where applicable

Trailer wiring socket with Switchable Rear Fog Lamp Shut-Off Contact Switch F216 :

Multi-pin connector assignments for Switchable Rear Fog Lamp Shut-Off Contact Switch F216 (where applicable) --> Electrical Wiring Diagrams, Troubleshooting and Component Locations

97 - Wiring

Wiring Harnesses and Connectors, Repairing

Wiring Harnesses and Connectors, Repairing

--> Vehicle Electrical System, General Information

--> Wiring Harness and Connector Repairs, General Information

--> Airbag and Safety Belt Tensioner Wiring, Repairing

--> CAN-Bus Wiring, Repairing

--> Wire, 0.25 mm with Individual Crimp Connector, Repairing

--> Wire, 0.35 mm and Larger with Individual Crimp Connector, Repairing

--> Wire, 0.25 mm with Intermediate Wire Section, Repairing

--> Wire, 0.35 mm or Larger with Intermediate Wire Section, Repairing

Special tools, testers and auxiliary items required

Fig. 53: Wiring Harness Repair Kit V.A.S 1978
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Wiring Harness Repair Kit VAS 1978 with

Fig. 54: Upgrade Kit For VAS1978 (VAS1978/50)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Upgrade kit VAS 1978/50

Fig. 55: Wiring Harness Repair Set VAS 1978A
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • or Wiring Harness Repair Set VAS 1978A

NOTE:
  • The Upgrade Kit VAS 1978/50 is required to bring the "old" Wiring Harness Repair Kit VAS 1978 up to the new standard of the Wiring Harness Repair Set VAS 1978A.

CAUTION:
  • Wiring harness and socket repairs may only be carried out with the Wiring Harness Repair Kit VAS 1978 or Wiring Harness Repair Set VAS 1978A.
  • Observe the country-specific requirements.

Fig. 56: Opened Wiring Harness Repair Kit VAS 1978
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:
  • Usage of the Wiring Harness Repair Kit VAS 1978 or Wiring Harness Repair Set VAS 1978A is described extensively in the accompanying usage instructions.
  • Repairs on open circuits and faulty connectors are also explained using examples.

Vehicle Electrical System, General Information

Vehicle Electrical System, General Information

CAUTION: Risk of injury.
  • Pay attention to stickers designating high voltage components. Prior to performing repairs, residual voltage must first be discharged.
  • Some tools are supplied with a tool safety clip, which is slid over the tool points after using the tool, in order to protect other workers from injuries and tool points from damage.

CAUTION:
  • Observe country-specific requirements.
  • By disconnecting battery ground (GND) wire, safe work on vehicle electrical system is guaranteed. With the ignition switched off, disconnect battery ground cable --> 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL .
  • Before starting a repair, the cause of the damage must be eliminated first, i.e. sharp edges on chassis parts, faulty consumers, corrosion etc.

NOTE:
  • If possible, do not loosen ground (GND) straps from body (danger of corrosion).
  • Further information, e.g. installing and removing the individual components, is described in the appropriate repair manual.

Wiring Harness and Connector Repairs, General Information

Wiring Harness and Connector Repairs, General Information

NOTE:
  • Observe general notes for repairs on the vehicle electrical system --> Vehicle Electrical System, General Information.
  • Not all of the wire cross sections contained in the vehicle are in the Wiring Harness Repair Kit VAS 1978 or Wiring Harness Repair Set VAS 1978A. If the required wire cross-section is not present, the next greater cross-section must be used.
  • For repairs on vehicle electrical system, soldering is not permitted.
  • Do not repair crimp connectors. If necessary, lay a wire parallel to the faulty wire.
  • After crimping, crimp connections must be heat-shrunk using hot air gun to prevent moisture penetration.
  • Shielded wires, such as RPM sensors and knock sensors, may not be repaired. If faulty, the entire harness must be replaced.
  • Exclusive use is to be made of yellow wires for wiring harness repairs.
  • Wiring harness repairs should not be made again in the wrapping on the vehicle-specific wiring harness.
  • Mark repaired areas using yellow adhesive tape.
  • Yellow wires and areas in the wiring harness wrapped with yellow adhesive tape mark a previously performed repair.
  • Perform a function test after each repair. If necessary, check DTC memory, erase and/or bring systems into basic setting.

Airbag and Safety Belt Tensioner Wiring, Repairing

Airbag and Safety Belt Tensioner Wiring, Repairing

NOTE:

CAUTION: Passenger protection malfunction due to faulty repairs to the airbag and belt tensioner wiring harness
  • Repairs on the airbag and seat belt wiring must only be performed on the vehicle using the Wiring Harness Repair Kit VAS 1978 or Repair Manual Wiring Set VAS 1978A and original replacement parts (connector housing, terminals, wires) in order to guarantee the repair quality required by Audi AG.
  • Wires at individual airbag modules may not be repaired.
  • If the wires or connectors on the airbag modules are damaged, the respective airbag module must be replaced for safety reasons.

  • A maximum of two repairs may be performed when repairing wires of airbag- and seat belt tensioner system. Repairs increase the electrical resistance in the wire and may trigger malfunctions in the system On Board Diagnostic (OBD).
  • Repairs in the area of the airbag or seat belt tensioner should be performed a maximum of 30 cm from the next terminal housing. Together with the identification using yellow adhesive tape, this procedure makes it possible to obtain a quick overview of previously performed repairs.

Fig. 57: Repairing Twisted Wire Pairs
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Both wires to the airbag igniter have a twist with 20 5 mm routing length. This routing length must be maintained when repairing the twisted wires.
  • When repairing, both wires to the airbag igniters must be the same length. When twisting the wires - 1 and 2 - together, the - A - = 20 mm routing length must be maintained.
  • While doing so, no section of wire must be greater than - B - = 100 mm without twisting of wires, e.g. in area of welded connectors - arrow -.
  • Repairs are to be documented in the Audi Service Plan under "Space for workshop entries" with a short commentary of scope of repairs, workshop stamp and signature.
  • Any warranty claims to Audi AG are voided if airbag wiring harness repairs were not performed using original replacement parts and the Wiring Harness Repair Kit VAS 1978 or Wiring Harness Repair Set VAS 1978A.

CAN-Bus Wiring, Repairing

CAN-Bus Wiring, Repairing

NOTE:

Fig. 58: Repairing Twisted Wire Pairs
Courtesy of VOLKSWAGEN UNITED STATES, INC.

An unshielded two-strand wire - 1 and 2 - with a cross section of 0.35 mm 2 or 0.5 mm 2 can be used as CAN-Bus wiring.

  • CAN bus wires have the following color coding:

Powertrain CAN Bus High orange/black
Comfort CAN Bus High orange/green
Infotainment CAN Bus High orange/violet
CAN Bus Wiring Low orange/brown

  • During repair work, both bus wires must have the same length. When twisting the wires - 1 and 2 - together, the - A - = 20 mm routing length must be maintained.
  • While doing so, no section of wire must be greater than - B - = 50 mm without twisting of wires, e.g. in area of welded connectors - arrow -.

Wire, 0.25 mm with Individual Crimp Connector, Repairing

Wire, 0.25 mm with Individual Crimp Connector, Repairing

Procedure

  • Free up the wire to be repaired approximately 20 cm on both sides of the repair point.

CAUTION: Risk of damaging the electrical wires.
  • Free up wrapped wiring harnesses carefully.

  • If necessary, removing the wiring harness wrapping using a knife.

Fig. 59: Cutting Wire Using Side-Cutter Function Of Wire Stripper
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Cut out the damaged wire section using wire stripper VAS 1978/3.

NOTE:
  • If, by cutting out the damaged wire section, both ends of the vehicle-specific single wire are too short for a repair using a single crimp connector, insert a repair wire section of matching length with two crimp connections --> Wire, 0.25 mm with Intermediate Wire Section, Repairing.

Fig. 60: Stripping Insulation At Wiring Using Stripping Pliers
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Adjust the sliding stop in the Wire Stripper VAS 1978/3 pliers jaws to 12 to 14 mm for the wire to be stripped.
  • Insert wire end from front up to stop into jaws of pliers and squeeze the pliers completely.
  • Open pliers again and remove the stripped wire end.
  • Twist bare strands one-half turn.
  • For the repair of a 0.25 mm 2 wire, use a small yellow crimp connector from the Wiring Harness Repair Set VAS 1978A.

Fig. 61: Crimping Pliers
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • To press the crimp connector, use the Crimping Pliers (Base Tool) VAS 1978/1-2 with Exchangeable Head, 0.35-2.5mm2 VAS 1978/1-1.

Fig. 62: Crimping Single Break Point
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Slide the small yellow crimp connector onto both stripped, uninsulated wire ends on the vehicle-specific single wire and crimp them using crimp pliers.

NOTE:
  • Do not crimp wire insulation.

Fig. 63: Heating Crimp Connection Using Hot Air Gun
Courtesy of VOLKSWAGEN UNITED STATES, INC.

After crimping, crimp connections must be heat-shrunk using hot air gun to prevent moisture penetration.

  • Put Shrink Tip For Hot Air Gun VAS 1978/15 on to Hot Air Gun, 220 V/ 50 Hz VAS 1978/14.

CAUTION: Risk of damaging surrounding components.
  • When heat-shrinking crimp connections, be careful not to damage any other wiring, plastic parts or insulating material with the hot nozzle of the hot air gun.
  • Always observe operating instructions of heat gun.

Fig. 64: Single Repair Point
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Heat crimp connection using hot air gun lengthwise from center outward until it is sealed completely and adhesive comes out the ends.
  • This is how the completed repair location with individual crimp connector should appear.

Fig. 65: Offsetting Crimp Connections
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:
  • Make sure that crimp connections do not lie directly next to each other when several wires need to be repaired. Arrange the crimp connectors at a slight offset so that the circumference of the wiring harness does not become too large.
  • If the repair point was previous taped, this point must be taped again with yellow insulating tape after repairs.
  • Secure the repaired wiring harness if necessary with a cable tie to prevent flapping noises while driving.

Wire, 0.35 mm and Larger with Individual Crimp Connector, Repairing

Wire, 0.35 mm and Larger with Individual Crimp Connector, Repairing

Procedure

  • Free up the wire to be repaired approximately 20 cm on both sides of the repair point.

CAUTION: Risk of damaging the electrical wires.
  • Free up wrapped wiring harnesses carefully.

  • If necessary, removing the wiring harness wrapping using a knife.

Fig. 66: Cutting Wire Using Side-Cutter Function Of Wire Stripper
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Cut out the damaged wire section using wire stripper VAS 1978/3.

NOTE:

Fig. 67: Stripping Insulation At Wiring Using Stripping Pliers
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Adjust the sliding stop in the Wire Stripper VAS 1978/3 pliers jaws to 6 to 7 mm for the wire to be stripped.
  • Insert wire end from front up to stop into jaws of pliers and squeeze the pliers completely.
  • Open pliers again and remove the stripped wire end.
  • For the repair, use a suitable crimp connector form the Wiring Harness Repair Set VAS 1978A.

Fig. 68: Crimping Pliers
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Use the Crimping Pliers (Base Tool) VAS 1978/1-2 to press the crimp connector.

The following exchangeable heads are available for the Crimping Pliers (Base Tool) VAS 1978/1-2 :

  • Exchangeable Head, 0.35-2.5mm VAS 1978/1-1
  • Exchangeable head, 4.0-6.0 mm2 VAS 1978/2 A

Fig. 69: Crimping Single Break Point
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Slide crimp connection on to both stripped wire ends of vehicle-specific single wire and crimp them using crimp pliers.

NOTE:
  • Do not crimp wire insulation.

Fig. 70: Heating Crimp Connection Using Hot Air Gun
Courtesy of VOLKSWAGEN UNITED STATES, INC.

After crimping, crimp connections must be heat-shrunk using hot air gun to prevent moisture penetration.

  • Put Shrink Tip For Hot Air Gun VAS 1978/15 on to Hot Air Gun, 220 V/ 50 Hz VAS 1978/14.

CAUTION: Risk of damaging surrounding components.
  • When heat-shrinking crimp connections, be careful not to damage any other wiring, plastic parts or insulating material with the hot nozzle of the hot air gun.
  • Always observe operating instructions of heat gun.

Fig. 71: Single Repair Point
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Heat crimp connection using hot air gun lengthwise from center outward until it is sealed completely and adhesive comes out the ends.
  • This is how the completed repair location with individual crimp connector should appear.

Fig. 72: Offsetting Crimp Connections
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:
  • Make sure that crimp connections do not lie directly next to each other when several wires need to be repaired. Arrange the crimp connectors at a slight offset so that the circumference of the wiring harness does not become too large.
  • If the repair point was previous taped, this point must be taped again with yellow insulating tape after repairs.
  • Secure the repaired wiring harness if necessary with a cable tie to prevent flapping noises while driving.

Wire, 0.25 mm with Intermediate Wire Section, Repairing

Wire, 0.25 mm with Intermediate Wire Section, Repairing

NOTE:
  • Only 0.5 mm 2 repair wires are available for repairing a 0.25 mm 2 wire.

Procedure

  • Free up the wire to be repaired at two places approximately 20 cm on both sides of the repair point.

CAUTION: Risk of damaging the electrical wires.
  • Free up wrapped wiring harnesses carefully.

  • If necessary, removing the wiring harness wrapping using a knife.

Fig. 73: Cutting Wire Using Side-Cutter Function Of Wire Stripper
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Route yellow repair wire next to damaged wiring harness and cut repair wire to the required length using wire stripper VAS 1978/3.
  • Cut damaged wire section from the vehicle-specific single wire.

Fig. 74: Stripping Insulation At Wiring Using Stripping Pliers
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Adjust the sliding stop in the Wire Stripper VAS 1978/3 pliers jaws to 12 to 14 mm for the wire to be stripped.
  • Insert the vehicle-specific single wire end from the front into the pliers jaws as far as the stop and squeeze the pliers together completely.
  • Open pliers again and remove the stripped wire end.
  • Twist bare strands one-half turn.
  • Repeat the procedure on the other end of the vehicle-specific individual wire.

Fig. 75: Stripping Insulation At Wiring Using Stripping Pliers
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Adjust the sliding stop in the Wire Stripper VAS 1978/3 pliers jaws to 6 to 7 mm for the wire to be stripped.
  • Insert the yellow repair wire end from the front into the pliers jaws as far as the stop and squeeze the pliers together completely.
  • Open pliers again and remove the stripped wire end.
  • Repeat this procedure on the other repair wire end.
  • For the repair of a 0.25 mm 2 wire, use a small yellow crimp connector from the Wiring Harness Repair Set VAS 1978A.

Fig. 76: Crimping Pliers
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • To press the crimp connector, use the Crimping Pliers (Base Tool) VAS 1978/1-2 from the Wiring Harness Repair Set VAS 1978A with the Exchangeable Head, 0.35 mm-2.5 mm VAS 1978/1-1.
  • Slide the small yellow crimp connector onto the vehicle-specific single wire at one side and onto the repair wire at the other side.

Fig. 77: Crimping Single Break Point
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Crimp the crimp connection at both wire ends using crimp pliers.
  • Repeat this procedure at the other repair wire end.

NOTE:
  • Do not crimp wire insulation.

Fig. 78: Heating Crimp Connection Using Hot Air Gun
Courtesy of VOLKSWAGEN UNITED STATES, INC.

After crimping, crimp connections must be heat-shrunk using hot air gun to prevent moisture penetration.

  • Put Shrink Tip For Hot Air Gun VAS 1978/15 on to Hot Air Gun, 220 V/ 50 Hz VAS 1978/14.

CAUTION: Risk of damaging surrounding components.
  • When heat-shrinking crimp connections, be careful not to damage any other wiring, plastic parts or insulating material with the hot nozzle of the hot air gun.
  • Always observe operating instructions of heat gun.

Fig. 79: Wire Break With Dual Repair Point
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Heat crimp connection using hot air gun lengthwise from center outward until it is sealed completely and adhesive comes out the ends.
  • This is how the completed repair location with the inserted wire and two crimp connectors should look.

Fig. 80: Offsetting Crimp Connections
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:
  • Make sure that crimp connections do not lie directly next to each other when several wires need to be repaired. Arrange the crimp connectors at a slight offset so that the circumference of the wiring harness does not become too large.
  • If the repair point was previous taped, this point must be taped again with yellow insulating tape after repairs.
  • Secure the repaired wiring harness if necessary with a cable tie to prevent flapping noises while driving.

Wire, 0.35 mm or Larger with Intermediate Wire Section, Repairing

Wire, 0.35 mm or Larger with Intermediate Wire Section, Repairing

NOTE:
  • Only 0.5 mm 2 repair wires are available for repairing a 0.35 mm 2 wire.

Procedure

  • Free up the wire to be repaired at two places approximately 20 cm on both sides of the repair point.

CAUTION: Risk of damaging the electrical wires.
  • Free up wrapped wiring harnesses carefully.

  • If necessary, removing the wiring harness wrapping using a knife.

Fig. 81: Cutting Wire Using Side-Cutter Function Of Wire Stripper
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Route yellow repair wire next to damaged wiring harness and cut repair wire to the required length using wire stripper VAS 1978/3.
  • Cut damaged wire section from the vehicle-specific single wire.

Fig. 82: Stripping Insulation At Wiring Using Stripping Pliers
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Adjust the sliding stop in the Wire Stripper VAS 1978/3 pliers jaws to 6 to 7 mm for the wire to be stripped.
  • Insert the vehicle-specific single wire end from the front into the pliers jaws as far as the stop and squeeze the pliers together completely.
  • Open pliers again and remove the stripped wire end.
  • Repeat the procedure on the other end of the vehicle-specific individual wire.
  • For the repair, use two suitable crimp connectors form the Wiring Harness Repair Set VAS 1978A.

Fig. 83: Crimping Pliers
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Use the Crimping Pliers (Base Tool) VAS 1978/1-2 to press the crimp connector.

The following exchangeable heads are available for the Crimping Pliers (Base Tool) VAS 1978/1-2 :

  • Exchangeable Head, 0.35-2.5mm VAS 1978/1-1
  • Exchangeable head, 4.0-6.0 mm2 VAS 1978/2 A
  • Slide the crimp connector onto the vehicle-specific single wire at one side and onto repair wire at the other side.

Fig. 84: Crimping Single Break Point
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Crimp the crimp connection at both wire ends using crimp pliers.
  • Repeat this procedure on the other wire ends.

NOTE:
  • Do not crimp wire insulation.

Fig. 85: Heating Crimp Connection Using Hot Air Gun
Courtesy of VOLKSWAGEN UNITED STATES, INC.

After crimping, crimp connections must be heat-shrunk using hot air gun to prevent moisture penetration.

  • Put Shrink Tip For Hot Air Gun VAS 1978/15 on to Hot Air Gun, 220 V/ 50 Hz VAS 1978/14.

CAUTION: Risk of damaging surrounding components.
  • When heat-shrinking crimp connections, be careful not to damage any other wiring, plastic parts or insulating material with the hot nozzle of the hot air gun.
  • Always observe operating instructions of heat gun.

Fig. 86: Wire Break With Dual Repair Point
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Heat crimp connection using hot air gun lengthwise from center outward until it is sealed completely and adhesive comes out the ends.
  • This is how the completed repair location with the inserted wire and two crimp connectors should look.

Fig. 87: Offsetting Crimp Connections
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:
  • Make sure that crimp connections do not lie directly next to each other when several wires need to be repaired. Arrange the crimp connectors at a slight offset so that the circumference of the wiring harness does not become too large.
  • If the repair point was previous taped, this point must be taped again with yellow insulating tape after repairs.
  • Secure the repaired wiring harness if necessary with a cable tie to prevent flapping noises while driving.

Terminal Housings and Connectors, Repairing

Terminal Housings and Connectors, Repairing

--> Terminal Housing and Harness Connector Repairs, General Information

--> Contacts in Terminal Housing, Repairing

--> Single Wire Seals, Assembly

--> Terminal Housings with Insulation Displacement Terminal, Repairing

Terminal Housing and Harness Connector Repairs, General Information

Terminal Housing and Harness Connector Repairs, General Information

NOTE:
  • Observe general notes for repairs on the vehicle electrical system --> Vehicle Electrical System, General Information.
  • Allocation of crimp contacts with correct fit to contact housing is performed according to the part number stamped in on the contact housing. Terminal housing part numbers in conjunction with the appropriate crimp contacts; 70 - INTERIOR TRIM , chart 970-00.
  • Damaged contact housings must always be replaced.

Contacts in Terminal Housing, Repairing

Contacts in Terminal Housing, Repairing

Fig. 88: Releasing Terminal Lock And Pulling Wire With Single Wire Seal Toward Rear Out Of Terminal Housing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Procedure

  • Pull contact back out of housing - arrow - at single wire (with single wire seal if necessary).

Fig. 89: Cutting Off Old Terminal With Single Wire Seal
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Cut off old contact (with the single wire seal) from vehicle-specific wiring harness.
  • Determine yellow repair wire with correct contact from Wiring Harness Repair Set VAS 1978A.
  • Free up wire to be repaired approximately 20 cm on both sides of the repair point.

CAUTION: Risk of damaging the electrical wires.
  • Free up wrapped wiring harnesses carefully.

  • If necessary, remove wiring harness wrapping using knife.

Fig. 90: Inserting New Terminal Into Terminal Housing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Slide new repair wire contact into corresponding contact housing compartment until it engages.

Fig. 91: Cutting Wire Using Side-Cutter Function Of Wire Stripper
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Shorten repair wire and vehicle-specific wiring harness single wire as needed using the Wire Stripper VAS 1978/3.

Single Wire Seals, Assembly

Single Wire Seals, Assembly

Procedure

NOTE:
  • Single wire seals prevent the penetration of water and dirt into the contact housing. They are installed e.g. in the engine compartment and must be reinstalled after a repair.
  • Single wire seal is crimped on at the factory together with contact on the wire, this is not the case for repair wires. The single wire seal must be slid onto the wire before crimping the repair wire.
  • Single wire seals must always fit with the repair wire cross-section. Outer circumference of single wire seal is aligned according to chamber circumference of the contact housing. Perform assembly using only the assembly tool with correct fit.

Fig. 92: Sliding On Single Wire Seal
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Put single wire seal - A - on to free end of repair wire.
  • When doing this, the single wire seal small diameter must point toward the contact housing.

Fig. 93: Inserting New Terminal With Wire Seal
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Slide the single wire seal - A - onto the repair wire up to the contact housing and then into the housing as far as the stop using the appropriate assembly tool - B -.

Terminal Housings with Insulation Displacement Terminal, Repairing

Terminal Housings with Insulation Displacement Terminal, Repairing

Fig. 94: Identifying Terminal Housings With Insulation Displacement Terminal
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:
  • For technical reasons, contact housings for insulation displacement application can be supplied only with insulation displacement contacts slid on.
  • If these contacts are not needed, they can be removed as on any other contact housing.
  • Repair wires that already have the corresponding contacts crimped on are available.

Terminal Housings, Releasing and Disassembling

Terminal Housings, Releasing and Disassembling

Terminal Housings, Releasing and Disassembling

--> Terminal Housings, Release and Disassembly, General Information

--> Secondary Lock

--> Primary Lock

--> Primary Connector with Round Terminal Connector Systems

--> Primary Connector with Flat Terminal Connector Systems

--> Primary Connector with Flat Terminal Connector Systems

Terminal Housings, Release and Disassembly, General Information

Terminal Housings, Release and Disassembly, General Information

CAUTION: Risk of injury.
  • Some tools are supplied with a tool safety clip, which is slid over the tool points after using the tool, in order to protect other workers from injuries and tool points from damage.

NOTE:
  • Observe general notes for repairs on the vehicle electrical system --> Vehicle Electrical System, General Information.
  • Always use the release tools intended for the releasing process. Under no circumstances may terminals be pulled forcefully out of terminal housings.
  • Damaged contact housings must always be replaced.
  • Small screwdrivers may be used as an aid to release the secondary locks.
  • Chamber/pin assignment is located partially stamped in on secondary lock or rear side of terminal housing.
  • Detailed information on component locations of harness connectors --> Electrical Wiring Diagrams, Troubleshooting and Component Locations.
  • Allocation of the correct release tool to the respective retainers --> VAS 1978/35 instructions.

Secondary Lock

Secondary Lock

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

Fig. 95: Secondary Lock (Comb Type)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Example 1:

  • Release housing lock by removing "cam" - arrow -.

Fig. 96: Secondary Lock (Flap Type)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Example 2:

  • Release housing lock by opening "lid" - arrow -.

Fig. 97: Secondary Lock (Slider Type)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Example 3:

  • Release housing lock by disengaging "slider" - arrow -.

Primary Lock

Primary Lock

  • The primary lock is the locking mechanism of an individual crimp contact in the terminal housing.
  • If necessary, housing securing mechanisms (secondary locks) must be released or removed using specified tool before releasing the contacts --> Secondary Lock.
  • The shapes of the primary locks depicted in the following are only a selection which, as an example, should make clear the various functions of the secondary lock.
  • Allocation of the correct release tool to the respective locking mechanism --> VAS 1978/35 operating instructions.

Primary Connector with Round Terminal Connector Systems

Primary Connector with Round Terminal Connector Systems

Procedure

NOTE:
  • If necessary, housing securing mechanisms (secondary locks) must be released or removed using specified tool before releasing the contacts --> Secondary Lock.

Fig. 98: Removing Round Connector Terminal (1 of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Guide release tool (which fits terminal housing) into release channel on terminal housing as illustrated.
  • Grasp contact at wire and gently push into terminal housing - left arrow -.

NOTE:
  • By pushing contact in direction of terminal housing, contact retaining tabs are lifted off the housing shoulder and can be released using release tool.
  • At the same time, push release tool in direction of the terminal housing - right arrow - and pull the released contact out of the terminal housing.

Fig. 99: Removing Round Connector Terminal (2 of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Remove the release tool after removing the contact from the housing.

Primary Connector with Flat Terminal Connector Systems

Primary Connector with Flat Terminal Connector Systems

Procedure

NOTE:
  • If necessary, housing securing mechanisms (secondary locks) must be released or removed using specified tool before releasing contacts --> Secondary Lock.

Fig. 100: Removing Flat Connector Terminal With One Retaining Tab (1 Of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Flat connector system with one retaining tab:

  • Guide release tool (which fits terminal housing) into release channel on terminal housing.
  • Grasp contact at wire and push gently into terminal housing - arrow -.

NOTE:
  • By pushing contact in direction of terminal housing, contact retaining tab is lifted off the housing shoulder and can be released using release tool.

Fig. 101: Removing Flat Connector Terminal With One Retaining Tab (2 Of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • At the same time, push release tool in direction of terminal housing and pull released contact out of terminal housing - arrow -.
  • Remove release tool after removing contact from housing.

Fig. 102: Removing Flat Connector Terminal With Two Retaining Tab (1 Of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Flat connector system with two retaining tabs:

  • Guide release tool (which fits terminal housing) into release channel on terminal housing.
  • Grasp contact at wire and push gently into terminal housing until it stops - arrow -.

NOTE:
  • By pushing contact in direction of terminal housing, contact retaining tabs are lifted off the housing shoulder and can be released using release tool.

Fig. 103: Removing Flat Connector Terminal With Two Retaining Tab (2 Of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • At the same time, push release tool in direction of terminal housing and pull released contact out of terminal housing - arrow -.
  • Remove release tool after removing contact from housing.

Fig. 104: Removing Asymmetrical Flat Connector Terminal (1 of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Asymmetrical:

  • Guide release tool (which fits terminal housing) into release channel on terminal housing.
  • Grasp contact at wire and push gently into terminal housing - arrow -.

NOTE:
  • By pushing contact in direction of terminal housing, contact retaining tabs are lifted off the housing shoulder and can be released using release tool.

Fig. 105: Removing Asymmetrical Flat Connector Terminal (2 of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • At the same time, push release tool in the direction of terminal housing and pull released contact out of terminal housing - arrow -.
  • Remove the release tool after removing the contact from the housing.

Primary Connector with Special Connector Systems

Procedure

NOTE:
  • If necessary, housing securing mechanisms (secondary locks) must be released or removed using specified tool before releasing the contacts --> Secondary Lock.

Fig. 106: Removing Fasten Connector Terminal (1 Of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fasten contacts:

  • Guide release tool (that fits terminal housing) into release channel on terminal housing - arrow -.
  • Grasp contact at wire and push gently into terminal housing.

NOTE:
  • By pushing contact in direction of terminal housing, contact retaining tabs are lifted off the housing shoulder and can be released using release tool.

Fig. 107: Removing Fasten Connector Terminal (2 Of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • At the same time, push release tool in direction of terminal housing and pull released contact out of terminal housing - arrow -.
  • Remove release tool after removing contact from housing.

Fig. 108: Removing GT 150/280 Connector Terminal (1 Of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

GT 150/280 contacts:

  • Guide release tool (which fits terminal housing) under retaining tab into terminal housing.
  • Push tool into terminal housing until it stops - arrow -.

Fig. 109: Removing GT 150/280 Connector Terminal (2 Of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Contact is ejected from the terminal housing.
  • Remove release tool after removing contact from housing.

Fig. 110: Removing Connector Terminal Without Releasing Tabs (1 Of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Contacts without retaining tabs:

  • Insert release tool under retaining tab of terminal housing.
  • Push release tool through until it stops by gently lifting - arrow -.

Fig. 111: Removing Connector Terminal Without Releasing Tabs (2 Of 2)
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Contact is ejected from terminal housing.
  • Remove release tool after removing the contact from housing.

Antenna Wires, Repairing

Antenna Wires, Repairing

A repair procedure has been developed for repairing antenna wires. Instead of a complete antenna wire, connecting wires of different lengths and various adapter leads are now available as replacement parts.

Replacement parts; Special Catalog Electrical Connection Elements ; Accessories; Sub 35 chart 035-20.

NOTE:
  • Do not repair antenna wires. Replace them using connector and adapter wires available as original replacement parts.
  • These original replacement parts are suitable for all antenna wires and wire cross sections that need to be replaced.
  • Individual antenna connectors are not designed to be replaced.
  • The wires must be used retroactively for all Audi models, for all installed antenna wire diameters.
  • All adapter leads and connecting wires are suitable for various transmission and reception signals.
  • The repair concept can also be used as a testing or retrofitting solution.

Special tools, testers and auxiliary items required

Fig. 112: Assembly Overview Of Antenna Wire
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • - 1 - Adapter wire, for connection to radio; length: approximately 30 cm
  • - 2 - Connecting wire, available in various lengths
  • - 3 - Adapter wire, for connection to antenna; length: approximately 30 cm

Procedure

Example: Antenna wire from radio to antenna is faulty.

  • Separate connectors of the faulty antenna wiring from associated components.
  • Determine path of faulty antenna wire in vehicle and measure total length of antenna wire to be replaced.

Fig. 113: Assembly Overview Of Antenna Wire
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • The entire length of antenna wire consists of the length of required adapter wires - 1 and 3 - and connecting wire - 2 -.
  • Subtract 60 cm from the total length of antenna wire measured, to receive the length of connecting wire required.
  • Obtain the correct length of the required adapter wires and connecting wires as an original replacement part according.
  • Cut the connectors off of the faulty antenna wiring.
  • Leave the remaining antenna wire in vehicle.
  • Connect adapter wires to associated components in the vehicle.
  • Provide harness connectors with piece of foam hose to avoid rattle.
  • Route and secure connecting wire parallel to old antenna wire.

NOTE:
  • Antenna wires must not be kinked or excessively bent! The bending radius must never be below 50 mm.
  • Connect the connecting wire with the adapter leads.
  • To avoid rattle, slide on suitable piece of foam hose onto antenna connector.
  • Perform function test.

Fiber Optic Cable

Fiber Optic Cable

CAUTION: Do not excessively bend or kink fiber optic cables. (min. bending radius 25 mm).

--> Fiber Optic Cables, Repairing

--> Fiber Optic Cable, Separating from Wiring Harness Connector

Fiber Optic Cables, Repairing

Fiber Optic Cables, Repairing

Special tools, testers and auxiliary items required

Fig. 114: Fiber Optic Plier Repair Set VAS 6223
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Fiber Optic Plier Repair Set VAS 6223

Fig. 115: Air Hose Pliers VAS 6228
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Air Hose Pliers VAS 6228

Fig. 116: Pliers For Fiber-Optic Conductor VAS 6223/1 Cutting Device
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Checking remaining cut indicator

  • Start by checking remaining cut indicator:
  • The Pliers For Fiber-optic Conductor VAS 6223/1 cutting device can perform approx. 1260 cuts. The blade is rotated for each further cut.
  • The remaining cut indicator - arrow - displays the last 150 cuts available.
  • Once no further cuts are available, the blade is blocked. It must then be replaced --> Pliers For Fiber-optic Conductor VAS 6223/1 instructions.

Fig. 117: Preparing Pliers For Fiber Optic Conductor VAS 6223/1
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Preparing Pliers For Fiber Optic Conductor VAS 6223/1

  • Release transportation safeguard at cutter by loosening Allen bolt - arrow -.

Fig. 118: Fiber Optic Cable, Cutting To Length
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fiber optic cable, cutting to length

  • Establish length of fiber optic cable required.
  • Open Pliers For Fiber Optic Conductor VAS 6223/1 and insert fiber-optic cable - 1 - into trimming station.
  • Close cutting tool to cut fiber optic cable to length.

Fig. 119: Opening Pliers For Fiber Optic Conductor VAS 6223/1
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Stripping

  • Open Pliers For Fiber Optic Conductor VAS 6223/1.
  • Stripping lever must be in lower position - arrow -.
  • Place fiber optic cable - 1 - in stripping point.
  • Fiber-optic cable must terminate flush to rear side of cutting pliers.

Fig. 120: Closing Pliers For Fiber Optic Conductor VAS 6223/1 Until Stop And Keep Closed
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Close Pliers For Fiber Optic Conductor VAS 6223/1 until stop and keep closed.
  • Lift up stripping lever - arrow -.
  • Open cutting tool and remove fiber optic cable - 1 -.
  • Detach separated section of insulation from fiber optic cable.

Fig. 121: Sliding Fiber Optic Cable Into Cutting Point
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Precision cutting (production of optical end face)

  • Slide fiber optic cable - 1 - into cutting point.
  • Insulation must make contact with cutting point stop - arrow -.
  • Close Pliers For Fiber Optic Conductor VAS 6223/1.

Fig. 122: Pressing Cutting Unit Down
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Press cutting unit - arrow - down.
  • Open Pliers For Fiber Optic Conductor VAS 6223/1 and remove fiber-optic cable - 1 -.

NOTE:
  • Fiber optic cable is only to be placed on an absolutely clean surface.

Fig. 123: Preparing Pliers For Fiber Optic Conductor VAS 6223/1
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Activating transportation safeguard

  • Close Pliers For Fiber Optic Conductor VAS 6223/1.
  • Secure hex socket screw - arrow - for transportation safeguard on blade.

Fig. 124: Opening Securing Lever On Crimping Pliers For Fiber-Optic Cable VAS 6223/2
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Attaching brass pin contact to fiber optic cable

  • Open securing lever on Crimping Pliers For Fiber-optic Cable VAS 6223/2 - arrow 1 - and - arrow 2 -.

Fig. 125: Closing Securing Lever On Crimping Pliers For Fiber-Optic Cable VAS 6223/2
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Insert brass pin contact - 1 - in mount.
  • Close securing lever on Crimping Pliers For Fiber-optic Cable VAS 6223/2 - arrow -.

Fig. 126: Sliding Fiber Optic Cable Into Brass Pin Contact As Far As Spring-Loaded Stop
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Slide fiber optic cable - 2 - into brass pin contact - 1 - as far as spring-loaded stop.
  • Slide fiber-optic cable further in up to fixed stop and close Crimping Pliers For Fiber-optic Cable VAS 6223/2.
  • Open Crimping Pliers For Fiber-optic Cable and remove fiber-optic cable with brass pin contact.

CAUTION: Do not excessively bend or kink fiber optic cables. (min. bending radius 25 mm).

Fig. 127: Checking Proper Attachment Of Brass Pin Contact To Fiber Optic Cable
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Check proper attachment of brass pin contact - 2 - to fiber optic cable - 1 -.
  • 4 crimp points must be visible at brass connection pin.
  • The brass pin contact must not be able to be removed by hand from fiber-optic cable.
  • End face of fiber optic cable is located 0.01 to 0.1 mm behind brass pin contact (visual inspection).

NOTE:

Fig. 128: Cutting Corrugated Tube To Appropriate Length Using Air Hose Pliers VAS 6228 Or A Sharp Knife
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Installing corrugated tube on fiber-optic cable

  • Cut corrugated tube to appropriate length.
  • Use air hose pliers VAS 6228 or a sharp knife for cutting.
  • The corrugated tube must not be cut through using a side cutter under any circumstances
  • The corrugated tube must be cut on the wave peak - arrow - , not in the wave trough.

Fig. 129: Guiding Fiber-Optic Cable Into Crimping Pliers For Fiber-Optic Cable VAS 6223/10
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Guide fiber-optic cable into Crimping Pliers For Fiber-optic Cable VAS 6223/10 as shown in illustration.
  • Position Crimping Pliers For Fiber-optic Cable at slot of corrugated tube.
  • Position Crimping Pliers For Fiber-optic Cable at slot of corrugated tube. By doing this, fiber-optic cable is fed in corrugated tube.

Fiber Optic Cable, Separating from Wiring Harness Connector

Fiber Optic Cable, Separating from Wiring Harness Connector

Fig. 130: Releasing Catch In Fiber Optic Cable Connector Using Small Screw Driver
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Removing

  • Unplug fiber-optic cable connection from control module or device.
  • Use small screw driver to release catch in fiber optic cable connector - arrow -.

Fig. 131: Pulling Fiber Optic Cable Basic Module Out Of Connector Housing
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Pull fiber optic cable basic module - 2 - out of connector housing - 1 -.

Fig. 132: Making Colored Dots To Mark Assignment Of Fiber Optic Cable To Corresponding Sockets In Basic Module
Courtesy of VOLKSWAGEN UNITED STATES, INC.

CAUTION:
  • Make colored dots to mark assignment of fiber optic cable - 5 - to corresponding sockets in basic module - 1 -.
  • Note the arrows - 3 - for allocation on the base module "IN" and "OUT".

  • Release secondary catch - 6 - (blue pin) using a small screwdriver - arrow -.
  • Release retaining tab - 2 - and remove fiber optic cable - 5 - with brass connector pin - 4 - from basic module - 1 -.

Installing

Install in reverse order of removal, observing the following:

  • Install fiber optic cable in line with markings.

Fig. 133: Fiber-Optic Cable Harness Connector And Protective Cap For Cable Connector VAS 6223/9
Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:
  • Seal open harness connector - 2 - for fiber-optic cable using Protective Cap For Cable Connector VAS 6223/9 - 1 -.
  • Protective cap prevents contamination of or mechanical damage to end face of fiber optic cable which would impair signal transmission.

Vehicle Diagnosis, Testing and Information Systems

Vehicle Diagnosis, Testing and Information Systems

--> Safety Precautions

--> Vehicle Diagnosis, Testing and Information System VAS 5051B, Connecting

Safety Precautions

Safety Precautions

Audi A3, Audi A4, Audi A4 Cabriolet, Audi A5, Audi A6, Audi A8 Audi Q7

CAUTION:
  • During road tests using a vehicle diagnostic and information system, there is the hazard of extreme to lethal injuries!
  • If vehicle diagnostic and information system is deposited in the action area of an airbag during a road test, here is the hazard of extreme to lethal injuries in the event the airbag deploys!
  • During road tests, have a second person sitting in the rear seat to operate the vehicle diagnostic and information system.
  • Due to weight, size and need for manual operation of diagnostic tester while vehicle is driven on public roads, diagnostic tester must be used only with a Driver operating the vehicle and an Diagnostic Tester Operator operating the test equipment.
  • Do not use Diagnostic Tester with Driver only. Always use two persons to conduct test.
  • Do not place Diagnostic Tester on lap of Driver or front seat passenger because emergency stop may dislodge diagnostic tester and cause airbag deployment with risk of injury to Diagnostic Tester Operator.
  • Place diagnostic tester in rear seating area and secure by available safety belt.
  • Diagnostic Tester Operator must be seated in the other rear seating position, after sliding front passenger seat and moving the seat back as far forward as possible. Do not activate the seat back release lever.
  • Diagnostic Tester Operator must wear safety belt.

Fig. 134: Diagnostic Tester Operator Wearing Safety Belt
Courtesy of VOLKSWAGEN UNITED STATES, INC.

Audi TT and Audi R8

CAUTION:
  • During road tests using a vehicle diagnostic and information system, there is the hazard of extreme to lethal injuries!
  • If vehicle diagnostic and information system is deposited in the action area of an airbag during a road test, here is the hazard of extreme to lethal injuries in the event the airbag deploys!
  • During road tests, have a second person sitting in the passengers seat to operate the vehicle diagnostic and information system.
  • Only use the Vehicle Diagnosis And Service System VAS 5052 or Diagnostic System VAS 5053.
  • Due to weight, size and need for manual operation of diagnostic tester while vehicle is driven on public roads, diagnostic tester must be used only with a Driver operating the vehicle and an Diagnostic Tester Operator operating the test equipment.
  • Do not use Diagnostic Tester with Driver only. Always use two persons to conduct test.
  • Position the passengers seat as far back as possible.
  • Diagnostic Tester Operator must wear safety belt.
  • Diagnostic tester - 1 - must lie flat on the Tester Operators legs and be operated only by that person, as shown in the illustration.

NOTE:
  • All adaptations, coding, etc. can be performed with the Vehicle Diagnosis, Testing and Information System VAS 5051B and the Vehicle Diagnosis And Service System VAS 5052.
  • All work instructions can be reached in the operating modes "Guided Fault Finding" and "Guided Functions".
  • Additional information:

911203 VAS 5052 Design and Function

Vehicle Diagnosis, Testing and Information System VAS 5051B, Connecting

Vehicle Diagnosis, Testing and Information System VAS 5051B, Connecting

NOTE:
  • Follow the current operating instructions for the Vehicle Diagnosis, Testing and Information System VAS 5051B , which can be displayed by selecting the "Administration" and "operators handbook" buttons.

Special tools, testers and auxiliary items required

Fig. 135: Identifying Vehicle Diagnosis, Testing And Information System VAS 5051B
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • Vehicle Diagnosis, Testing and Information System VAS 5051B
  • Diagnostic Cable 5 Meters VAS 5051/6B or
  • Diagnostic cable VAS 5051/5A (3m)

NOTE:
  • Only use the diagnostic cables listed for diagnosis because they are equipped with CAN cables and allow CAN diagnosis or CAN communication.

Procedure

  • Engage the parking brake.
  • Move manual shift lever into neutral or place automatic transmission selector lever in "P" or "N" position.

Fig. 136: Locating Data Link Connector
Courtesy of VOLKSWAGEN UNITED STATES, INC.

  • With the ignition switched off, connect the Vehicle Diagnosis, Testing and Information System VAS 5051B with the diagnostic cable to the vehicle Data Link Connector (DLC) - arrow -.
  • Switch on ignition.
  • Turn off all electrical consumers.

NOTE:
  • If a malfunction is displayed --> VAS 5051B operating instructions.
  • The Vehicle Diagnosis And Service System VAS 5052 or Diagnostic System VAS 5053 is connected the same way.

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