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Repair Manual
Beetle 2012 , Golf 2015 ,
Golf Variant 2007 ,
Golf Variant 2010 ,
Golf Variant 2015en , Jetta 1999 ,
AG. Volkswagen AG d
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The Beetle Cabriolet 2012
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Edition 01.2015
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Repair Group
27 - Battery, Starter, Generator, Cruise Control
92 - Wiper/Washer Systems
94 - Exterior Lights, Switches
96 - Interior Lights, Switches
97 - Wiring
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Technical information should always be available to the foremen and mechanics, because their
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careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
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safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a t. C rig
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27 - Battery, Starter, Generator, Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.2 Battery General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
es, in part or in w
t to the co
1.4 Battery Post/Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Battery, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
rrectness of i
2.1 Different Types of Batteries, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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2.5 Battery Tester VAS6161 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
m
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2.8 Current Draw Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
iva
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2.9 Battery, Checking Resting Voltage, Vehicles in Storage or Inventory . . . . . . . . . . . . . . . . 30
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3 Battery, Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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3.1 Battery Charger VAS5095A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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3.2 Battery Charger VAS5900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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3.3 Battery Charger VAS5903 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
agen
Prote AG.
3.4 Battery Charger VAS5906 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.5 Battery Tester Charger Kit GRX3000VAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.6 Solar Battery Maintainer VAS6102A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.7 Severely Discharged Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4 Cruise Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.1 Cruise Control System Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.2 Cruise Control System, Activating and Deactivating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
92 - Wiper/Washer Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1 Washer Fluid Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.1 Windshield and Rear Window Washer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.2 Headlamp Washer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
1.3 Washer Fluid Hoses, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2 Joint-Free Wiper Blade Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.1 Joint-Free Wiper Blade Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
97 - Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1 Vehicle Diagnosis, Testing and Information Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Contents i
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
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ii Contents
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
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1.1.3 EFB Battery with Visual Indicator, Enhanced ,
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page 2
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Caution
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Do not remove any of the labels on the battery and do not add
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WARNING
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has no color or is bright yellow. Jump starting must not be
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1. Battery 1
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Beetle 2012 , Golf 2015 , Golf Variant d 2007 , Golf Variant 2010 ... uara
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Electrical Equipment General Information
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1.1.2 AGM Battery
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Maintenance-free Battery - A- with fixed electrolyte (AGM battery)
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Caution
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Do not remove any of the labels on the battery and do not add
urposes, in part or in wh
distilled water. Perform only a visual inspection. Note the chap
t to the co
ter on battery testing. Refer to
2 Battery, Checking, page 7 .
rrectne
Lead-acid battery, where the electrolyte is fixed in an absorbent
ss
glass mat (AGM). The Battery - A- is closed and equipped with
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breather valves.
inform
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electrolyte. AGM is on the Battery - A- to identify it.
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When replacing an AGM battery, another AGM battery must be
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Using approved battery chargers, all tests can be performed on C py
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AGM batteries. Observe the settings on the battery charger. Refer gh ht
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to 2 Battery, Checking, page 7 . cop Vo
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1.1.3 EFB Battery with Visual Indicator, En
hanced
Maintenance-free Battery - A- with fluid electrolyte (wet battery)
Caution
Do not remove any of the labels on the battery and do not add
distilled water. Perform only a visual inspection. Note the chap
ter on battery testing. Refer to
2 Battery, Checking, page 7 .
WARNING
Note
Note
Caution
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Risk of injury. Follow
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Refer to c
1.3 Warnings and Safety Precautions, page 3 .
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1. Battery 3
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
WARNING
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When charging and when resting after charging, explosive
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gas is present. In extreme cases, if the Battery - A- is han
erm
ab
dled inappropriately, the emitted gases may cause the
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battery to explode.
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Replace a Battery - A- if the visual indicator has no color
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spec
or is bright yellow. They may not be tested or charged
urposes, in part or in wh
t to the co
plosion during testing, charging or jump starting.
Producing sparks by sanding, welding, cutting and open
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flames, (also from smoking near the battery) is forbidden.
Producing sparks through electrostatic discharge must al
so be avoided. Always touch the vehicle body before
ss
touching the Battery - A- .
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ventilated locations.
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2- Wear protective eyewear when working on the Battery - A- .
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3- Always keep acid and Batteries - A- out of the reach of chil
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4- Disposal: old batteries require special disposal. They may
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t to the co
only be disposed of at a suitable collection facility and only
in consideration of legal regulations.
5- Do not dispose of old batteries in household waste.
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6- When handling Batteries - A- , there is a risk of explosion.
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7- Always follow instructions on the Battery - A- , in the Parts
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fore protective gloves and eyewear must be worn when
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tipped because acid may spill from the ventilation openings.
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1.3.3 Working on Airbag System
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WARNING
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1. Battery 5
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General
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olkswagen AG - Edition 01.2015
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1.4 Battery Post/Terminal
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Caution
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In order to prevent damage to the battery terminals and battery
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posts, observe the following:
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The battery terminal clamps should be mounted so that
the battery terminal sits flush with the clamp or protrudes
out of it.
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After tightening the battery terminal clamps to the speci
fied torque, the threaded connections must not be tight
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ened again.
nform
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i
Equipment; Rep. Gr. 27 ; Battery; Battery Assembly Overview .
on
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2 Battery, Checking
2.1 Different Types of Batteries, Checking, page 7
2.2 Visual Inspection, page 9
2.3 Color Display in Battery Cover, Checking, Visual Indicator,
page 10
2.4 Battery Tester with Printer VAS5097A , page 12
2.5 Battery Tester VAS6161 , page 18
2.6 Midtronics Battery Tester MCR340VKT , page 24
2.7 Battery Test with Vehicle Diagnostic Tester, page 28
2.8 Current Draw Test, page 28
2.9 Battery, Checking Resting Voltage, Vehicles in Storage or
Inventory, page 30
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WARNING
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Risk of injury. Follow all warning messages and safety pre
cautions. Refer to
1.3 Warnings and Safety Precautions, page 3 .
rrectness of i
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page 10 .
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Two colors. Refer to t. Cop py
2.3.2 2-Color Visual Indicator, Checking, from 04/2008,
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page 11 . op Vo
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WARNING
2. Battery, Checking 7
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
AG. Volkswagen AG d
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The Battery Tester with Printer - VAS5097A- is no longer
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warranty testing. Only the Battery Tester - VAS6161- is still being
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used.
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3. Battery load test using
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Battery Tester with Printer - VAS5097A- . Refer to
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2.4.3 Battery Load Test, page 13 .
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Battery Tester - VAS6161- . Refer to es, in part or in w
t to the co
2.5 Battery Tester VAS6161 , page 18 .
Midtronics Battery Tester - MCR340VKT- (USA/Canada only).
Refer to
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2.6 Midtronics Battery Tester MCR340VKT , page 24 .
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cautions. Refer to Cop py
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Perform the Tests in the Following Sequence:
1. Visual inspection. Refer to
2.2 Visual Inspection, page 9 .
Note
WARNING
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1. Visual inspection. Refer to
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2.2 Visual Inspection, page 9 .
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Note
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The Battery Tester with Printer - VAS5097A- is no longer used for
es, in part or in w
warranty testing. Only the Battery Tester - VAS6161- is still being
t to the co
used.
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Battery Tester with Printer - VAS5097A- . Refer to
l purpos
nform
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VAS6161 , page 19 .
at
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in t
Midtronics Battery Tester - MCR340VKT- (USA/Canada only).
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Refer to
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3. Depending on the result of the battery load test, perform t. Cop py
current draw test. Refer to
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2.8 Current Draw Test, page 28 . cop Vo
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2.2 Visual Inspection
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WARNING
Caution
2. Battery, Checking 9
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
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2.3.1 3-Color Visual Indicator, Checking, un
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through 03/2008
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WARNING
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cautions. Refer to
1.3 Warnings and Safety Precautions, page 3 .
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Visual Indicator General Information:
ss
The visual indicator provides information concerning the electro
o
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lyte level and the Battery - A- charge level.
inform
mer
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Air bubbles can form under the visual indicator, especially if a
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WARNING
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Do not check or charge a Battery - A- when the visual indicator
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has no color or is bright yellow. Jump starting must not be
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used!
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urposes, in part or in wh
There is a risk of explosion during testing, charging or jump
t to the co
starting.
These Batteries - A- must be replaced.
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2.3.2 2-Color Visual Indicator, Checking,
ss o
from 04/2008
cial p
f inform
mer
atio
WARNING
om
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cautions. Refer to
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1.3 Warnings and Safety Precautions, page 3 .
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Visual Indicator General Information:
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The green visual indicator for the charge level indicator is no
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longer used for these Batteries - A- . Only black or no color or
bright yellow are used.
The visual indicator shows the Battery - A- electrolyte level.
It is no longer possible to read the Battery - A- charge level using
the visual indicator. It is necessary to perform a battery test. Refer
to 2.4.3 Battery Load Test, page 13 .
To obtain an accurate reading, gently tap the charge indicator with
a screwdriver handle or rock vehicle slightly. By doing this, the air
bubbles that occur normally during battery charging (even during
vehicle operation) that adversely affect charge indicator reading
will be displaced. Thereby, the color indicator of the visual indi
cator is more accurate.
Note
2. Battery, Checking 11
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
WARNING
WARNING
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cautions. Refer to
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t to the co
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1) Batteries - A- with cold crank amps greater than 499 A according to DIN can
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The Batteries - A- are tested by being loaded with current that Cop py
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corresponds to the starter current of a vehicle. Under this load,
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the Battery - A- is evaluated and the measured results are output cop Vo
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Note
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2.4.6 Printed Test Results Explanations, page 17 .
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Test result evaluation. Refer to
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2.4.7 Test Result Evaluation, page 17 .
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2.4.2 Battery Tester with Printer - VAS5097A-
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spec
Device Description
es, in part or in w
t to the co
Battery Tester with Printer - VAS5097A-
1- LED green, Device in use
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2- LED red, Device connected with terminals reversed
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4- Start button
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7- Sliding switch (battery hook-up to the Battery - A- /at jump
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start point)
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Cop py
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8- Paper-feed -button
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9- Printer Prote
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WARNING
2. Battery, Checking 13
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
Procedure
WARNING
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These Batteries - A- must be replaced.
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ab
ility
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Note
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spec
es, in part or in w
t to the co
rrectness of i
Caution
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nform
mercia
at
om
io
Check the visual indicator on Batteries - A- with visual indica
n
c
in t
r
tor. Refer to
o
his
te
do
riv
ing, page 7 .
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for
en
ng
Note
If the Battery - A- does not state this value in DIN but rather in IEC
or EN/SAE, then convert the value using the table (refer to
2.4.4 Cold Crank Amps Table, page 15 ) or the table on the
Battery Tester with Printer - VAS5097A- .
Set the cold crank amps with the cold crank amps selector
switch. Refer to
2.4.2 Battery Tester with Printer VAS5097A Device De
scription, page 13 .
Set the measuring range (80 to 379 A or 380 to 499 A) using
the ON/OFF switch. Refer to
2.4.2 Battery Tester with Printer VAS5097A Device De
scription, page 13 .
Note
Note
ce
le
pt
an
d
y li
2.4.5 Battery Load Test Results, page 16 . If the Battery
rm
ab
pe
ility
Tester with Printer - VAS5097A- does not start, (the LED does not
ot
wit
, is n
h re
Refer to 3 Battery, Charging, page 31 .
hole
spec
Switch off the Battery Tester with Printer - VAS5097A- . Refer
es, in part or in w
to
t to the co
2.4.2 Battery Tester with Printer VAS5097A Device De
scription, page 13 .
rrectness of i
Remove the test terminals.
l purpos
Note nform
ercia
a
com
tion in
thi
s
Only perform the test once. Repeating the test will not produce
iva
do
r
accurate results.
rp
cum
fo
en
ng
2. Battery, Checking 15
Beetle 2012 , Golf 2015 , Golf Variant
. Volks2007
wagen , Golf Variant 2010 ...
gen AG AG do
Electrical Equipment General
VolkInformation
swa - Edition 01.2015
es n
ot
by gu
ara
ed nte
ris
tho Cold Crank Amps in A eo
au ra
c
EN/ SAE ss IEC DIN
ce
e
nl
pt
du
304 345 215 244 180 204
an
itte
y li
346 387 245 274 204 229
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
556 597 395 424 330 354
598 639 425 454 355 379
rrectness of i
640 657 455 464 380 389
l purpos
nform
ercia
at
712 729 495 504 420 429
om
ion
c
in t
or
his
te
do
priv
c
766 783 525 534 450 459
um
for
en
ng
t.
784 801 Cop
yi
535 544 Co
py 460 469
802 819 545 554 470 479
ht. rig
rig ht
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820 837 555 564 480 489
co Vo
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838 855 565 574 490 499. Refer to 2).
AG.
2) Batteries - A- with cold crank amps greater than 499 A according to DIN can be tested with the setting for 499 A according to DIN.
ce
le
un
pt
an
5- Vehicle data and date. For tester to fill out.
d
itte
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erm
ab
ility
ot p
Note
wit
is n
h re
ole,
spec
The printed test results are required for warranty claims.
urposes, in part or in wh
t to the co
Only perform the test once. Repeating the test will not produce
accurate results.
rrectnes
2.4.7 Test Result Evaluation
s o
cial p
f inform
Printout Measures
mer
atio
m
n
c
i
or
n
Starting power good Battery - A- is OK.
thi
te
sd
a
o
pr
c
current draw test. Refer to
um
r
fo
en
ng
2. Battery, Checking 17
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
ce
e
nl
pt
du
an
2.5.5 Service Test, Performing, page 21 itte
y li
erm
ab
2.5.6 Warranty Test, Performing, page 22
ility
ot p
wit
2.5.7 Explanation of Test Results, page 22
, is n
h re
hole
spec
es, in part or in w
t to the co
2.5.1 General Information
rrectness of i
WARNING
l purpos
nform
mercia
at
om
ion
It is not necessary to disconnect or remove the Battery - A- when
c
in t
or
his
ate
do
riv
cum
or
en
ng
t.
yi Co
op
The Battery Tester - VAS6161- stores all battery types. C py
t. rig
gh ht
yri by
The data can be stored on an SD memory card. cop Vo
by lksw
cted agen
Prote
The Battery Tester - VAS6161- can be updated via an interface
AG.
Note
ce
le
un
pt
an
d
itte
y li
Battery Tester - VAS6161-
erm
ab
ility
ot p
wit
is n
WARNING
h re
ole,
spec
urposes, in part or in wh
t to the co
cautions. Refer to
1.3 Warnings and Safety Precautions, page 3 .
rrectne
Procedure
ss o
cial p
WARNING f inform
mer
n
c
i
or
used!
thi
te
sd
va
o
pr
cum
starting.
r
fo
en
ng
t.
yi Co
These Batteries - A- must be replaced. t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
Turn off the ignition and all electrical consumers and remove
the ignition key.
Check the visual indicator on Batteries - A- with visual indica
tor. Refer to
2. Battery, Checking 19
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Editionen01.2015
AG. Volkswagen AG
ag does
ksw not
y Vol gu
2.1.1 Battery with Color Display, Visual Indicator,
ed
b Check ara
nte
ing, page 7 . oris eo
th
au ra
c
Switch on the Battery Tester - VAS6161-ss . Refer to
ce
le
2.5.2 Battery Tester VAS6161 Device Description,
un
pt
an
page 19 .
d
itte
y li
rm
ab
Connect the red terminal (+) to the positive terminal of the
pe
ility
Battery - A- .
ot
wit
, is n
h re
Connect the black terminal (-) to the negative terminal for the hole
spec
Battery - A- .
es, in part or in w
t to the co
Note
rrectness of i
Make sure the test terminals make good contact!
l purpos
nform
ercia
a
com
ti
2.5.4 Maintenance Test, Performing, page 20 .
on in
r
te o
thi
Service test. Refer to
s
iva
do
r
rp
cum
fo
en
ng
t.
yi
2.5.6 Warranty Test, Performing, page 22 .
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
Note Prote
cted AG.
agen
WARNING
Procedure
Select Maintenance Test.
Connect the scanner.
Note
pt
du
an
itte
y li
erm
ab
WARNING ility
ot p
wit
, is n
used!
es, in part or in w
t to the co
Procedure
nform
ercia
at
om
nal.
in t
or
his
ate
cum
or
en
ng
t.
yi
infrared sensor approximately 5 cm above the battery pole
Co
op py
until the temperature is stable. t. C rig
gh ht
pyri by
Vo
Select battery type (Normal, AGM, 2*6 V or Gel).
co lksw
by
cted agen
Prote AG.
Select Norm (CCA, JIS, DIN, SAE, IEC or EN).
Start the test.
Print out the test notes.
2. Battery, Checking 21
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
WARNING
Procedure
Select Warranty Test.
Select inside the vehicle or outside of the vehicle.
Select at the battery pole or at the battery jump start termi
. Volkswagen AG
nal. swa
gen AG does
olk not
yV gu
Section vehicle model. e db ara
nte
ris
ho eo
Determine the temperature
aut above the Battery - A- . Hold the ra
c
infrared sensor approximately
ss
5 cm above the battery pole
ce
le
pt
an
d
itte
y li
Select battery type (Normal, AGM, 2*6 V or Gel).
erm
ab
ility
ot p
wit
is n
h re
Start the test.
ole,
spec
urposes, in part or in wh
2- Test result
ss
3- Measured voltage
o
cial p
f inform
atio
VAS6161-
c
i
or
n thi
te
o
pr
cum
r
en
ng
t.
yi Co
8- Battery terminal clamp position set on the Battery Tester - t. Cop py
VAS6161-
rig
gh ht
pyri by
Vo
o
by c
9- Selected battery type
lksw
cted agen
Prote AG.
Note
ce
e
pt
du
an
fer to
itte
y li
3 Battery, Charging,
erm
ab
ility
page 31 .
ot p
wit
, is n
h re
and perform the test again.
hole
spec
es, in part or in w
t to the co
can occur due to a weak cable
contact.
rrectness of i
Battery cell faulty - replace Replace the Battery - A- .
Refer to Electrical Equip
l purpos
atio
rectly to the Battery - A- and
om
n in
thi
terminal.
te
sd
iva
o
r
rp
cu
m
f
en
ng
t.
yi
Battery test result Measure
Co
Cop py
t. rig
gh
Battery - A- good No measure
ht
pyri by
Vo
o
by c lksw
Battery - A- , charge immedi cted Charge the Battery - A- . Re
agen
Prote AG.
ately fer to
3 Battery, Charging,
page 31 .
Mark as defective Mark the Battery - A- as de
fective.
Check the tester connection Disconnect the Battery - A-
and perform the test again.
2. Battery, Checking 23
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
ce
e
nl
pt
du
an
2.6.4 Test Result Evaluation, page 26
itte
y li
erm
ab
2.6.5 Midtronics Battery Tester MCR340VKT Troubleshoot
ility
ot p
ing, page 27
wit
, is n
h re
2.6.1 General Information
hole
spec
es, in part or in w
t to the co
WARNING
rrectness of i
cautions. Refer to
l purpos
nf
ercia
o
Observe the Midtronics Battery Tester - MCR340VKT- Operating
rm
m
Instructions.
atio
om
n in
c
thi
e
Refer to
t
sd
iva
o
r
rp
cu
scription, page 24 .
o
m
f
en
ng
t.
yi Co
Battery test. Refer to t. Cop py
2.6.3 Battery Test, Performing using Midtronics Battery
rig
gh ht
yri by
Tester MCR340VKT , page 25 . cop Vo
by lksw
cted agen
Prote
Troubleshooting. Refer to
AG.
WARNING
ce
e
nl
pt
du
an
itte
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has no color or is bright yellow. Jump starting must not be
erm
ab
used!
ility
ot p
wit
, is n
h re
starting.
hole
spec
es, in part or in w
t to the co
Requirements
rrectness of i
Read the device description. Refer to
l purpos
nform
ercia
at
om
ion
c
in t
or
his
Battery - A- .
ate
do
priv
c
Select the battery type (standard or AGM).
um
for
en
ng
t.
Remove the covers on the Battery - A- from the positive and
yi Co
op py
negative terminals. t. C rig
gh ht
pyri by
Use a fender protector or some type of cover before using any
co Vo
by lksw
cted
equipment inside the engine compartment or inside the pas
agen
Prote AG.
senger compartment.
Close all the doors.
Note
Procedure
WARNING
2. Battery, Checking 25
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
Turn off the ignition and all electrical consumers and remove
the ignition key.
Check the visual indicator on Batteries - A- with visual indica
tor. Refer to
2.1.1 Battery with Color Display, Visual Indicator, Check
ing, page 7 .
Switch on the Midtronics Battery Tester - MCR340VKT- . Refer
to Midtronics Battery Tester - MCR340VKT- Operating In
structions.
. Volkswagen AG
a gen AG d
Connect the red terminalVo(+)
lkswto the positive terminalesof
o
nothe
t gu
Battery - A- . ed
by ara
n ris te
Connect the black tho eo
au terminal (-) to the negative terminal for the r ac
Battery - A- . ss
ce
le
un
pt
an
d
itte
y li
Note
rm
ab
pe
ility
ot
wit
Make sure the test terminals make good contact!
, is n
h re
hole
spec
Select warranty test in the menu.
es, in part or in w
t to the co
Select inside the vehicle or outside of the vehicle.
rrectness of i
Note
l purpos
If the test results are needed to process a warranty claim, use the
print function on the Midtronics Battery Tester - MCR340VKT- .
nform
mercia
tion in
Write down the Battery - A- DIN value taken from the battery
r
te o
thi
label. If the label does not state a DIN value, then enter the
s
iva
do
SAE value.
r
rp
cum
fo
en
g
t.
yi Co
MCR340VKT- and perform a battery test. Refer to Midtronics . Cop py
Battery Tester - MCR340VKT- Operating Instructions.
ht rig
rig ht
py by
co Vo
If using an SAE value, go to other in the menu and change
by lksw
cted agen
Prote
DIN to SAE. Refer to the Midtronics Battery Tester -
AG.
Note
Always use the DIN value on the battery label! Otherwise the test
result will be incorrect.
ce
e
nl
pt
du
an
MCR340VKT- Troubleshooting
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
together with suggested solutions.
es, in part or in w
t to the co
Refer to the Midtronics Battery Tester - MCR340VKT- Operating
Instructions for any messages not listed.
rrectness of i
Display Message Measure
l purpos
atio
battery terminals.
om
n in
or c
sd
a
o
r
rp
cu
m
f
t.
yi
Gr. 27 ; Overview - Battery )
Co
Cop py
and are not corroded.
t. rig
gh ht
pyri by
Vo
co lksw
by
Prote
cted Charge the Battery - A- . Re
agen
fer to
AG.
3 Battery, Charging,
page 31 .
System noises Switch off all electrical con
sumers.
2. Battery, Checking 27
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
Note
If the test was performed at the battery jump start terminal and
the message still does not go away, then perform the test directly
on the Battery - A- .
pt
an
d
WARNING
itte
y li
rm
ab
pe
ility
wit
h re
used!
hole
spec
t to the co
starting.
These Batteries - A- must be replaced.
rrectness of i
l purpos
Make sure the correct charging mode is set on the battery charger
so the current draw test is not inaccurate.
nform
ercia
a
com
page 32 .
ion in
r
te o
cum
fo
t.
3.3 Battery Charger VAS5903 , page 48 .
yi Co
Cop py
t. rig
gh ht
yri by
28
cop Vo
by lksw
Rep. Gr.27 - Battery, Starter, Generator, Cruise Control Prote
cted AG.
agen
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
Note
The current draw test should always be performed if the test using
the Battery Tester with Printer - VAS5097A- had the following re
sults:
1- Starting power sufficient
2- Starting power insufficient
3- Starting power very insufficient
4- cannot be tested - charge the Battery - A- and perform the
test again
5- Battery Tester with Printer - VAS5097A- does not turn on
(no LED, no printout)
Depending on the test results Battery Tester with Printer -
VAS5097A- (refer to 2.4.7 Test Result Evaluation, page 17 ),
additional test steps or work for a clear evaluation of the battery
charge must be made.
By checking a current draw capacity on a Battery - A- during the
charging procedure, it can be determined in a short time whether
a partially discharged or severely discharged Battery - A- can be
come operable again by further charging. Refer
wage
n AG. to
Volkswagen AG
does
3.7 Severely Discharged Batteries,
yV
olkspage 68 . not
gu b ara
ed
Test Prerequisites thoris nte
e or
au ac
When charging a battery,
ss the temperature of the battery must
ce
be at least 10 C.
le
un
pt
an
d
itte
ab
h re
VAS6356/4A- ).
The Battery Charger - VAS5900- and the Battery Charger -
VAS5903- indicate the current draw. The Battery Charger -
rrectne
Procedure
cial p
f inform
atio
charging process.
om
n
c
n thi
te
sd
va
Test Result
i
o
pr
cum
r
fo
t.
yi
5 minutes after charging begins.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Battery, Checking 29
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
Example:
With a 60 Ah battery, the charge current must be greater than 6 A
5 minutes after charging begins.
Charge the Battery - A- completely when the charge current is
greater than 10% of the nominal capacity.
Let the Battery - A- sit for two hours and then perform the bat
tery load test. Refer to 2.4.3 Battery Load Test, page 13 .
If the charge current is less than 10% of the nominal capacity (less
than 6 A for a 60 Ah battery) five minutes after starting the charg
ing, then replace the Battery - A- . Refer to Electrical Equip
ment; Rep. Gr. 27 ; Battery; Battery, Removing and Installing .
In warranty and Goodwill cases, fill out the battery test sheet
and keep it with the Battery - A- .
ce
le
un
pt
Risk of injury. Follow all warning messages and safety pre
an
d
itte
y li
cautions. Refer to
erm
ab
1.3 Warnings and Safety Precautions, page 3 .
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
care work as an assessment criteria for the Battery - A- condition.
The resting voltage measurement serves to determine whether it
is necessary to recharge the Battery - A- on vehicles in storage
rrectne
or inventory. Refer to Maintenance Tables Service for Vehicles
in Storage or Inventory.
ss o
Test Conditions
cial p
f inform
The Battery - A- may not be charged or discharged for at least
mer
atio
two days.
om
n
c
Procedure
or
n thi
te
sd
a
o
pr
en
ng
t.
yi
Test result
Co
Cop py
t. rig
gh ht
yri
No Load Voltage Charge Level Battery - A- Charge
p by
co Vo
by lksw
cted agen
11.60 V 0% Discharged. Performance capacity diminished completely.
Prote AG.
Charging totally discharged batteries. Refer to
3.7 Severely Discharged Batteries, page 68 .
3 Battery, Charging
3.1 Battery Charger VAS5095A , page 31
3.2 Battery Charger VAS5900 , page 37
3.3 Battery Charger VAS5903 , page 48
3.4 Battery Charger VAS5906 , page 59
3.5 Battery Tester Charger Kit GRX3000VAS , page 61
3.6 Solar Battery Maintainer VAS6102A , page 67
3.7 Severely Discharged Batteries, page 68
ce
le
un
pt
an
d
y li
page 36
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
WARNING
es, in part or in w
t to the co
Risk of injury. Follow all warning messages and safety pre
cautions. Refer to
rrectness of i
1.3 Warnings and Safety Precautions, page 3 .
l purpos
nform
mercia
a
com
tion in
r
WARNING
te o
thi
s
iva
do
r
rp
t.
yi
used!
Co
Cop py
ht. rig
There is a risk of explosion during testing, charging or jump
rig ht
py by
o Vo
starting. by c lksw
cted agen
Prote AG.
These Batteries - A- must be replaced.
3. Battery, Charging 31
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
AG. Volkswagen AG d
agen oes
lksw not
Charge the Battery - A- . Refer to byV
o gu
ara
3.1.3 Battery, Charging with Batteryris Charger VAS5059A ,
ed
nte
page 32 . aut
ho eo
ra
ss c
Severely discharged Battery - A- , charging. Refer to
ce
e
nl
3.1.4 Severely Discharged Battery, Charging with Battery
pt
du
an
itte
Charger VAS5059A , page 34 .
y li
erm
ab
Support mode. Refer to
ility
ot p
wit
, is n
h re
page 34 .
hole
spec
Buffer mode/maintenance charging. Refer to
es, in part or in w
t to the co
page 36 .
rrectness of i
Description
l purpos
nf
ercia
orm
The battery is charged without amperage or voltage surges.
m
atio
m
n in
c
thi
e
sd
iva
o
r
rp
cu
Battery Charger - VAS5095A-
o
m
f
en
ng
t.
yi
1- ON/OFF -Switch (0 = OFF)
Co
Cop py
ht. rig
2- Charge current display (I greater than 12 A)
rig ht
py by
co Vo
by lksw
cted
3- Battery - A- charge current display, partially charged (great
agen
Prote AG.
er than 90 %)
4- Maintenance charging, lights up green when the Battery -
A- is charged
5- Interference indicator
6- Support mode indicator
7- Support Mode/Normal Mode selector switch
WARNING
Caution
While charging, always set the battery type to 2.4 V/C (Volts/
Battery Cell). This applies to all Batteries - A- .
Note
WARNING
AG. Volkswagen A
Do not check or charge a Battery - A- when ksw the visual indicator
agen G do
es n
has no color or is bright yellow. dJump
y Vol starting must not be ot g
ua
b
used! se ran
ri tee
o h
ut or
There is a risk of explosionss aduring testing, charging or jump ac
starting.
ce
e
nl
pt
du
an
These Batteries - A- must be replaced.
itte
y li
erm
ab
ility
ot p
wit
, is n
Procedure
h re
hole
Turn off the ignition and all electrical consumers and remove
spec
es, in part or in w
t to the co
Check the battery type setting on the battery type switch.
Refer to
rrectness of i
3.1.2 Battery Charger VAS5059A Device Description,
page 32 . The battery type switch must be set to 2.4V/C
l purpos
(Volts/Battery Cell).
Connect the red charge terminal (+) to the positive terminal of
nform
ercia
the Battery - A- .
m
at
om
ion
c
in t
Note
or
his
ate
do
riv
cum
or
en
ng
t.
must be connected to the body ground. The Start/Stop system
yi Co
op py
will malfunction when it is connected to the Battery - A- negative t. C rig
gh ht
terminal. yri
p by
co Vo
by lksw
cted agen
Prote AG.
Connect the black charge terminal (-) to the negative terminal
of the Battery - A- /negative connector.
Switch on the Battery Charger - VAS5095A- . Refer to
3.1.2 Battery Charger VAS5059A Device Description,
page 32 .
Charge current displays. Refer to
Fig. Battery Charger -VAS5095A- , page 32 -2- and -3- light
up yellow. The Battery - A- is partially charged (approximately
90 %) when only the yellow LED -3- is on.
If the green LED. Refer to
Fig. Battery Charger -VAS5095A- , page 32 -4- is also on,
then the Battery Charger - VAS5095A- has switched to mainte
nance charging. The Battery - A- is charged.
Switch off the Battery Charger - VAS5095A- . Refer to
3.1.2 Battery Charger VAS5059A Device Description,
page 32 .
Remove the charging clamps from the battery terminals.
3. Battery, Charging 33
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
n AG. Volkswagen AG do
Electrical Equipment General Information - Editionks01.2015
wage es n
ol ot g
yV ua
db ran
3.1.4 Severely Discharged Battery, Charging
e
ris tee
tho or
au
with Battery Charger - VAS5059A-
ss
ac
ce
le
un
pt
an
d
itte
WARNING
y li
erm
ab
ility
ot p
Risk of injury. Follow all warning messages and safety pre
wit
is n
cautions. Refer to
h re
ole,
1.3 Warnings and Safety Precautions, page 3 .
spec
urposes, in part or in wh
t to the co
The Battery Charger - VAS5095A- automatically detects severely
discharged Batteries - A- and starts the charging process con
rrectne
servatively with a low charge current. The charge current is
automatically adjusted to the battery charge state.
s
For information in the chapter. Refer to
s o
cial p
f
3.7 Severely Discharged Batteries, page 68 .
inform
mer
atio
m
n
c
i
or
n
placed prior to delivery. Pre-existing damage cannot be ruled
thi
te
out.
sd
iva
o
pr
cum
r
fo
en
ng
WARNING
t.
yi Co
Cop py
ht. rig
Do not check or charge a Battery - A- when the visual indicator
rig ht
py by
o Vo
has no color or is bright yellow. Jump starting must not be by c lksw
cted agen
used! Prote AG.
Procedure
Charge the Battery - A- . Refer to
3.1.3 Battery, Charging with Battery Charger VAS5059A ,
page 32 .
WARNING
WARNING
n AG. Volkswagen AG do
kswage es n
Do not check or charge a Battery - A- when the visual indicator ol ot g
byV ua
has no color or is bright yellow. Jump starting must ir se not be
d ran
tee
used! autho
or
ac
ss
There is a risk of explosion during testing, charging or jump
ce
e
nl
starting.
pt
du
an
itte
y li
These Batteries - A- must be replaced.
erm
ab
ility
ot p
wit
, is n
h re
Procedure
hole
spec
es, in part or in w
t to the co
Caution
rrectness of i
in the operation mode charging severely discharged bat
teries/Support mode. Connect the charger clamps to the
l purpos
nf
ercia
orm
This constitutes an explosion risk.
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
Remove the Battery - A- . Refer to Electrical Equipment;
o
m
f
en
ng
Clamp the red charging clamp (+) to the vehicle positive bat
tery terminal.
Note
Attach the black charging clamp (-) to the vehicle battery neg
ative terminal.
Check the setting for the support mode/standard opera-
tion switch. Refer to
3.1.2 Battery Charger VAS5059A Device Description,
page 32 . Support mode must be on.
3. Battery, Charging 35
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
WARNING
WARNING
pt
y li
ab
pe
ility
Procedure
ot
wit
, is n
h re
page 32 .
es, in part or in w
t to the co
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
WARNING
pt
an
d
y li
used!
rm
ab
pe
ility
wit
, is n
starting.
h re
hole
spec
t to the co
38 .
m
a
com
thi
page 38 .
s
iva
do
r
rp
en
t.
yi Co
page 40 . ht. Cop py
rig
rig ht
Severely discharged Battery - A- , charging. Refer to
py by
co Vo
3.2.5 Severely Discharged Battery, Charging with Battery
by lksw
cted agen
Prote
Charger VAS5900 , page 43 .
AG.
3. Battery, Charging 37
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
3- -button Down
4- START/STOP -button
AG. Volkswagen AG d
agen oes
5- INFO -button Volksw not
gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
ab
- VAS5900-
ility
ot p
wit
, is n
h re
Special tools and workshop equipment required
hole
t to the co
WARNING
rrectness of i
cautions. Refer to
1.3 Warnings and Safety Precautions, page 3 .
nform
mercia
at
om
WARNING
on
c
in t
or
his
te
do
riv
cum
or
used!
f
en
ng
t.
yi Co
op
There is a risk of explosion during testing, charging or jump C py
t. rig
starting.
gh ht
pyri by
Vo
o
by c lksw
These Batteries - A- must be replaced. cted agen
Prote AG.
Note
ce
le
un
pt
an
d
y li
erm
38 .
ab
ility
ot p
wit
is n
h re
ole,
The symbol -1- for standard charge of wet batteries or the sym
spec
urposes, in part or in wh
t to the co
Set the battery capacity (Ah) on the Battery - A- to be charged
with the corresponding button or button.
rrectne
Connect the red charge terminal (+) to the positive terminal of
the Battery - A- .
ss o
cial p
f inform
mer
Note
atio
om
n
c
i
or
n thi
Monitoring Control Module - J367- , the black charge terminal (-)
te
sd
a
o
pr
en
ng
terminal.
t.
yi Co
Cop py
ht. rig
ht
Connect the black charge terminal (-) to the negative terminal
rig by
opy Vo
of the Battery - A- /negative connector.
by c lksw
cted agen
Prote AG.
The Battery Charger - VAS5900- recognizes the nominal voltage
of the connected Battery - A- (6 V/12 V/24 V) and begins the
charging process automatically.
3. Battery, Charging 39
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
With a charge status of 100 %, all bars are indicated on the display
-1-.
With the standard charge, parallel operation of electrical con
sumers during the charging process is possible. The charging
time is lengthened by this.
Depending on the battery type, the Battery Charger - VAS5900-
switches to maintenance charging after 1 to 7 hours. To reach a
100% charge level, the Battery - A- should remain connected to
the Battery Charger - VAS5900- .
Possible malfunctions and how they are handled
1- Displayed voltage does not match the nominal voltage:
Hold down the button or button until the charging process
begins.
2- Displayed battery voltage does not match the nominal volt
age - the charging process has w
already
agen
AG.begun:
Volkswagen AG
doe s no
ks
Vol t gu
Press the START/STOP button
ed
by two times. ara
ris nte
o eo
Hold down the button
aut or button until the charging process
h
ra
s c
begins again. s
ce
e
nl
pt
du
an
itte
y li
Battery - A- , if the battery voltage is less than 2V:
erm
ab
ility
ot p
wit
, is n
h re
The selected battery type and Ampere hours (Ah) are displayed.
hole
spec
Battery - A- charging, ending
es, in part or in w
Charge
rm
m
atio
m
n in
or c
thi
e
sd
iva
o
r
rp
cu
o
m
f
WARNING
en
ng
t.
yi Co
Cop py
ht. rig
Risk of injury. Follow all warning messages and safety pre rig ht
py by
cautions. Refer to co Vo
by lksw
1.3 Warnings and Safety Precautions, page 3 .
cted agen
Prote AG.
Caution
WARNING
ce
e
nl
pt
du
an
itte
y li
erm
ab
Caution
ility
ot p
wit
, is n
h re
hole
spec
Operating Instructions.
es, in part or in w
t to the co
Service Charging is suitable for:
Wet batteries having a visual indicator which allows charg
rrectness of i
ing (visual indicator black or green).
l purpos
nform
ercia
at
this. Check the visual indicator after charging, immediately before
om
ion
the Battery - A- is used. Refer to
c
in t
or
his
ate
page 10 .
do
priv
cum
for
en
ng
t.
yi Co
Note t. Cop py
rig
gh ht
yri by
The Battery - A- temperature must be at least 10 C.
cop Vo
by lksw
cted agen
Prote AG.
Procedure
Turn off the ignition and all electrical consumers and remove
the ignition key.
Connect the Battery Charger - VAS5900- to the power supply.
The last selected mode is shown on the display. Refer to
3.2.2 Battery Charger VAS5900 Device Description, page
38 .
3. Battery, Charging 41
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
Note
ce
le
un
pt
Connect the black charge terminal (-) to the negative terminal
an
d
itte
y li
erm
ab
ility
The Battery Charger - VAS5900- recognizes the nominal voltage
ot p
wit
of the connected Battery - A- (6 V/12 V/24 V) and begins the
is n
h re
charging process automatically.
ole,
spec
urposes, in part or in wh
t to the co
the charge level is approximately 80 to 85% of the battery voltage.
The fourth bar is indicated on the display -1-. The Battery - A- is
now ready to be used.
rrectness
Note
o
cial p
f inform
A successful service charge depends on the degree of sulfation
mer
n
c
i
or
sd
iva
o
r
cum
r
fo
en
ng
ce
e
nl
pt
du
an
itte
y li
erm
ab
WARNING
ility
ot p
wit
, is n
h re
Do not check or charge a Battery - A- when the visual indicator
hole
spec
has no color or is bright yellow. Jump starting must not be
es, in part or in w
used!
t to the co
There is a risk of explosion during testing, charging or jump
starting.
rrectness of i
These Batteries - A- must be replaced.
l purpos
nf
ercia
Caution
orm
m
atio
m
n in
or c
thi
te
sd
iva
o
battery terminals correctly according to polarity!
r
rp
cu
o
m
f
en
ng
Note
Procedure
Turn off the ignition and all electrical consumers and remove
the ignition key.
Connect the Battery Charger - VAS5900- to the power supply.
The last selected mode is shown on the display. Refer to
3. Battery, Charging 43
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
Note
ce
le
un
pt
an
d
Note
itte
y li
erm
ab
ility
If no button is touched within five seconds, the Battery Charger -
ot p
wit
VAS5900- will return to the main menu (operating mode selec
is n
h re
tion).
ole,
spec
urposes, in part or in wh
t to the co
Then the inquiry about the correct polarity of the charging clamps
is made.
rrectne
Check correct polarity connection of charger clamps.
ss
Confirm charging clamps are connected to correct poles via
o
cial p
START/STOP button.
inform
mer
discharged Battery - A- .
o
n
c
i
or
sd
iva
o
r
cum
r
fo
en
ng
Mode
Special tools and workshop equipment required
Battery Charger - VAS5900-
General Information
The support mode provides the vehicle electrical system with
voltage when the Battery - A- is removed or disconnected.
For more information. Refer to the Battery Charger - VAS5900-
Operating Instructions.
The support mode is used for the following situations:
Vehicle electrical system support mode with the Battery - A-
not installed
Maintaining the voltage when the battery is being replaced
Systems test without the Battery - A-
WARNING
WARNING
ce
le
un
pt
Caution
an
d
itte
y li
rm
ab
The polarity protection of the charger clamps is not active
pe
ility
in the operation mode charging severely discharged bat
ot
wit
, is n
h re
battery terminals correctly according to polarity!
hole
spec
es, in part or in w
t to the co
This constitutes an explosion risk.
Do not touch START/STOP button when battery cables are
rrectness of i
tion in
thi
do
cum
38 .
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Battery, Charging 45
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
Caution
Note
pt
an
d
itte
y li
erm
ab
Note ility
ot p
wit
is n
h re
spec
tion).
t to the co
Then the inquiry about the correct polarity of the charging clamps
is made.
ss o
f inform
START/STOP button.
atio
om
n
c
n thi
e
mode.
t
sd
iva
o
pr
cum
en
ng
t.
yi
Press the START/STOP -button.
Co
Cop py
t. rig
gh ht
Remove the charging clamps from the battery terminals. pyri by
Vo
co lksw
by
cted agen
Disconnect the Battery Charger - VAS5900- from the power. Prote AG.
Note
WARNING
WARNING
-1-.
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Battery, Charging 47
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
ce
e
nl
pt
du
an
itte
y li
erm
ab
WARNING
ility
ot p
wit
, is n
h re
hole
cautions. Refer to
spec
1.3 Warnings and Safety Precautions, page 3 .
es, in part or in w
t to the co
rrectness of i
WARNING
l purpos
nform
ercia
used!
m
at
om
io
starting.
n
c
in t
or
his
e
do
priv
cum
for
en
ng
t.
Observe the Battery Charger - VAS5903- Operating Instructions.
yi Co
Cop py
t. rig
Battery Charger - VAS5903- device description. Refer to gh ht
yri by
3.3.2 Battery Charger VAS5903 Device Description, page
op Vo
by c lksw
49 .
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
Control field overview
an
d
itte
y li
erm
1- Display
ab
ility
ot p
2- -button Up
wit
is n
h re
ole,
3- -button Down
spec
urposes, in part or in wh
4- START/STOP -button
t to the co
5- INFO -button
rrectness o
cial p
f in
- VAS5903-
atio
om
n
c
i
or
sd
va
o
pr
cum
r
fo
en
ng
t.
yi Co
WARNING
t. Cop py
rig
gh ht
yri by
Risk of injury. Follow all warning messages and safety pre
cop Vo
by lksw
cted
cautions. Refer to
agen
Prote AG.
1.3 Warnings and Safety Precautions, page 3 .
WARNING
Note
3. Battery, Charging 49
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
Procedure
Turn off the ignition and all electrical consumers and remove
the ignition key.
Connect the Battery Charger - VAS5903- to the power supply.
The last selected operation mode is shown on the display.
Refer to
3.3.2 Battery Charger VAS5903 Device Description, page
49 .
Set the battery type with the INFO button.
The symbol -1- for standard charge of wet batteries or the sym
bol -2- for standard charge of Gel/Absorbent Glass Mat (AGM)
batteries is indicated in the display.
Set the battery capacity (Ah) on the Battery - A- to be charged
with the corresponding button or button.
Connect the red charge terminal (+) to the positive terminal of
the Battery - A- .
Note
y li
erm
ab
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
With a charge status of 100%, all bars are indicated on the display
-1-.
With the battery type standard charge, parallel operation of
electrical consumers during the charging process is possible. The
charging time is lengthened by this.
Depending on the battery type, the Battery Charger - VAS5903-
switches to maintenance charging after 1 to 7 hours. To reach a
100% charge level, the Battery - A- should remain connected to
the Battery Charger - VAS5903- .
Possible malfunctions and how they are handled
1- Displayed voltage does not match the nominal voltage:
Hold down the button or button until the charging process
begins.
2- Displayed battery voltage
n AG. Vdoes
olkswanot match
gen AG do
rated voltage -
charging process wage
olks has already begun:
es n
V o t gu
by ara
Press theorisSTART/STOP
ed button two times. nte
h eo
ut ra
Holdssdown
a the button or button until the charging processc
begins again.
ce
e
nl
pt
du
an
3- The charger does not recognize a Battery - A- , when the
itte
y li
erm
h re
The selected battery type and Ampere hours (Ah) are displayed.
hole
spec
es, in part or in w
Charge
m
at
om
ion
c
his
ate
cum
for
en
ng
t.
WARNING
yi Co
Cop py
t. rig
gh ht
yri
Risk of injury. Follow all warning messages and safety pre
p by
co Vo
cautions. Refer to
by lksw
cted agen
Prote
1.3 Warnings and Safety Precautions, page 3 .
AG.
WARNING
3. Battery, Charging 51
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
Caution
Caution
n AG. Volkswagen AG do
wage e
Always set the mode that ycorresponds
Volks
to the Battery - A-s nduring
ot g
the charging process.risRefer to the Battery Charger - VAS5903-
b ua
ed ran
Operating Instructions.
utho tee
or
s a ac
Refresh charging is suitable for wet batteries, which must be
s
ce
e
pt
du
an
itte
y li
Do not use the refresh charge mode on maintenance-free wet
erm
ab
batteries.
ility
ot p
wit
, is n
h re
hole
spec
Batteries - A- that are possibly faulty (sulfation). The Battery - A-
es, in part or in w
t to the co
is then charged to the maximum specific gravity of the electrolyte
and the plates are reactivated (removal of sulfation layer).
Note rrectness of i
l purpos
Procedure
m
at
om
ion
Turn off the ignition and all electrical consumers and remove
c
in t
or
do
riv
cum
or
en
ng
t.
yi
Refer to
Co
op py
3.3.2 Battery Charger VAS5903 Device Description, page t. C rig
gh ht
49 . pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
ce
le
pt
an
d
itte
y li
erm
ab
The Battery Charger - VAS5900- begins the final charging when
ility
ot p
wit
is n
h re
now ready to be used.
ole,
spec
urposes, in part or in wh
t to the co
Note
on the Battery - A- .
ss o
f inform
atio
m
n
c
begins.
i
or
n thi
te
sd
a
o
pr
en
ng
t.
yi
Press the START/STOP button two times.
Co
Cop py
t. rig
gh
Hold down the button or button until the charging process
ht
pyri by
Vo
o
begins.
c by lksw
cted agen
Prote AG.
3- The charger does not recognize a Battery - A- , when the
battery voltage is less than 2 V:
The display remains unchanged.
The set operating mode and Ampere-hours (Ah) are displayed.
Battery - A- charging, ending
Press the START/STOP -button.
Remove the charging clamps from the battery terminals.
Disconnect the Battery Charger - VAS5903- from the power.
3. Battery, Charging 53
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
AG. Volkswagen AG d
agen
3.3.5 Severely Discharged Battery, Charging
oes
ksw not
Vol gu
by ara
with Battery Chargerri - VAS5903-
ed
s nte
tho eo
au ra
Special tools and workshop equipment
ss required c
ce
e
nl
pt
Battery Charger - VAS5903-
du
an
itte
y li
erm
ab
ility
WARNING
ot p
wit
, is n
h re
Risk of injury. Follow all warning messages and safety pre
hole
spec
cautions. Refer to
es, in part or in w
t to the co
rrectness of i
WARNING
l purpos
nform
ercia
used!
m
at
There is a risk of explosion during testing, charging or jump
om
ion
starting.
c
in t
or
his
te
do
priv
cum
for
en
ng
t.
yi Co
Cop py
Caution
t. rig
gh ht
pyri by
Vo
co lksw
by
The polarity protection of the charger clamps is not active
cted agen
Prote AG.
in the operation mode charging severely discharged bat
teries/Support mode. Connect the charger clamps to the
battery terminals correctly according to polarity!
Always set the mode that corresponds to the Battery - A-
during the charging process. Refer to the Battery Charger
- VAS5903- Operating Instructions.
The Battery Charger - VAS5903- does not recognize the
severely discharged Battery - A- . Refer to
3.7 Severely Discharged Batteries, page 68 .
Do not touch START/STOP button when battery cables are
incorrectly connected! The Battery Charger - VAS5903-
can become damaged.
Note
Procedure
Turn off the ignition and all electrical consumers and remove
the ignition key.
Connect the Battery Charger - VAS5903- to the power supply.
The last selected operation mode is shown on the display.
Refer to
3.3.2 Battery Charger VAS5903 Device Description, page
n AG. Volkswagen AG do
49 . olks
wage es n
o V t gu
by ara
Set the battery type with the INFO
ris
ed button. nte
ho eo
ut
The symbol -1- for service charge
ss
a of wet batteries or the symbol ra
c
-2- for service charge of Gel/Absorbent Glass Mat (AGM) bat
ce
le
un
pt
teries is indicated in the display.
an
d
itte
y li
Set the battery capacity (Ah) on the Battery - A- to be charged
rm
ab
pe
ility
with the corresponding button or button.
ot
wit
, is n
h re
hole
the Battery - A- .
spec
es, in part or in w
t to the co
Note
rrectness of i
On vehicles with a Start/Stop function and an installed Battery
Monitoring Control Module - J367- , the black charge terminal (-)
l purpos
nform
mercia
a
com
t
Connect the black charge terminal (-) to the negative terminal
ion in
of the Battery - A- /negative connector.
r
te o
thi
s
iva
do
r
rp
c
selection Charging severely discharged batteries/Support
um
fo
mode is activated.
en
ng
t.
yi Co
op py
Press the corresponding -button or button to adjust the
. C rig
ht ht
rig
battery voltage(6 V/12 V/24 V). py by
co Vo
by lksw
cted agen
Prote AG.
Note
3. Battery, Charging 55
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
General Information
The support mode provides the vehicle electrical system with
voltage when the Battery - A- is removed or disconnected.
For more information. Refer to the Battery Charger - VAS5903-
Operating Instructions.
The support mode is used for the following situations:
Vehicle electrical system support mode with the Battery - A-
not installed
Maintaining the voltage when the battery is being replaced
Systems test without the Battery - A-
WARNING
WARNING
ce
e
Procedure
nl
pt
du
an
itte
y li
erm
ab
Caution
ility
ot p
wit
, is n
h re
hole
spec
teries/Support mode. Connect the charger clamps to the
es, in part or in w
t to the co
battery terminals correctly according to polarity!
It can result in sparks due to short circuit. rrectness of i
This constitutes an explosion risk.
l purpos
at
om
ion
c
in t
or
his
e
do
riv
cum
for
en
g
t.
yi Co
op
The last selected operation mode is shown on the display. C py
t. rig
Refer to
gh ht
pyri by
3.3.2 Battery Charger VAS5903 Device Description, page
o Vo
by c lksw
cted
49 .
agen
Prote AG.
Caution
AG. Volkswagen AG d
agen oes
Note o lksw not
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d by ara
ise nte
r
On vehicles with a Start/Stop function and anauinstalled
tho
Battery eo
ra
Monitoring Control Module - J367- , the black
s charge terminal (-)
s c
must be connected to the body ground. The Start/Stop system
ce
le
un
pt
will malfunction when it is connected to the Battery - A- negative
an
d
itte
terminal.
y li
erm
ab
ility
ot p
wit
is n
h re
of the Battery - A- /negative connector.
ole,
spec
urposes, in part or in wh
t to the co
selection Charging severely discharged batteries/Support
mode is activated.
Press the corresponding -button or button to adjust the
rrectne
battery voltage(6 V/12 V/24 V).
ss o
cial p
f
Note
inform
mer
atio
m
n
c
i
tion).
or
n thi
te
sd
iva
o
pr
c
Select the battery voltage by pressing the START/STOP button.
um
r
fo
en
ng
t.
yi
Then the inquiry about the correct polarity of the charging clamps
Co
op py
is made.
t. C rig
gh ht
pyri by
Vo
Check correct polarity connection of charger clamps.
o
by c lksw
cted agen
Prote AG.
Confirm charging clamps are connected to correct poles via
START/STOP button.
3. Battery, Charging 57
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
n AG. Volkswagen AG do
ks wage es n
Maintenance charging can be performed without time restrictions.
Vol ot g
by ua
The Battery - A- can be used constantly. ris
ed ran
tee
tho or
s au ac
s
Note
ce
le
un
pt
an
d
itte
y li
Observe the maintenance notes of the battery manufacturer.
rm
ab
pe
ility
ot
wit
, is n
h re
WARNING
hole
spec
Risk of injury. Follow all warning messages and safety pre es, in part or in w
t to the co
cautions. Refer to
1.3 Warnings and Safety Precautions, page 3 .
rrectness of i
l purpos
WARNING
nform
ercia
a
com
ti
used!
on in
r
te o
thi
There is a risk of explosion during testing, charging or jump
s
iva
do
starting.
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
If the Battery - A- is fully charged, the Battery Charger - VAS5903- cop Vo
by lksw
starts maintenance charging. cted agen
Prote AG.
Procedure
Proceed as if charging the Battery - A- . Refer to
3.3.3 Battery, Charging with Battery Charger VAS5903 ,
page 49 .
With a charge status of 100%, all bars are indicated on the display
-1-.
WARNING
WARNING
ce
e
pt
du
an
itte
y li
erm
ab
3.4.2 Battery Charger VAS5906 Device Description, page
ility
ot p
59 .
wit
, is n
h re
Charge the Battery - A- . Refer to
hole
spec
3.4.3 Battery, Charging with Battery Charger VAS5906 ,
es, in part or in w
page 60 .
t to the co
3.4.2 Battery Charger - VAS5906- Device De
scription rrectness of i
l purpos
at
om
io
in t
r
ies.
o
his
ate
do
riv
cum
or
en
g
charging.
n
t.
yi Co
Cop py
After the battery - A- is completely charged, the Battery Charger
t. rig
gh ht
yri by
- VAS5906- switches into the maintenance charging for long-term cop Vo
by lksw
operation. cted agen
Prote AG.
3. Battery, Charging 59
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
WARNING
WARNING
Volkswa
Do not check or charge a Batteryksw
a-geA-
n Awhen
G.
thegvisual
en AG
dindicator
oes
has no color or is brightbyyellow.
Vol
Jump starting must not not
gbe
ua
used! ris
ed ran
te
tho eo
There is a risk of
ss
aexplosion
u
during testing, charging or jump ra
c
starting.
ce
e
nl
pt
du
an
y li
erm
ab
ility
ot p
wit
Procedure
, is n
h re
hole
Turn off the ignition and all electrical consumers and remove
spec
t to the co
WARNING
m
at
om
ion
c
in t
his
e
cautions. Refer to
at
do
riv
cum
for
en
ng
t.
yi Co
op py
Connect the red charge terminal (+) to the positive terminal of t. C rig
gh ht
the Battery - A- . pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
Caution
scription, page 62
pt
du
an
itte
y li
ab
GRX3000VAS , page 63
ility
ot p
wit
, is n
ing, page 65
hole
spec
es, in part or in w
WARNING
rrectness of i
l purpos
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3. Battery, Charging 61
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
Beetle 2012 , Golf 2015 , Golf Variant 2007 aut , Golf Variant 2010 ... ra
c
s
Electrical Equipment General Information - Edition 01.2015 s
ce
le
un
pt
an
d
itte
y li
erm
ab
WARNING
ility
ot p
wit
is n
Do not check or charge a Battery - A- when the visual indicator
h re
ole,
has no color or is bright yellow. Jump starting must not be
spec
used!
urposes, in part or in wh
t to the co
There is a risk of explosion during testing, charging or jump
starting.
rrectne
These Batteries - A- must be replaced.
ss
Observe the Battery Tester Charger Kit - GRX3000VAS- Oper
o
cial p
f i
ating Instructions.
nform
mer
Battery Tester Charger Kit - GRX3000VAS- device descrip
atio
tion. Refer to om
n
c
i
3.5.2 Battery Tester Charger Kit GRX3000VAS Device or
n thi
e
Description, page 62 .
t
sd
iva
o
pr
c
Charge the Battery - A- . Refer to
um
r
fo
en
ng
3.5.3 Battery, Charging with Battery Tester Charger Kit
t.
yi Co
GRX3000VAS , page 63 . Cop py
t. rig
gh ht
yri
Battery Tester Charger Kit - GRX3000VAS- troubleshooting. p by
o Vo
by c
Refer to
lksw
cted agen
Prote
3.5.4 Battery Tester Charger Kit GRX3000VAS Trouble
AG.
shooting, page 65 .
WARNING
WARNING
Keep open flame and sparks away from the Batteries - A- and
do not smoke.
The Battery Tester Charger Kit - GRX3000VAS- must be
switched off when connecting or disconnect the cables.
Do not remove the plugs while charging.
Overcharging sulfated Batteries - A- can cause an explosion.
Precision tools may not be kept in areas where batteries are
charged. Chemical reactions can lead to corrosion.
WARNING
n AG. Volkswagen A
Do not check or chargeoalksBattery
wage - A- when theGvisual
does indicator
not
has no color or isd bright
by V yellow. Jump starting must gunot be
ara
used! orise nte
e h
ut or
There is a srisk
s a of explosion during testing, charging or jump ac
starting.
ce
e
nl
pt
du
an
These Batteries - A- must be replaced.
itte
y li
erm
ab
ility
ot p
wit
, is n
t to the co
Requirements
WARNING
rrectness of i
l purpos
orm
atio
m
starting.
o
n in
or c
thi
sd
iva
o
r
rp
cu
o
m
f
en
ng
Note
3. Battery, Charging 63
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
Procedure
Turn off the ignition and all electrical consumers and remove
the ignition key.
olkswagen AG
en AG. V
Connect the red charge terminal (+) to the positive
ksw terminal of
ag does
not
Vol
the Battery - A- . ed
by gu
ara
ris nte
ho eo
aut ra
ss c
Note
ce
e
nl
pt
du
an
On vehicles with a Start/Stop function and an installed Battery
itte
y li
erm
ab
ility
must be connected to the body ground. The Start/Stop system
ot p
wit
will malfunction when it is connected to the Battery - A- negative
, is n
h re
terminal.
hole
spec
es, in part or in w
t to the co
of the Battery - A- /negative connector.
Connect the Battery Tester Charger Kit - GRX3000VAS- to the
rrectness of i
power supply.
l purpos
nform
ercia
at
om
ion
c
in t
or
his
ate
do
riv
cum
or
en
ng
t.
yi Co
Cop py
t. rig
gh ht
Note pyri by
Vo
o
by c lksw
cted agen
Prote AG.
For more information. Refer to the Battery Tester Charger Kit
- GRX3000VAS- Operating Instructions.
Select the necessary menu points for the test type warranty.
Note
WARNING
Note
pt
y li
erm
ab
GRX3000VAS- Troubleshooting
wit
is n
h re
ole,
Note
ss o
cial p
f i
For any messages not listed. Refer to the Battery Tester Charger
nform
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
3. Battery, Charging 65
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
ce
e
Make sure the battery pole
nl
pt
du
is tightened to the tightening
an
itte
y li
specification and is not cor
erm
ab
roded.
ility
ot p
wit
Terminals connected? Battery Tester Charger Kit -
, is n
h re
GRX3000VAS- safety function.
hole
spec
Connect the charging
es, in part or in w
t to the co
before starting the charging
process.
System noises Switch off all electrical con
rrectness of i
sumers.
l purpos
nf
ercia
orm
System Control Module -
m
atio
m
n in
or c
thi
e
sd
iva
o
r
rp
cu
Disconnect any doubtful or
o
m
f
en
ng
ce
le
voltage of 14.3 V and a maximum charge current of 255 mA.
un
pt
an
d
itte
y li
All chargeable lead- and lead gel batteries can be charged with
erm
ab
the Solar Battery Maintainer - VAS6102A- .
ility
ot p
wit
The Solar Battery Maintainer - VAS6102A- is connected to the
is n
h re
diagnostic connection in the vehicle.
ole,
spec
urposes, in part or in wh
t to the co
tegrated inside the frame which displays the function being per
formed. The brighter the LED, the higher the charging current.
It is not possible to overcharge the Battery - A- due to the inte
rrectne
grated electronics.
ss
The Solar Battery Maintainer - VAS6102A- is secured on the in
o
cial p
f i
terior rearview mirror -1-. The bottom rests on the instrument
nform
panel -2-.
mer
atio
om
n
c
i
or
n
Note
thi
te
sd
iva
o
pr
c
The Solar Battery Maintainer - VAS6102A- must not touch the
um
r
fo
en
instrument panel completely. Only the bottom edge may be used
ng
t.
yi Co
for support. If it touches completely, the color of the instrument Cop py
panel could change.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Battery, Charging 67
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
Procedure
Secure the Solar Battery Maintainer - VAS6102A- to the inte
rior rearview mirror -1-.
Lay the bottom on the instrument panel -2-.
Note
WARNING
olkswagen AG
en AG. V
A Battery - A- is designated as severely discharged if the restingksw
ag does
not
Vol
voltage is less than 11.6 V. db
y gu
ara
e nte
ris
utho eo
ra
WARNING ss
a c ce
e
nl
pt
du
y li
ab
used!
ility
ot p
wit
, is n
starting.
hole
spec
es, in part or in w
Caution
l purpos
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
Batteries - A- that have not been used for a long time will dis
charge by themselves.
In severely discharged Batteries - A- , the electrolyte consists
almost completely of water,
wage
nbecause the
AG. Volkswageacid
n AG dportion has been
oes
greatly reduced. y Volks not
gu b ara
ed
Severely discharged
tho
ris Batteries - A- become sulfated, meaning
nte
e
all of the splate
au surfaces of the Batteries - A- harden. or
ac
s
The sulfation process may be reversed if a severely dis
ce
e
nl
pt
du
an
itte
y li
erm
ab
If the Battery - A- is not recharged, the plates will continue to
ility
ot p
wit
, is n
h re
hole
spec
placed prior to delivery. Pre-existing damage cannot be ruled
es, in part or in w
t to the co
out.
Procedure
rrectness of i
Check the Battery - A- resting voltage. Refer to
l purpos
nf
ercia
orm
Battery Charger - VAS5095A- . Refer to
m
atio
m
n in
c
thi
te
sd
a
o
r
rp
cu
m
f
t.
yi Co
op
Battery Charger - VAS5903- . Refer to
C py
t. rig
gh
3.3.5 Severely Discharged Battery, Charging with Battery
ht
pyri by
Vo
o
Charger VAS5903 , page 54 . by c lksw
cted agen
Prote AG.
Battery Charger - VAS5906- . Refer to
3.4.3 Battery, Charging with Battery Charger VAS5906 ,
page 60 .
Battery Tester Charger Kit - GRX3000VAS- . Refer to
3.5.3 Battery, Charging with Battery Tester Charger Kit
GRX3000VAS , page 63 .
3. Battery, Charging 69
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
lection and the following menu options one after the other:
un
pt
an
d
itte
y li
Powertrain
rm
ab
pe
ility
Engine code
ot
wit
, is n
h re
01 - OBD-capable systems
hole
spec
t to the co
system
Functions
rrectness of i
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
5 Special Tools
Special tools and workshop equipment required
Analog/Digital Multimeter - FLU83III-
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
5. Special Tools 71
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
Battery Charger - VAS5906- s aut ra
c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
1 Washer Fluid Hoses
erm
ab
ility
ot p
wit
, is n
h re
page 73
hole
spec
1.2 Headlamp Washer System, page 74
es, in part or in w
t to the co
1.3 Washer Fluid Hoses, Servicing, page 74
rrectness of i
System
l purpos
Procedure
nform
ercia
at
om
io
To secure the connection, push both halves of coupling to
n
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
1.2 Headlamp Washer System
ce
e
nl
pt
du
an
itte
y li
Procedure
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
rection of the -arrow- and connect the hose connection. Check
es, in part or in w
t to the co
the securing clip for secure locking by attempting to pull it off
without depressing the clip.
rrectness of i
l purpos
nform
mercia
at
om
io
1.3 Washer Fluid Hoses, Servicing
n
c
in t
or
his
ate
cum
or
en
ng
t.
yi Co
op
1.3.3 Corrugated Tube, Repairing, page 75 C py
t. rig
gh ht
yri by
1.3.1 General Information
op Vo
by c lksw
cted agen
Prote AG.
A new repair concept has been developed for repairing washer
system hoses. Various individual hose connectors, adapters, Eth
ylene Propylene Diene Methylene (EPDM) rubber hoses and
shrink tubing will be offered as replacement parts.
Replacement parts are found in the Parts Catalog.
The replacement parts are available both for the repair of a
smooth tube as well as for the repair of a corrugated tube.
Select the appropriate EPDM hose -2- and cable tie. Refer to
the Parts Catalog.
Cut a length of EPDM-hose -2-, so that the smooth tube ends
-1- and -3- can be pushed approximately 10 mm into the
EPDM-hose -2-.
Note wage
n AG. Volkswagen AG do
es n
olks ot g
byV ua
Area to be repaired must not be under stressrisof
ed stretching or ran
tee
bending. autho
or
ac
ss
If the damaged area is longer than 20 mm, a new section of
ce
le
un
y li
rm
ab
pe
ility
Procedure
ot
wit
, is n
h re
spec
es, in part or in w
Press the connecting piece -2- into the corrugated tube -2-
l purpos
-arrow A-.
Warm the end of the corrugated tube -4- using the Hot Air
nform
ercia
Blower - VAS5179- .
m
a
com
ti
Press the connecting piece -3- into the corrugated tube -4-
on in
-arrow B-.
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
tics
nl
pt
du
an
itte
y li
2.1 Joint-Free Wiper Blade Characteristics, page 77
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
replace them with blades made by the same manufacturer.
The wiper blades can be identified by the wiper arm mount.
rrectness of i
Bosch Wiper Blades -1 and 2-:
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
Federal Mogul Wiper Blades -1-:
p by
co Vo
by lksw
cted agen
Prote AG.
3 Special Tools
Special tools and workshop equipment required
Hot Air Blower - VAS5179- or
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
1 HID Headlamp Usage and Safety
e
nl
pt
du
an
itte
Precautions
y li
erm
ab
ility
ot p
1.1 Safety Precautions, page 79
wit
, is n
h re
1.1 Safety Precautions
hole
spec
es, in part or in w
If Performing Assembly Work on HID Headlamps, Note the Fol
t to the co
lowing
Notes on hazardous high voltage/currents. Refer to
rrectness of i
page 79
l purpos
Notes on pressure, temperature and radiation/electric arc. Re
fer to page 80
nf
ercia
orm
page 81
m
atio
om
n in
or c
page 81
thi
te
sd
iva
o
Special tools and workshop equipment required
r
rp
cu
o
m
f
en
ng
Protective eyewear
t.
yi Co
Cop py
Gloves ht. rig
rig ht
py by
co Vo
by lksw
cted agen
WARNING
Prote AG.
WARNING
WARNING
WARNING
AG. Volkswagen AG d
agen
Turn off the ignition and all electrical consumers and re Volksw
oes
not
gu
move the ignition key. se
db
y ara
nte
i
or eo
When working on headlamp system, ensure all compo ut
h
ra
sa
nents are without voltage, including relieving residual volt
s c
ce
le
age after switching headlamps off.
un
pt
an
d
itte
Residual voltages are discharged by switching low beam
y li
rm
ab
on and off again after ignition key was removed.
pe
ility
ot
wit
Make sure lamps cannot be switched on when working on
, is n
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headlamp system.
hole
spec
es, in part or in w
t to the co
Notes on Pressure, Temperature and Radiation/Glare
rrectness of i
WARNING
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com
tio
The glass HID headlamp bulbs can become very hot - risk
n in
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of burning!
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Avoid looking directly into light beam, since UV radiation
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of the HID lamp is approximately 2.5 times higher than that
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Cop py
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Avoid looking into light beam (risk of glare), it can have
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lasting negative effects on vision. cop Vo
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WARNING
Caution
WARNING
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ion
c
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for
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Cop py
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Prote AG.
Caution
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spec
es, in part or in w
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rrectness of i
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Cop py
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1.2 Cigarette Lighter
erm
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U1 , Removing and In
ility
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stalling, page 83
wit
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3 - Socket - U-
hole
spec
Removing and instal
es, in part or in w
t to the co
ling. Refer to
1.2 Cigarette Lighter
U1 , Removing and In
rrectness of i
stalling, page 83
l purpos
nf
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5 - Mounting Sleeve
orm
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atio
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L42-
o
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or c
12 V/1.2 W bulb
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cu
ling. Refer to
o
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f
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Caution
Note
The procedure for removing and installing is the same for all
Sockets - U- and is only described for the cigarette lighter socket.
Removing
Disconnect the Battery - A- . Refer to Electrical Equipment;
Rep. Gr. 27 ; Battery; Battery, Disconnecting and Connecting .
Remove the Cigarette Lighter - U1- from the Socket - U- .
Note
Caution
pt
du
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erm
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ility
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, is n
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hole
spec
es, in part or in w
Caution
nform
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at
om
the Socket - U- .
in t
or
his
ate
do
priv
cum
for
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t.
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Cop py
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Caution
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Make sure not to damage any of the surrounding components
ot
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when using the Thrust Piece - T40148/1- .
, is n
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hole
spec
es, in part or in w
t to the co
Note
rrectness of i
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nform
ercia
a
com
ti
connector.
on in
r
te o
thi
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Release the Cigarette Lighter Release Tool - T40148- tabs by
r
rp
cum
fo
pressing the spindle -1- in the direction of the -arrow B-. Then
en
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t.
turn the Cigarette Lighter Release Tool - T40148- -2- slightly
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op
to the left direction of -arrow A- and release. Remove the Cig
C py
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gh
arette Lighter Release Tool - T40148- from the Socket - U- .
ht
pyri by
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by c lksw
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Prote AG.
Note
Caution
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e
Removing
nl
pt
du
an
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Remove the Cigarette Lighter - U1- . Refer to
erm
ab
1.2 Cigarette Lighter U1 , Removing and Installing,
ility
ot p
page 83 .
wit
, is n
h re
Press the tabs -1- in the direction of the -arrow- and remove
hole
spec
the mounting sleeve with the bulb holder.
es, in part or in w
t to the co
Unclip bulb holder from mounting sleeve.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
cum
or
en
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t.
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Cop py
t. rig
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pyri by
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Prote AG.
n AG. Volkswagen AG do
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spec
es, in part or in w
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Cop py
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Prote AG.
2 Special Tools
Special tools and workshop equipment required
Cigarette Lighter Release Tool - T40148-
AG. Volkswagen AG d
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pt
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c
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for
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Prote AG.
97 Wiring
1 Vehicle Diagnosis, Testing and Infor
mation Systems
1.1 Description of Vehicle Diagnosis, Testing and Information
Systems, page 89
1.2 Connect the Vehicle Diagnostic Tester , page 89
1.3 Vehicle Diagnostic Tester, Connecting, Golf MY 1998
through 2003, page 90
WARNING
Note
pt
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an
itte
ab
VAS5051
ility
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spec
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atio
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Cop py
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Prote AG.
1. Vehicle Diagnosis, Testing and Information Systems
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
Procedure
Turn off the ignition and all electrical consumers and remove
the ignition key.
On vehicles with automatic transmissions, move the selector n AG. Volkswagen AG do
lever to the P or N position. lkswage es n
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byV ua
On vehicles with manual transmissions, move the shift lever ir se
d ran
tee
to the neutral position. autho
or
ac
ss
With the ignition switched off, connect the Vehicle Diagnostic
ce
e
nl
Tester to the vehicle diagnostic connection-arrow-.
pt
du
an
itte
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Turn on the ignition.
erm
ab
ility
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The method for connecting all Vehicle Diagnostic Tester can be
wit
, is n
derived from the sequence described above.
h re
hole
spec
Component location and connector assignment for the diagnostic
es, in part or in w
t to the co
ponent locations.
rrectness of i
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nform
Golf MY 1998 through 2003
mercia
at
Special tools and workshop equipment required
om
ion
c
in t
r
his
ate
do
riv
Procedure
p
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for
en
Turn off the ignition and all electrical consumers and remove
ng
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the ignition key. t. Cop py
rig
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On vehicles with automatic transmissions, move the selector pyri by
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co
lever to the P or N position.
by lksw
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Prote AG.
On vehicles with manual transmissions, move the shift lever
to the neutral position.
Remove the trim panel -1- in the direction of the -arrow-.
With the ignition switched off, connect the Vehicle Diagnostic
Tester to the vehicle diagnostic connection.
Turn on the ignition.
Note
The method for connecting all other Vehicle Diagnostic Tester can
be derived from the sequence described above.
2 Connectors
2.1 Wiring Harnesses and Connectors, Repairing,
page 91
2.2 Vehicle Electrical System, General Repair Information,
page 96
2.3 Wiring Harnesses, Repairing, page 98
ce
le
un
pt
2.1.9 Wiring Harness Repair Set - Hot Air Blower
an
d
itte
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VAS1978/14A , page 95
rm
ab
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ility
2.1.10 Crimping Pliers - .35-2.5mm VAS1978/1A ,
ot
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page 95
h re
hole
spec
2.1.1 Wiring Harness Repair Set - VAS1978-
es, in part or in w
t to the co
The Wiring Harness Repair Set - VAS1978- makes optimal repair
quality possible in the realm of vehicle electronics. Using the
tools, repairs affecting harness connectors and for breaks in wir
rrectness of i
ing can be performed. For this purpose, complete repair wires with
terminals already crimped on are used and can be connected to
l purpos
tion in
r
thi
s
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do
Additional information:
r
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fo
t.
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structions. t. Cop py
rig
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pyri by
Vo
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Prote AG.
2. Connectors 91
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
ce
le
pt
an
d
itte
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Upgrade Kit For VAS1978 - VAS1978/50-
rm
ab
pe
ility
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2.1.3 Wiring Harness Repair Set -
, is n
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hole
VAS1978A-
spec
es, in part or in w
t to the co
The new Wiring Harness Repair Set - VAS1978A- makes optimal
repair quality possible in the realm of vehicle electronics. Using
the new pliers, repairs affecting harness connectors and for
rrectness of i
breaks in wiring can be performed. For this purpose, complete
repair wires with terminals already crimped on are used and can
l purpos
tio
thi
do
r
rp
cum
en
ng
t.
yi
Additional information:
Co
Cop py
t. rig
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Refer to Wiring Harness Repair Set - VAS1978A- Operating yri
p by
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Instructions.
c by lksw
cted agen
Prote AG.
The Wiring Harness Repair Set - VAS1978A- was replaced by the
Wiring Harness Repair Set - VAS1978B- .
ce
le
Set - VAS1978- / Wiring Harness Repair Set - VAS1978A- / Wiring
un
pt
Harness Repair Set - VAS1978B- and is used to crimp the crimp
an
d
itte
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connectors during the wiring harness repair.
erm
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ility
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Color of crimp Color of crimping Wire cross-section
wit
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connectors slot
h re
ole,
spec
yellow yellow 0.35 mm2
urposes, in part or in wh
t to the co
Red Red 0.5 mm2 through
1.0 mm2
Blue Blue 1.5 mm2 through
rrectne
2.5 mm2
s
yellow yellow 4.0 mm2 through
s o
6.0 mm2
cial p
f inform
mer
atio
m
Note
o
n
c
i
or
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sd
The Wiring Harness Repair - Crimping Plier - Base Tool -
iva
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r
cum
r
fo
en
ng
t.
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Wiring Harness Repair Set - Crimping Head - 4-6mm -
Co
op py
VAS1978/2A- to crimp the connections as an alternative.
. C rig
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rig by
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Always be sure to use the correct crimping slot for the crimp
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connector used. Prote AG.
WARNING
Some tools are supplied with a tool safety clip, which is slid
over the tool points after using the tool, in order to protect other
workers from injuries and tool points from damage.
2. Connectors 93
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
pers - VAS1978/3-
spec
es, in part or in w
t to the co
The Wiring Harness Repair Set - Wire Strippers - VAS1978/3- is
used for professional stripping and cutting of wires.
rrectness of i
The Wiring Harness Repair Set - Wire Strippers - VAS1978/3- are
a component of the Wiring Harness Repair Set - VAS1978- / Wir
l purpos
nform
ercia
a
com
t
desired length of wire insulation to be removed.
ion in
r
te o
Stripping
thi
s
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do
Set the slideable stop in pliers-jaws to the desired length di
r
rp
cum
fo
mension to be stripped. en
ng
t.
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Cop py
Insert the wire end from the front up to the stop into the jaws
t. rig
gh ht
yri
of pliers and squeeze the Wiring Harness Repair Set - Wire
p by
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by c lksw
Strippers - VAS1978/3- together completely. Prote
cted AG.
agen
Cut the wires using the side-cutter function on the top of the
Wiring Harness Repair Set - Wire Strippers - VAS1978/3- .
Caution
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pt
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After crimping, the crimp connectors must be heat-shrunk using
rm
ab
pe
ility
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hole
spec
is a component of the Wiring Harness Repair Set - VAS1978- /
es, in part or in w
t to the co
Set - VAS1978B- .
rrectness of i
2.1.10 Crimping Pliers - .35-2.5mm -
l purpos
VAS1978/1A-
The Crimping Pliers - .35-2.5mm - VAS1978/1A- or the Wiring
nform
ercia
a
com
ti
thi
do
r
rp
en
VAS1978/1A- .
ng
t.
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op py
The following crimping heads are available for the Wiring Harness
t. C rig
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Repair - Crimping Plier - Base Tool - VAS1978/1-2- :
pyri by
Vo
co lksw
by
cted agen
Wiring Harness Repair - Crimping Head - .35-2.5mm -
Prote AG.
VAS1978/1-1-
Wiring Harness Repair Set - Crimping Head - 4-6mm -
VAS1978/2 A-
Wiring Harness Repair Set - Crimping Head - JPT -
VAS1978/9-1-
In conjunction with Wiring Harness Repair Set - Crimping Head -
JPT - VAS1978/9-1- , crimping pliers are used to crimp terminals
onto individual wires when repairing wiring cross-sections up to
0.35 mm2 .
Changing Exchangeable Head
Completely open the Wiring Harness Repair - Crimping Plier
- Base Tool - VAS1978/1-2- .
2. Connectors 95
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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aut ra
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nl
pt
du
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erm
ab
ility
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wit
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spec
pair Information
es, in part or in w
t to the co
Caution
rrectness of i
at
om
ion
c
in t
r
WARNING
o
his
ate
do
priv
Some tools are supplied with a tool safety clip, which is slid
cum
for
over the tool points after using the tool, in order to protect other
en
ng
t.
yi
workers from injuries and tool points from damage.
Co
Cop py
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rig ht
py by
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by lksw
When performing repairs, always heed any notes, cautions cted agen
Prote AG.
and warnings found in the applicable repair manual.
ce
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Wiring harness repairs may not be performed again in the
rm
ab
wrapping of the vehicle-specific wiring harness and are to be
pe
ility
marked with yellow adhesive tape.
ot
wit
, is n
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These yellow wires and every location on wiring harness wrap
hole
spec
ped in yellow insulating tape indicates a previous repair.
es, in part or in w
t to the co
Crimp connections must never be repaired. Route a wire par
allel to the faulty wire.
After crimping, the crimp connectors must be heat-shrunk us
rrectness of i
ing the Wiring Harness Repair Set - Hot Air Blower -
l purpos
tion in
thi
page 101 .
s
iva
do
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cum
fo
t.
yi
basic setting.
Co
Cop py
t. rig
gh
If possible, do not loosen ground (GND) straps from body
ht
pyri by
Vo
o
(danger of corrosion).
c by lksw
cted agen
Prote AG.
Not all wire cross-sections in the vehicle are contained in the
Wiring Harness Repair Set - VAS1978B- and its previous ver
sions. If the required wire cross-section is not present, the next
greater cross-section must be used.
Shielded harnesses may not be repaired. If faulty, the entire
harness must be replaced.
Heat-resistant wires have been installed in the vehicle at var
ious locations, mainly in the engine compartment. Heat-resist
ant wires can be recognized by their somewhat duller and
softer insulation. Only heat-resistant wires may be used to re
pair these wires.
2. Connectors 97
AG. Volkswagen AG d
agen o
Beetle 2012 , Golf 2015 , Golf Variant 2007 Vol , Golf Variant 2010 ...ot gu
ksw es n
by
Electrical Equipment General Information
ris
e- Edition 01.2015
d ara
nt ee
tho or
au ac
2.3 Wiring Harnesses, Repairing ss
ce
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un
pt
2.3.1 Wiring Harnesses, Repair Information, page 98
an
d
itte
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rm
ab
2.3.2 Airbag and Belt Tensioner Wire Repair Information,
pe
ility
page 98
ot
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2.3.3 CAN Bus Lines Repair Information, page 100
hole
spec
2.3.4 Wires with Cross Section up to 0.35 mm 2, Repairing,
es, in part or in w
t to the co
page 101
2.3.5 Wire Break with Single Repair Point, page 103
rrectness of i
2.3.6 Wire Break with Dual Repair Point, page 105
l purpos
nform
ercia
system. Refer to
m
a
2.2 Vehicle Electrical System, General Repair Information,
com
tio
page 96 .
n in
r
te o
thi
Not all wire cross-sections in the vehicle are contained in the
s
iva
do
Wiring Harness Repair Set - VAS1978- / Wiring Harness Re
r
rp
cum
pair Set - VAS1978A- . If the required wire cross-section is not
fo
en
ng
WARNING
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es, in part or in w
t to the co
rrectness of i
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t.
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Cop py
t. rig
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pyri by
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co lksw
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Prote AG.
2. Connectors 99
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
. Volkswage
Electrical Equipment General Informationsw- aEdition
gen AG 01.2015n AG doe
s
k not
Vol gu
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Wires from the airbag and seat belt tensioner
ris
e wiring harness nte
utho Harness Repair Set -
may only be repaired using the Wiring eo
ra
a
VAS1978- / Wiring Harness Repairss Set - VAS1978A- / Wiring c
Harness Repair Set - VAS1978B- .
ce
e
nl
pt
du
an
itte
Pay attention to stickers on vehicle designating high voltage
y li
erm
ab
components. When performing repairs, residual voltage must
ility
ot p
be discharged. Refer to Rep. Gr. 00 ; Safety Precautions;
wit
Pyrotechnic Components Safety Precautions . , is n
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hole
spec
es, in part or in w
t to the co
crease the electrical resistance in the wire and may trigger
malfunctions in the system On Board Diagnostic (OBD).
When repairing airbag or safety belt tensioner wiring, crimp
rrectness of i
connectors must be shrunk to prevent corrosion.
l purpos
nf
ercia
o
Do not wrap the repair point again into the vehicle-specific
rm
m
atio
wiring harness and mark the repair point very visibly with yel
om
n in
or c
thi
e
sd
iva
o
r
rp
cu
housing. Together with the identification via yellow insulating
o
m
f
en
ng
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Heated Oxygen Sensor
erm
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ility
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RPM sensor
wit
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Mass Airflow Sensor
hole
spec
By using the Crimping Pliers - JPT - VAS1978/9A- or the Wiring
es, in part or in w
t to the co
the Wiring Harness Repair Set - Crimping Head - JPT -
VAS1978/9-1- installed, the correct connection between crimp
contact, wire and single wire seal is guaranteed. The tool is to be
rrectness of i
used only for the purpose described.
l purpos
Note
nf
ercia
orm
m
repair wires. The same version of the contact that was installed
o
n in
or c
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rp
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m
f
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t.
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Insert the Wiring Harness Repair Set - Crimping Head - JPT -
Co
op py
VAS1978/9-1- into the Wiring Harness Repair - Crimping Plier
. C rig
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rig
- Base Tool - VAS1978/1-2- . Refer to py by
co Vo
2.1.10 Crimping Pliers - .35-2.5mm VAS1978/1A ,
by lksw
cted agen
Prote
page 95 .
AG.
2. Connectors 101
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
. Volkswagen AG
a gen AG does
Place the single wire seal onto the repair wire.
Vol
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Note ss
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When doing this, the smaller diameter of single wire seal must be
an
d
itte
facing in the direction of the contact to be crimped on.
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Open the Wiring Harness Repair - Crimping Plier - Base Tool
rrectness of i
- VAS1978/1-2- (green body) and insert the repair wire end
into the stripping slot of the Wiring Harness Repair - Crimping
l purpos
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Cop py
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Close the Wiring Harness Repair - Crimping Plier - Base Tool yri
p by
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- VAS1978/1-2- completely.
c by lksw
cted agen
Prote AG.
Reopen the Wiring Harness Repair - Crimping Plier - Base
Tool - VAS1978/1-2- and remove the stripped wire end.
Insert the new crimp contact into the Wiring Harness Repair -
Crimping Plier - Base Tool - VAS1978/1-2- mount.
Insert the stripped wire end with positioned single wire seal
into crimp contact until it makes contact on Wire-Stop.
Crimp the contact, wire and single wire seal by completely
closing the Wiring Harness Repair - Crimping Plier - Base Tool
- VAS1978/1-2- .
Reopen the Wiring Harness Repair - Crimping Plier - Base
Tool - VAS1978/1-2- and remove the finished crimped-on con
tact.
AG. Volkswagen AG d
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ility
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es, in part or in w
knife.
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ate
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Cop py
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Prote AG.
2. Connectors 103
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
Cut out the damaged section of wire using the Wiring Harness
Repair Set - Wire Strippers - VAS1978/3- .
Note
If, by cutting out the damaged wire section, both ends of the ve
hicle-specific single wire are too short for a repair using a single
crimp connector, insert a repair wire section of matching length
with two crimp connectors. Refer to
2.3.6 Wire Break with Dual Repair Point, page 105 . agen
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Strip the wire ends 6 to 7 mm using the WiringsHarness Repair
Set - Wire Strippers - VAS1978/3- .
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es, in part or in w
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rrectness of i
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Slide the crimp connector onto both stripped wire ends of the
vehicle-specific single wire and crimp them using the Crimping
nf
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Note
or
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Always be sure to use the correct crimping slot for the crimping
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connection used.
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Do not crimp wire insulation. Cop py
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After crimping, the crimp connectors must be heat-shrunk using
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the Wiring Harness Repair Set - Hot Air Blower - VAS1978/14A-
Prote AG.
Heat the crimp connector using the Wiring Harness Repair Set
- Hot Air Blower - VAS1978/14A- lengthwise from the center
outward until it is sealed completely and the adhesive comes
out at the ends.
Caution
Note
ce
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nl
pt
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Place the yellow repair wire next to the damaged wiring har
itte
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erm
ness and cut the repair wire to the required length using the
ab
Wiring Harness Repair Set - Wire Strippers - VAS1978/3- . ility
ot p
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wire.
spec
es, in part or in w
t to the co
rrectness of i
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nf
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Cop py
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Prote AG.
2. Connectors 105
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
Crimp the crimp connector at both wire ends using the Crimp
ing Pliers - .35-2.5mm - VAS1978/1A- .
Repeat this procedure at the other repair wire end.
AG. Volkswagen AG d
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Always beusure
tho to use the correct crimping slot for the crimping eo
ra
connection
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used. c
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After crimping, the crimp connectors must be heat-shrunk using
pe
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the Wiring Harness Repair Set - Hot Air Blower - VAS1978/14A-
ot
wit
, is n
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hole
spec
Place the Wiring Harness Repair - Blower - Shrink Element -
es, in part or in w
t to the co
Blower - VAS1978/14A- .
Heat the crimp connector using the Wiring Harness Repair Set
rrectness of i
- Hot Air Blower - VAS1978/14A- lengthwise from the center
l purpos
nform
ercia
Caution
m
a
com
tion in
thi
do
the hot nozzle of the Wiring Harness Repair Set - Hot Air Blow
r
rp
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er - VAS1978/14A- .
fo
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Always follow the Wiring Harness Repair Set - Hot Air Blower
Co
Cop py
- VAS1978/14A- Operating Instructions!
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Prote AG.
Note
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distributor.
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ondary locks.
h re
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spec
es, in part or in w
t to the co
Detailed information on component locations of harness con
nectors. Refer to Wiring diagrams, Troubleshooting & Com
ponent locations.
The allocation of the correct release tools to the respective locking rrectness of i
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at
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ion
in t
or
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op py
Secondary lock is distinguished by a different color from the rest t. C rig
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of the connector housing. It simplifies recognizing the secondary yri
p by
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lock and clarifies its function.
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Prote AG.
Example 2
Housing securing mechanism is released by opening a flap
-arrow-.
Example 3
Housing securing mechanism can be released by disengaging a
slider -arrow-.
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The shapes of the primary locks depicted in the following are only
a selection which, as an example, should make clear the various
s
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The allocation of the correct release tools for the respective locks Cop py
can be found in the table in the Release Tool Set - VAS1978/35-
t. rig
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Operating Instructions.
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Prote AG.
Note
At the same time, push the release tool in the direction of the
connector housing and pull the released contact out of the
connector housing.
After removing the contact, release tool can be pulled out of the
connector housing again.
Guide the release tool which fits the connector housing into
pt
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rm
ab
pe
Grasp the contact at the wire and gently push it into the con
ility
ot
h re
hole
spec
Note
es, in part or in w
t to the co
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Cop py
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rig ht
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Prote AG.
At the same time, push the release tool in the direction of the
connector housing and pull the released contact out of the
connector housing -arrow-.
After removing the contact, release tool can be pulled out of the
connector housing again.
Flat Connector System with Two Retaining Tabs
Guide the release tool which fits the connector housing into
release channel on the connector housing.
Grasp the contact at the wire and gently push it into the con
nector housing-arrow-.
Note
At the same time, push the release tool in the direction of the
connector housing and pull the released contact out of the
connector housing -arrow-.
After removing the contact, release tool can be pulled out of the
connector housing again.
Asymmetrical
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Guide the release tool which fits the connector housing into
an
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ab
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Grasp the contact at the wire and gently push it into the con
ot
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es, in part or in w
Note
t to the co
contact retaining tabs are lifted off the housing shoulder and can
be released using the release tool.
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110
Prote AG.
Rep. Gr.97 - Wiring
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
At the same time, push the release tool in the direction of the
connector housing and pull the released contact out of the
connector housing -arrow-.
After removing the contact, release tool can be pulled out of the
connector housing again.
pt
du
an
Grasp the contact at the wire and gently push it into the con
itte
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nector housing.
erm
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ility
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Note
hole
spec
es, in part or in w
contact retaining tabs are lifted off the housing shoulder and can
be released using the release tool.
rrectness of i
l purpos
At the same time, push the release tool in the direction of the
connector housing and pull the released contact out of the
nf
ercia
After removing the contact, release tool can be pulled out of the
atio
m
n in
or c
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e
GT 150/280 Contacts
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Prote AG.
Guide the release tool which fits the connector housing under
the retaining tab into connector housing.
Insert the tool all the way -arrow- into the connector housing.
AG. Volkswagen AG d
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Repairing
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Repair Information
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Allocation of crimp contacts with correct fit to connector hous
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ing is performed according to the part number stamped in on by c lksw
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the connector housing. Part numbers of connector housing are Prote AG.
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Insert new contact of repair wire into connector housing until
ot
wit
it engages.
, is n
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hole
spec
es, in part or in w
t to the co
Note
rrectness of i
When doing this, the small diameter of the single seal must point
toward the connector housing.
l purpos
Slide the single wire seal into the connector housing using the
nform
ercia
a
com
tion in
r
thi
s
single wire using the Wiring Harness Repair Set - Wire Strip
iva
do
r
pers - VAS1978/3- .
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Cop py
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Prote AG.
Strip the ends of the repair wire and the vehicle-specific single
wire 6 to 7 mm using the Wiring Harness Repair Set - Wire
Strippers - VAS1978/3- .
Crimp the stripped ends of the repair wire and single wire of
vehicle-specific wiring harness using the Crimping Pliers - .
35-2.5mm - VAS1978/1A- and a crimp connector as described
in chapter Open circuit with single repair point.
AG. Volkswagen AG d
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Note
d
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ab
ility
Make sure that crimp connections do not lie directly next to
ot p
wit
each other when several wires need to be repaired. Arrange
is n
h re
the crimp connectors at a slight offset so that the circumfer
ole,
spec
ence of the wiring harness does not become too large.
urposes, in part or in wh
t to the co
In the event the repair point was previous taped, this point
must be taped anew with yellow insulating tape after repairs.
Secure the repaired wiring harness with a cable tie to prevent
rrectne
flapping noises while driving.
ss o
cial p
f
3.2.3 Single Wire Seals, Installing
inform
mer
atio
om
n
Note
c
i
or
n thi
te
sd
a
Single wire seals prevent the penetration of water and dirt into
iv
o
pr
en
ng
Cut off the old contact with single wire seal from the vehicle-
specific wiring harness.
Slide repair wire with the new contact into the corresponding
chamber of connector housing until it engages -arrow-.
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Put single wire seals -A-
au onto the free end of the repair wire.
t or
ac
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un
pt
an
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Note
itte
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rm
ab
pe
ility
When doing this, the small diameter of the single wire seal must
ot
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spec
Slide single wire seal -A- on the repair wire up to the connector
es, in part or in w
t to the co
housing -arrows-.
rrectness of i
l purpos
Slide single wire seal -A- all the way into the connector housing
using the corresponding assembly tool -B-.
nform
mercia
a
com
tion in
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3.2.4 Connector Housing with Insulation Dis
utho
ir se tee
or
placement Connections, Repairing
ss
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un
pt
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itte
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Note
rm
ab
pe
ility
ot
wit
For technical reasons, the connector housing for the wire ter
, is n
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minals can be supplied only with the contacts pushed in.
hole
spec
These contacts can be removed at every other connector
es, in part or in w
t to the co
housing in the event they are not required.
Repair wires which have already been equipped with corre
sponding contacts crimped on are available. Refer to the Parts rrectness of i
Catalog.
l purpos
nform
mercia
a
com
tion in
r
te o
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t.
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Cop py
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Prote AG.
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nl
4.1.2 Wiring Eyelets, Repairing, page 117
pt
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4.1.3 Threaded Connections, Repairing, page 119
erm
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4.1.4 Battery Clamps and Battery Terminals, Cleaning,
wit
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page 120
h re
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spec
4.1.5 Protecting, page 121
es, in part or in w
t to the co
4.1.1 Using Contact Surface Cleaning Set -
VAS6410-
rrectness of i
The Contact Surface Cleaning Set - VAS6410- makes optimal
l purpos
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ercia
orm
Cleaning Set - VAS6410- is adapted to the vehicle structural
m
atio
m
n in
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procedure.
or
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Note
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The illustrations of the service work only serve as examples.
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Contact Surface Cleaning Set - VAS6410- Prote
cted AG.
agen
Note
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nl
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WARNING itte
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ab
ility
Risk of injury. Follow all warning messages and safety pre
ot p
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cautions. Refer to
, is n
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1.3 Warnings and Safety Precautions, page 3 .
hole
spec
es, in part or in w
t to the co
Procedure
Disconnect the Battery - A- . Refer to Electrical Equipment;
rrectness of i
Rep. Gr. 27 ; Battery; Battery, Disconnecting and Connecting .
l purpos
Loosen the cap nut and remove the wiring eyelet from the
threaded connection.
nform
ercia
at
Select the corresponding adapter and the corresponding
om
io
sanding pad.
n
c
in t
or
his
ate
do
priv
c
Note
um
for
en
ng
t.
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The sanding block can be used instead. Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Caution
Prote AG.
Make sure the tin layer is not worn down too much and the
copper is not visible. A galvanic element can form from this,
destroying the metal and causing incorrect repairs.
Note
Due to the different thicknesses of the tin layer, the cleaning proc
ess must be performed in several steps and a visual inspection
of the wiring eyelet between steps is necessary.
Insert the adapter in the wiring eyelet and sand off the corro
sion and contamination with circular motions.
Check the wiring eyelet and sand it again.
Remove the burr on the wiring eyelet with the deburrer. . Volkswagen AG
gen AG does
swa
Install the wiring eyelet to the specified tightening specifica
y Volk not
gu
tion. Refer to Electrical Equipment; Rep. Gr. 97ris;eCompo
db ara
nte
nent Location Overview - Relay Carriers, Fuse Panels ut
ho and E- eo
ra
Boxes or Electrical Equipment; Rep. Gr. 27 ss a; Overview - c
Battery .
ce
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un
pt
an
d
Protect the connection with the corresponding protection ma
itte
y li
terial. Refer to 4.1.5 Protecting, page 121 .
erm
ab
ility
ot p
Connect the Battery - A- . Refer to Electrical Equipment;
wit
is n
Rep. Gr. 27 ; Battery; Battery, Disconnecting and Connecting .
h re
ole,
spec
urposes, in part or in wh
WARNING
t to the co
Risk of injury. Follow all warning messages and safety pre
cautions. Refer to
rrectne
1.3 Warnings and Safety Precautions, page 3 .
ss o
cial p
f inform
4.1.3 Threaded Connections, Repairing
mer
atio
m
n
c
i
or
n thi
Torque Wrench 1331 5-50Nm - VAG1331-
te
sd
iva
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pr
cum
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fo
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ng
Note
t.
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Cop py
t. rig
gh
Do not use rust remover, contact spray or grease because the
ht
pyri by
Vo
lack of friction will cause the torque to be exceeded when in
o
by c lksw
cted agen
stalling and this will lead to the threaded connection breaking. Prote AG.
The gray sanding pads are for slight contamination and suit
able for "soft surfaces". The red sanding pads are for heavy
contamination and suitable for "hard surfaces".
WARNING
Procedure
Disconnect the Battery - A- . Refer to Electrical Equipment;
Rep. Gr. 27 ; Battery; Battery, Disconnecting and Connecting .
Loosen the cap nut and remove the wiring eyelet from the
threaded connection.
Check the threaded connection for corrosion and dirt.
Select the corresponding adapter and the corresponding
sanding pad for the threaded connection.
Caution
Make sure the tin layer is not worn down too much and the
copper is not visible. A galvanic element Acan
G. Voform
lkswagfrom
en AGthis,
destroying the metal and causing oincorrect
lksw
agen repairs. does
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ss
Note
ce
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un
pt
an
d
itte
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Due to the different thicknesses of the tin layer, the cleaning proc
erm
ab
ess must be performed in several steps and a visual inspection
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
Insert the adapter in the threaded connection and sand off the
t to the co
corrosion and contamination with circular motions.
Check the threaded connection and sand it again.
rrectne
Fasten the connection and the anti-twist mechanism to the
specified tightening specification. Refer to Electrical Equip
ment; Rep. Gr. 97 ; Component Location Overview - Relay
ss o
Carriers, Fuse Panels and E-Boxes or Electrical Equipment;
cial p
n
c
i
or
n thi
sd
a
o
pr
cum
r
fo
en
ng
t.
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WARNING
Co
Cop py
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rig ht
by
Risk of injury. Follow all warning messages and safety pre copy Vo
by lksw
cautions. Refer to cted agen
Prote AG.
1.3 Warnings and Safety Precautions, page 3 .
Note
WARNING
Procedure
Disconnect the Battery - A- . Refer to Electrical Equipment;
Rep. Gr. 27 ; Battery; Battery, Disconnecting and Connecting .
Check the battery terminal and battery pole for corrosion and
dirt.
The battery terminal clamp is cleaned with the battery terminal
cleaner wire brush using circular motions.
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The battery terminal is cleaned with the bottom side of the termi
pe
ility
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hole
WARNING
spec
es, in part or in w
t to the co
4.1.5 Protecting
com
tion in
r
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thi
s
iva
do
Caution
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rp
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Procedure
Hold the injector under the wiring eyelet and spray all around wage
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s
the pins. yV
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u or
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itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
Hold the injector above the wiring eyelet and spray all around
the pins and wiring eyelet.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
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t.
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Cop py
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Prote AG.
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General Information
un
pt
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If a repair is necessary, antenna wires may not be repaired,
rm
ab
but rather are to be replaced with genuine replacement parts,
pe
ility
such as connecting wires and adapter leads.
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wit
, is n
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Replacement parts are found in the Parts Catalog.
hole
spec
These genuine replacement parts are suitable for all antenna
es, in part or in w
t to the co
wires and wire cross sections, that require replacement.
Connector housing for antenna wires can be obtained as a
replacement part only in one color, but can be used for all an
rrectness of i
tenna connector colors.
l purpos
nform
ercia
a
com
tion in
All adapter leads and connecting wires are suitable for various
r
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do
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market solution.
n
t.
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op py
5.2 Overview - Antenna Wiring
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Overview of Antenna Wiring Prote
cted AG.
agen
The entire length of the antenna wire consists of the length of the
required adapter leads -1 and 3- as well as the connecting wire
-2-.
Subtract 60 cm from the total length of antenna wire meas
ured, to receive the length of connecting wire -2- required.
Obtain the required adapter cables -1 and 3- as well as the
calculated length of connecting line -2- as original replacement
part according to the Parts Catalog.
Cut the connectors off of the faulty antenna wiring.
Leave the rest of the defective antenna wire in the vehicle.
Connect the adapter leads -1 and 3- to devices in the vehicle.
Route and secure connecting wire -2- in the immediate vicinity
of the series-installed wire routing.
Note
AG. Volkswagen AG d
Antenna wires must not be kinked or excessively bent! The bend
olks
wage
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not
ing radius must not be less than 50 mm. db
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Connect the connecting wire with the adapter leads.
ss
au ra
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e
pt
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itte
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erm
ab
ility
ot p
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
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atio
om
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or c
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Cop py
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rig ht
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Prote AG.
6 Fiber-Optic Cable
6.1 Fiber-Optic Cables, Repairing, page 125
6.2 Fiber-Optic Cable, Assembling, page 125
6.3 Fiber-Optic Cable, Disconnecting from Wiring Harness
Connector, page 130
Note
Procedure:
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Assemble the afiber-optic
ut cable. Refer to or
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6.2 Fiber-Optic Cable, Assembling, page 125 .
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Caution
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Do not bend the fiber-optic cable too much. The bending radius
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Protect the connector and the connection box from dust. Place
the cap on the trunk.
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Fiber-Optic Conductor Repair Set - VAS6223A- t. Cop py
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Hose Cutting Pliers - VAS6228- p by
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Vehicle Diagnostic Tester Prote AG.
Caution
Do not bend the fiber-optic cable too much. The bending radius
must be no less than 25 mm.
Fiber optic cables must not be routed over sharp edges.
The fiber-optic cable must not be dirty or touched with bare
fingers.
Fiber optic cables may not be heated.
It is not permitted to twist together 2 fiber optic cables or one
fiber optic cable with a copper wire.
Protect the connector and the connection box from dust. Place
the cap on the trunk.
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Mount the Tool Head for therise Fiber-Optic Repair Set - Pliers -
d b ara
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Remove the locating
s pin in the direction of the -arrow-.
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Open the Fiber-Optic Repair Set - Pliers and lay the fiber-optic
cable -1- in direction of the -arrow- in the mount.
Establish length of fiber optic cable required.
Close the Fiber-Optic Repair Set - Pliers - VAS6223/1- to cut
the fiber-optic cable to length.
Stripping
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Close the Fiber-Optic Repair Set - Pliers - VAS6223/1- until it s
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stops and keep closed.
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Turn the wire stripper lever in the direction of the -arrow-.
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Remove the fiber-optic cable.
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Precision Cutting (production of optical end face)
hole
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Close the Fiber-Optic Repair Set - Pliers - VAS6223/1- and
com
tion in
remove the wire.
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Visually inspect the wire -1- to make sure that it was cut cor
rectly and that there are no burrs on the front surface.
Note
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Insert a brass pin contact -1- in the mount. s
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Insert the fiber-optic cable into the brass pin contact -arrow-
all the way up to the threaded stop and then close the Fiber-
nform
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Caution
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4 crimped points must be visible on the brass connecting pin.
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The brass pin contact must not be able to be removed by hand
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from fiber-optic cable.
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The front surface of the fiber-optic cable is 0.01 to 0.1 mm
spec
behind the brass pin contact (visual check).
urposes, in part or in wh
t to the co
Note
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Connector couplings are available for connecting the fiber-op
tic cables. Refer to Parts Catalog.
ss o
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To install the new fiber optic cable in wiring harness connector.
inform
Refer to
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Cut the corrugated tube to the fitting length using Hose Cutting
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The corrugated tube must be cut on the wave peak -arrow-, p by
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not in the wave trough.
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Use the Hose Cutting Pliers - VAS6228- or a sharp knife for
cutting.
The corrugated tube must not be cut using a side cutter under
any circumstances.
The corrugated tube must audibly engage in the fiber-optic
cable housing when installing.
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Caution
spec
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Install the cap on the trunk, in order to protect the fiber-
optic cable from dust and dirt.
Use a new housing since it is likely that the secondary lock
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was damaged during the removal of the fiber-optic cable.
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Installing
ion in
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Install the fiber-optic cable according to the markings.
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Push the corrugated tube into the connector housing until it
Prote AG.
audibly engages.
Seal open fiber-optic cable connector -2- with Fiber-Optic Re
pair Set - Connector Protective Caps - VAS6223/9- -item 1-.
The protective cap prevents contamination of or mechanical
damage to front surface of fiber optic cable which would impair
signal transmission.
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7 Heated Oxygen Sensor, Replacing
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7.1 Heated Oxygen Sensor, Replacing, 4-Pin Universal Oxy
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urposes, in part or in wh
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7.3 Oxygen Sensor Unit Protective Pipes, page 132
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Pin Universal Oxygen Sensor
ss
Use the faulty sensor as a guide for installing all of the accompa
o
cial p
f
nying attachments, cable ties or marking bands.
inform
mer
atio
m
sult in malfunctions.
o
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Procedure
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132
agen
Prote AG.
Rep. Gr.97 - Wiring
Beetle 2012 , Golf 2015 , Golf Variant 2007 , Golf Variant 2010 ...
Electrical Equipment General Information - Edition 01.2015
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8 Special Tools
Special tools and workshop equipment required
Torque Wrench 1331 5-50Nm - VAG1331-
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Wiring aut
Harness Repair Set - VAS1978- ra
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AG. Volkswagen AG d
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9 Revision History
Re Dat Job Type Feedback # Notes Editor
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6 04/ Correction y Volks Added miss ot Tom
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4 11/ Correction N/A Deleted Yam
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Cautions & Warnings
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Please read these WARNINGS and CAUTIONS before proceeding with maintenance
h re
ole,
and repair work. You must answer that you have read and you understand these
spec
urposes, in part or in wh
WARNINGS and CAUTIONS before you will be allowed to view this information.
t to the co
= If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this manual, we
rrectne
suggest you leave such repairs to an authorized Volkswagen retailer or other qualified shop. We especially urge
you to consult an authorized Volkswagen retailer before beginning repairs on any vehicle that may still be covered
ss
wholly or in part by any of the extensive warranties issued by Volkswagen.
o
cial p
f inform
= Disconnect the battery negative terminal (ground strap) whenever you work on the fuel system or the electrical
mer
system. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.
atio
om
n
c
i
or
n
= Volkswagen is constantly improving its vehicles and sometimes these changes, both in parts and specifications,
thi
te
sd
a
are made applicable to earlier models. Therefore, part numbers listed in this manual are for reference only. Always
iv
o
pr
cum
check with your authorized Volkswagen retailer parts department for the latest information.
r
fo
en
ng
t.
yi Co
op
= Any time the battery has been disconnected on an automatic transmission vehicle, it will be necessary to C py
ht. rig
rig ht
reestablish Transmission Control Module (TCM) basic settings using the VAG 1551 Scan Tool (ST). copy by
Vo
lksw
by
cted agen
Prote AG.
= Never work under a lifted vehicle unless it is solidly supported on stands designed for the purpose. Do not support
a vehicle on cinder blocks, hollow tiles or other props that may crumble under continuous load. Never work under a
vehicle that is supported solely by a jack. Never work under the vehicle while the engine is running.
= For vehicles equipped with an anti-theft radio, be sure of the correct radio activation code before disconnecting the
battery or removing the radio. If the wrong code is entered when the power is restored, the radio may lock up and
become inoperable, even if the correct code is used in a later attempt.
= If you are going to work under a vehicle on the ground, make sure that the ground is level. Block the wheels to
keep the vehicle from rolling. Disconnect the battery negative terminal (ground strap) to prevent others from
starting the vehicle while you are under it.
= Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to yourself and
others if you are tired, upset or have taken medicine or any other substances that may impair you or keep you from
being fully alert.
= Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.
= Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid. Wear
goggles, gloves and other protective clothing whenever the job requires working with harmful substances.
= Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near
machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery, severe
injury could result.
= Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used
only once and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts,
washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners with
new parts where indicated, and any other time it is deemed necessary by inspection.
Page 1 of 3
2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0
Cautions & Warnings
= Illuminate the work area adequately but safely. Use a portable safety light for working inside or under the vehicle.
Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled
fuel or oil.
= Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not create dust by
grinding, sanding, or by cleaning with compressed air. Avoid breathing asbestos fibers and asbestos dust.
Breathing asbestos can cause serious diseases such as asbestosis or cancer, and may result in death.
= Finger rings should be removed so that they cannot cause electrical shorts, get caught in running machinery, or be
crushed by heavy parts.
= Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the
instructions thoroughly; do not attempt shortcuts. Use tools that are appropriate to the work and use only
replacement parts meeting Volkswagen specifications. Makeshift tools, parts and procedures will not make good
repairs.
.
n AGin gen AG Volkswa
= Catch draining fuel, oil or brake fluid
age suitable containers.
does Do not use empty food or beverage containers that
olksw not
might mislead someone by into drinking from them. Store flammable
V gu
ara fluids away from fire hazards. Wipe up spills at
d
ise the oily rags, which can ignite and burn
once, but do not store ntspontaneously.
or h
e eo
ut ra
ssa c
= Use pneumatic and
electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten
ce
e
nl
pt
fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque
du
an
itte
listed.
y li
erm
ab
ility
ot p
= Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping hydrogen gas is wit
, is n
ignited, it will ignite gas trapped in the cells and cause the battery to explode. h re
hole
spec
es, in part or in w
= Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of
t to the co
the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local ordinances that
govern the disposal of wastes.
rrectness of i
= The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C system should be
l purpos
serviced only by trained automotive service technicians using approved refrigerant recovery/recycling equipment,
trained in related safety precautions, and familiar with regulations governing the discharging and disposal of
automotive chemical refrigerants.
nform
mercia
at
= Before doing any electrical welding on vehicles equipped with anti-lock brakes (ABS), disconnect the battery
om
ion
c
negative terminal (ground strap) and the ABS control module connector.
in t
or
his
ate
do
riv
= Do not expose any part of the A/C system to high temperatures such as open flame. Excessive heat will increase
p
cum
or
en
ng
t.
yi Co
op py
= When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the Transmission
t. C rig
gh ht
yri
Control Module (TCM), the ABS control module, and the trip computer. In cases where one or more of these
p by
co Vo
by lksw
components is not separately fused, disconnect the control module connector(s). Prote
cted AG.
agen
= Some of the vehicles covered by this manual are equipped with a supplemental restraint system (SRS), that
automatically deploys an airbag in the event of a frontal impact. The airbag is operated by an explosive device.
Handled improperly or without adequate safeguards, it can be accidentally activated and cause serious personal
injury. To guard against personal injury or airbag system failure, only trained Volkswagen Service technicians
should test, disassemble or service the airbag system.
Page 2 of 3
2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0
Cautions & Warnings
= Do not quick-charge the battery (for boost starting) for longer than one minute, and do not exceed 16.5 volts at the
battery with the boosting cables attached. Wait at least one minute before boosting the battery a second time.
= Never use a test light to conduct electrical tests of the airbag system. The system must only be tested by trained
Volkswagen Service technicians using the VAG 1551 Scan Tool (ST) or an approved equivalent. The airbag unit
must never be electrically tested while it is not installed in the vehicle.
ce
le
= When driving or riding in an airbag-equipped vehicle, never hold test equipment in your hands or lap while the
un
pt
an
d
itte
vehicle is in motion. Objects between you and the airbag can increase the risk of injury in an accident.
y li
rm
ab
pe
ility
ot
wit
, is n
h re
I have read and I understand these Cautions and Warnings.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Page 3 of 3
2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0