SM 13.c

Service
AG. Volkswagen AG d
agen
Workshop Manual
oes
olksw not
y V gu
d b ara
rise nte
Amarok 2011 ➤ , Amarok 2017 ➤ , tho eo

au ra
s c
Caddy 2004 ➤ , Caddy 2011 ➤ ,

s
ce
e
nl
pt
du
an
Caddy 2016 ➤ , California 2010 ➤ ,
itte
y li
erm
ab
Crafter 2006 ➤ , Crafter 2017 ➤ ,
ility
ot p
wit
, is n
TGE 2017 ➤ , Transporter 2004 ➤ ,
h re
hole
spec
Transporter 2010 ➤ ,
es, in part or in w
t to the co
Transporter 2016 ➤ , e-Crafter 2019 ➤ ,
e-TGE 2019 ➤
rrectness of i
Electrical system - general information
l purpos
Edition 01.2019
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.
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
27 - Starter, current supply, CCS
90 - Gauges, instruments
92 - Windscreen wash/wipe system
94 - Lights, bulbs, switches - exterior
96 - Lights, bulbs, switches - interior
97 - Wiring
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
.
Technical information should always be available to the foremen and mechanics, because their
t rig
gh ht
yri by
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and cop Vo
by lksw
cted
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
agen
Prote AG.
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2019 Volkswagen AG, Wolfsburg D4B8025555B

Amarok 2011 ➤ , Amarok 2017 ➤ , Caddy 2004 ➤ , Caddy 2011 ➤ , Caddy 2 ...
Electrical system - general information - Edition 01.2019
Contents
27 - Starter, current supply, CCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Fundamentals for batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Warning notices and safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Types of batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Battery terminal connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Checking battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Checking the various types of batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Information about battery replacement and battery gas venting . . . . . . . . . . . . . . . . . . . . 8
2.4 Checking colour indicator in battery cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5 Battery tester with printer VAS 6161 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.6 Battery tester DSS-7814 SET, MAN TGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.7 Current draw test . . . . . . . . . .k.s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
n AG. Vol wagen AG do
2.8 No-load current measurement
lkswage . . . . . . . . . e. s.n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
o ot g
yV
3 Charging the dbattery . . . . . . . . . . . . . . . . . . . . . u.a.ra. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b 28
ir se nt
3.1 Totally discharged
utho batteries . . . . . . . . . . . . . . . . . . .e.e o.r . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
a a
3.2 Battery
ss charger VAS 5095 A . . . . . . . . . . . . . . . . . . . . . c. . . . . . . . . . . . . . . . . . . . . . . . . . . 29
ce
le
3.3 Battery charger VAS 5900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

un
pt
an
d
3.4 Battery charger VAS 5900 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

itte
y li
erm
ab
ility
ot p

wit
is n

h re
ole,
3.8 Midtronics INC 940 battery charger (USA/Canada only) . . . . . . . . . . . . . . . . . . . . . . . . . . spec 78

3.9 Battery charger Fronius Acctiva Professional 35A, MAN TGE . . . . . . . . . . . . . . . . . . . . . . 81

t to the co
3.10 Solar charger module VAS 6102A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

4 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
rrectne
4.1 Checking function of poly V-belt pulley with freewheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

5 Cruise control system (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
ss o
5.1 General description - cruise control system (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

cial p
f in
5.2 Activating and deactivating cruise control system (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . . 87

form
mer
atio
90 - Gauges, instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
om
n
c
i
or
n thi
92 - Windscreen wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

te
sd
iva
o
pr
1 Washer fluid line hose couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

um
r
fo
en
ng
1.1 Hose couplings - windscreen and rear window washer system . . . . . . . . . . . . . . . . . . . . . . 89

t.
yi Co
op
1.2 Hose couplings - windscreen and rear window washer system . . . . . . . . . . . . . . . . . . . . . . 90
C py
t. rig
gh ht
1.3 Hose couplings - headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
yri
91
p by
co Vo
by lksw
2 Hose repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
cted agen
Prote AG.
2.1 General description - hose repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.2 Repairing smooth pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.3 Repairing corrugated pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
94 - Lights, bulbs, switches - exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

1 Operation and safety notes for gas discharge lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
96 - Lights, bulbs, switches - interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

1 Immobiliser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
1.1 General description - immobiliser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
1.2 Online system test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.3 Immobiliser control unit J362 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Contents i
Amarok 2011 ➤ , Amarok agen 2017 ➤ , Caddy
AG. Volkswagen AG d 2004 ➤ , Caddy 2011 ➤ , Caddy 2 ...
oes
ksw not
Electrical system
by V - general information - Edition
ol
g01.2019
ua
ed ran
oris tee
th o
1.4 Engine
au control
unit J623 . . . . . . . . . . . . . . . . . . . r.a.c
............................. 99
ss
1.5 Immobiliser reader coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
ce
le
un
pt
1.6 Replacement ignition key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
an
d
itte
y li
1.7 Ignition key - variable code transponder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
erm
ab
ility
1.8 New lock set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
ot p
wit
1.9 New identity on renewing all components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
is n
h re
ole,
2 12 V socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
spec
2.1 Removing and installing 12 V socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
t to the co
2.2 Removing and installing socket illumination bulb L42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3 Cigarette lighter U1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
rrectne
3.1 General description - cigarette lighter U1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.2 Assembly overview - cigarette lighter U1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
s
3.3 Removing and installing cigarette lighter socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
s o
cial p
f
3.4 Removing and installing cigarette lighter illumination bulb L28 . . . . . . . . . . . . . . . . . . . . . . 109
inform
mer
97 - Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
atio
om
n
1 Vehicle diagnosis, testing and information systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
c
i
or
n thi
e
1.1 General description - vehicle diagnosis, testing and information system . . . . . . . . . . . . . . 110
t
sd
iva
o
1.2 Connecting vehicle diagnostic tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
pr
cum
r
fo
en
ng
2 Wiring harness and connector repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

yi
t.
Co 113
op
2.1 General notes concerning repairs to vehicle electrical system . . . . . . . . . . . . . . . . . . . . . . 113
C py
t. rig
gh
2.2 Wiring harness repair set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
ht
pyri by
Vo
co
2.3 Tool descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
by lksw
cted agen
Prote AG.
2.4 Repairs to electrical wiring harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
2.5 Repairs to fibre optic cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
2.6 Repair of aerial wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
2.7 Repairing connector housings and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
2.8 Releasing and dismantling connector housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
3 Cleaning contact surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
3.1 General description - contact surface cleaning set VAS 6410 . . . . . . . . . . . . . . . . . . . . . . 174
3.2 Repairing ring terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
3.3 Repairing threaded electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
3.4 Cleaning battery terminal clamp and battery terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
3.5 Preserving threaded electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
4 Renewing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
4.1 General notes - renewing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
4.2 Types of protective tube on uniform Lambda probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
4.3 Renewing LSF Lambda probe (4-pin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
4.4 Renewing LSU lambda probe (6-pin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
5 ESD workplace VAS 6613 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
5.1 Use of ESD workplace VAS 6613 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
ii Contents
27 – Starter, current supply, CCS

1 Battery
(VRL012510; Edition 01.2019)
⇒ “1.1 Fundamentals for batteries”, page 1
⇒ “1.2 Warning notices and safety regulations”, page 1
⇒ “1.3 Types of batteries”, page 3
⇒ “1.4 Battery terminal connection”, page 5
1.1 Fundamentals for batteries
WARNING
Danger of injury! Comply with the warning notices and safety

regulations ⇒ page 1 !
Caution
To prevent damage to the battery or to the vehicle, observe

notes concerning the battery types ⇒ page 3 .
olkswagen AG
en AG. V
To ensure long use of the battery, the battery
ksw must be checked, es not
ag do
Vol
serviced and maintained accordingedtob the specifications in this
y gu
ara
manual. ho
ris nte
e t or
au ac
Apart from supplying energyssfor starting the engine, the battery
has other tasks: it acts as a buffer and supplies electrical energy
ce
le
un
pt
to the complete electrical on-board supply of the vehicle.

an
d
itte
y li
erm
ab
ility
ot p
Note
wit
is n
h re
ole,
For additional information, refer to ⇒ Self-study programme No.

spec
234 ; Vehicle batteries .

t to the co
1.2 Warning notices and safety regulations

rrectne
⇒ “1.2.1 Dangers when handling vehicle batteries”, page 1

s
⇒ “1.2.2 Safety markings on battery”, page 2

s o
cial p
f i
1.2.1 Dangers when handling vehicle batter‐

nform
mer
ies
atio
om
n
c
Recognition and avoidance of dangers

i
or
n thi
te
sd
a
Batteries can be dangerous. These dangers can be avoided when

iv
o
pr
the warnings on the battery, in the operating manual and in ELSA

um
r
fo
en
are observed.
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Battery 1
WARNING
♦ Untrained personnel e.g. apprentices and trainees, may

only work on batteries when supervised by a trained spe‐
cialist such as a vehicle mechanic/foreman or vehicle
electrician/foreman.
♦ Acid is highly corrosive. There is a considerable danger of
acid burns if personnel do not handle batteries correctly.
Therefore suitable measures must be taken to ensure that
equipment/solutions etc. are available to neutralize acid
burns. A suitable solution is: e.g. a soap solution.
♦ If electrolyte leaks from a battery it may cause skin burns
or acid corrosion and rusting on the vehicle. This may
damage safety relevant components on the vehicle.
♦ The gas which forms when charging and the gas which
may escape through vent valves is explosive. In extreme
cases a battery may explode if the battery is not handled
correctly.
♦ Batteries whose magic eye shows light yellow must wage
be
n AGre‐
. Volkswagen AG
does
placed. They must not be checked or charged y Volksand do not not
gu
slave/jump start. Danger of explosion when
ise
d b checking and ara
nte
charging or slave/jump starting. thor eo
u ra
sa c
♦ It is prohibited to cause sparks through
s grinding, welding,
ce
le
cutting operations and use naked lights in the vicinity of

un
pt
an
batteries. Smoking is also prohibited. Sparks generated
d
itte
y li
by electrostatic charging must also be avoided. Always
erm
ab
touch the vehicle body before touching the battery.
ility
ot p
wit
is n
♦ Only work on batteries in well ventilated and suitable
h re
ole,
rooms.
spec
t to the co
1.2.2 Safety markings on battery
rrectne
Safety markings on battery
1. - Fires, sparks, naked flames and smoking are prohibited when
ss
handling batteries. Avoid sparks as well as electrostatic discharge

o
cial p
when working with cables and electrical units. Avoid short circuits.
inform
Therefore never lay a tool on a battery.

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

om
n
c
i
or
3. - Keep children away from acid and batteries.

thi
te
sd
va
4. - Disposal: old batteries are classed as hazardous waste. They

i
o
pr
cum
r
may only be disposed of through a suitable collection centre and

fo
en
ng
only in accordance with respective legislation.

t.
yi Co
Cop py
t. rig
5. - Never dispose of old batteries in household waste system! opyri
gh by
Vo
ht
c
6. - There is a danger of an explosion when working with batteries.
by lksw
cted agen
Prote
A highly explosive gas is produced when batteries are charged.
AG.
7. - Always follow instructions given on battery in ELSA ⇒ Elec‐

trical System, General Information; Rep. gr. 27 ; Battery; Warning
notices and safety regulations and in the operating manual.
8. - Battery acid is very caustic; therefore wear eye protection and
gloves when working with batteries. Do not tilt battery. Acid can
leak out of the gas vents of some batteries.
2 Rep. gr.27 - Starter, current supply, CCS

1.3 Types of batteries

⇒ “1.3.1 Battery with standard colour indicator”, page 3
⇒ “1.3.2 Battery with enhanced colour indicator”, page 3
⇒ “1.3.3 Absorbent glass mat battery”, page 4
1.3.1 Battery with »standard« colour indicator

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

water.
Only perform visual inspections on batteries.
Observe the notes given in the chapters concerning battery
tests ⇒ page 6 . wage
e ks s no
Vol t gu
d by ara
e nte
ris
utho eo
ra
WARNING ss
a c
ce
le
un
pt
It is not permissible to test or charge batteries whose colour
an
d
itte
y li
indicator is light yellow. Do not slave/jump start the vehicle!
rm
ab
pe
ility
Danger of explosion when checking and charging or slave/
ot
wit
, is n
jump starting.
h re
hole
spec
These batteries must be renewed.
es, in part or in w
t to the co
This battery is equipped with a colour indicator. The colour indi‐
cator provides information about the electrolyte level and the
rrectness of i
charge state of the battery. Checking the colour indicator
⇒ page 9
l purpos
1.3.2 Battery with »enhanced« colour indica‐

nform
ercia
tor
m
a
com
ti
This is a maintenance-free battery with liquid electrolyte (wet bat‐

on in
tery).
r
te o
thi
s
iva
do
r
rp
Caution
um
fo
en
ng
t.
yi Co
op
No stickers may be removed and do not replenish with distilled C py
t. rig
water.
gh ht
pyri by
Vo
co lksw
by
Only perform visual inspections on batteries. cted agen
Prote AG.
Observe the notes given in the chapters concerning battery

tests ⇒ page 6 .
1. Battery 3
WARNING

jump starting.
The battery is used for particular requirements in certain vehicles

equipped with a start/stop system. The battery can be identified
by the lettering “EFB” on the battery cover. EFB stands for »En‐
hanced Flooded Battery«.
Only replace an EFB battery with another EFB battery.
The EFB battery has a colour indicator to enable the electrolyte
level to be checked.
AG. Volkswagen AG d
agen oes
Checking the colour indicator ⇒ page 9 olksw not
byV gu
ara
ed
ris nte
ho eo
ut ra
Note ss a c
ce
le
un
pt
“EFB” batteries have been used in the smaller petrol engines with
an
d
itte
y li
start/stop systems and manual gearboxes as of 05.2011.
rm
ab
pe
ility
ot
wit
1.3.3 Absorbent glass mat battery
, is n
h re
hole
spec
This is a maintenance-free battery with a contained electrolyte
es, in part or in w
without colour indicator.
t to the co
Lead-acid battery where the electrolyte is contained within a mi‐
croscopic glass mat (AGM). The battery is sealed and fitted with
rrectness of i
valves.
l purpos
AGM is the abbreviation for absorbent glass mat.

Due to containment of the electrolyte, this type of battery cannot
nform
ercia
have a colour indicator. Absorbent glass mat batteries are iden‐

tified by the abbreviation AGM on the battery.
m
a
com
tion in
r
te o
thi
Note
s
iva
do
r
rp
cum
Always replace an absorbent glass mat battery with another ab‐

fo
en
ng
sorbent glass mat battery.

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

1.4 Battery terminal connection
Caution
To prevent damage to the battery terminal clamps and battery

terminals, the following should be observed:
♦ The battery terminal clamps should only be fitted by hand
and without using force.
♦ Battery terminals should not be coated with grease.
♦ The battery terminal clamps should be fitted in such a way
that the battery terminal is either flush with the clamp or
protruding from it.
♦ Once the battery terminal clamps have been tightened to
the specified torque, the threaded connections should not
be tightened any further.
Cleaning battery terminal clamps and battery terminals

⇒ page 178 .
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
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Battery 5
2 Checking battery
⇒ “2.1 Checking the various types of batteries”, page 6
⇒ “2.2 Visual check”, page 7
⇒ “2.3 Information about battery replacement and battery gas
venting”, page 8
⇒ “2.4 Checking colour indicator in battery cover”, page 9
⇒ “2.5 Battery tester with printer VAS 6161 ”, page 12
⇒ “2.6 Battery tester DSS-7814 SET, MAN TGE”, page 17
⇒ “2.7 Current draw test”, page 19 AG. Volkswagen AG d
agen oes
lksw not
⇒ “2.8 No-load current measurement”, page 20 d by Vo gu
ara
rise nte
2.1 Checking the various types of batteries tho eo
au ra
ss c
⇒ “2.1.1 Checking a battery with colour indicator”, page 6
ce
le
un
pt
an
d
itte
⇒ “2.1.2 Absorbent glass mat battery”, page 7
y li
erm
ab
ility
2.1.1 Checking a battery with colour indicator
ot p
wit
is n
h re
ole,
spec
WARNING
t to the co
rrectnes
Caution
s o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
c
Note
um
r
fo
en
ng
t.
yi Co
op
Observe the chapter “Battery” in ⇒ Maintenance ; Booklet for the C py
t. rig
respective vehicle!
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
Perform the checks in the following sequence:
AG.
1. Visual check ⇒ page 7

2. Colour indicator check: “3-colour” ⇒ page 9 or “2-colour”
⇒ page 10 .
WARNING

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

⇒ page 12 .

4. Depending on the result of the battery test, “perform current

draw test” ⇒ page 19 .
AG. Volkswagen AG d
2.1.2 Absorbent glass mat battery Volksw
agen oes
not
by gu
d ara
rise nte
o
WARNING auth eo
ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
Caution
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Note
nform
ercia
Observe the chapter “Battery” in ⇒ Maintenance ; Booklet for the

respective vehicle!
m
at
om
ion
c
Perform the checks in the following sequence:
in t
or
his
ate
1. Visual check ⇒ page 7
do
priv
cum
or
2. Battery check using battery tester with printer - VAS 6161-

f
en
ng
t.
yi
⇒ page 12
Co
Cop py
t. rig
gh
3. Depending on the result of the battery test, “perform current
ht
pyri by
draw test” ⇒ page 19 .
co Vo
by lksw
cted agen
Prote AG.
2.2 Visual check
WARNING

Caution

Before taking extensive measurements, visually check the con‐

dition of the exterior, the connections and whether the battery is
firmly seated!
Note
Observe the chapter "Battery" for the respective vehicle ⇒ Main‐

tenance ; Booklet .
2. Checking battery 7
Caution
♦ The battery will be damaged if the battery is not secured

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

♦ If battery housing is damaged Electrolyte can leak out if the
housing is damaged. If battery acid leaks out, serious damage
to the vehicle could be caused. Treat components affected by
leaked battery acid immediately with acid neutraliser or a soap
solution. AG. Volkswagen AG d
agen oes
lksw not
♦ Check whether the battery terminals (battery wire connec‐d by V o gu
ara
tions) are damaged. The necessary contact on the battery orise nte
terminal clamps cannot be guaranteed if the battery aterminals
ut
h eo
ra
are damaged. When connecting battery terminal clamps,
ss ad‐ c
here to tightening torque specified in the workshop manual
ce
e
nl
pt
du
“Electrical system” for the respective vehicle. If the battery ter‐
an
itte
y li
minal clamps are not correctly seated and tightened, the wiring
erm
ab
may burn. Which will cause malfunctions in the electrical sys‐
ility
ot p
tem. Safe operation of the vehicle is no longer guaranteed.
wit
, is n
h re
2.3 Information about battery replacement
hole
spec
and battery gas venting
es, in part or in w
t to the co
♦ For safety reasons, it is important to determine which side of
the battery gas is vented from.
rrectness of i
♦ For areas of application in which a gas vent hose is used, en‐
l purpos
sure that the gas vent hose is seated securely and that the gas
vent opening on the opposite side is sealed.
nf
ercia
♦ When renewing the vehicle battery, make absolutely sure that
or
the gas vent opening in the area of the positive battery terminal
m
m
atio
is not exposed. Should a vent opening be exposed in this area,
om
n in
it must be sealed with a plug and the vent in the area of the
or c
thi
negative battery terminal must be opened.
te
sd
iva
o
r
♦ If the vehicle is installed with an AGM battery outside the en‐

rp
cu
o
gine compartment, ensure that the battery is replaced with a

f
en
ng
t.
yi
different AGM battery.
Co
Cop py
ht. rig
♦ If there is a protective cap with sprayed on plug on the battery rig ht
py by
Vo
positive terminal of the replacement part battery
co lksw
by
cted agen
000.915.105.DX, with the exception of genuine battery part Prote AG.
number 000.915.105.DN and all Economy batteries with sin‐
gle index, this must also be changed on the negative battery
terminal or positive battery terminal side according to the sit‐
uation. List of batteries ⇒ page 9 .
♦ All AGM, EFB and EFB+ batteries along with 36 Ah battery
with part number 000.915.105.DN have a protective cap with‐
out sprayed on plug on the positive terminal. The gas vent on
the positive battery terminal side is already sealed here.
If a genuine replacement part battery is discovered with the fol‐
lowing part numbers, a red sealing plug must be fitted either on
the positive or negative battery terminal side. If this is not installed,
it must be retrofitted - part number 000.915.506.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
rise
d b
Amarok 2011 ➤ , Amarok 2017 ➤ ara , Caddy 2004 ➤
nte , Caddy 2011 ➤ , Caddy 2 ...
autho
Electrical system
eo
r a - general information - Edition 01.2019
ss c
ce
e
List of batteries with protective cap and sprayed on plug
nl
pt
du
an
itte
OES wet:
y li
erm
ab
ility
♦ “110 Ah” 000.915.105.DL
ot p
wit
, is n
♦ “95 Ah” 000.915.105.DK
h re
hole
spec
♦ “85 Ah” 000.915.105.DJ
es, in part or in w
t to the co
♦ “80 Ah” 000.915.105.DH
♦ “72 Ah” 000.915.105.DG
rrectness of i
♦ “61 Ah” 000.915.105.DE
l purpos
♦ “51 Ah” 000.915.105.DC

♦ “44 Ah” 000.915.105.DB
nform
ercia
Economy batteries:
m
at
om
ion
♦ “44 Ah” JZW.915.105.C
c
in t
or
his
te
♦ “61 Ah” JZW.915.105.

a
do
priv
cum
or
♦ “72 Ah” JZW.915.105.A

f
en
ng
t.
yi Co
♦ “80 Ah” JZW.915.105.F Cop py
t. rig
gh ht
yri
♦ “85 Ah” JZW.915.105.B p by
co Vo
by lksw
cted agen
♦ “95 Ah” JZW.915.105.E Prote AG.
2.4 Checking colour indicator in battery cov‐

er
⇒ “2.4.1 Checking colour indicator, 3-colour ”, page 9
⇒ “2.4.2 Checking colour indicator, 2-colour ”, page 10
2.4.1 Checking colour indicator, “3-colour”
WARNING

Caution

General information about colour indicator:

Applies for all batteries with “1J0”, “7N0” and “3B0” indexes in
original equipment and for all replacement batteries 191 915 105
AB and from “000 915 105 AX” index.
The colour indicator provides information about the electrolyte
level and the charge state of the battery.
Before carrying out visual check, tap the inspection window lightly
and carefully using the handle of a screwdriver. The air bubbles,
which can influence the display, will dissipate when doing this.
This will make the colour indicator reading more accurate.
Note
♦ Visual check of electrolyte level from above with battery posi‐

tioned horizontally.
♦ Air bubbles can form under the sight glass, particularly when
a battery has been recharged, i.e. also when the battery has
been charged during normal vehicle operation. These falsify
the reading of the colour indicator.
♦ Since the colour indicator is only located in one battery cell,
the indicator also only applies to this battery cell. Determining
the exact condition of the battery is only possible by means of
a battery test ⇒ page 12 .
♦ The colour indicator can be located at various positions on the
battery.
3 different colour displays are possible:

♦ »Green«, battery is charged sufficiently.
♦ »Black«, battery partly discharged, charge state < 65% or
AG. Volkswagen AG d
completely discharged lksw
agen oes
n o ot g
yV ua
♦ »Colourless or light yellow«, battery must be renewed.
ise
db ran
r tee
ho
aut or
ac
WARNING ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
jump starting.
h re
hole
spec
es, in part or in w
t to the co
2.4.2 Checking colour indicator, “2-colour”
rrectness of i
l purpos
WARNING nf
ercia

or
m
m
atio
om
n in
or c
thi
te
sd
a
Caution
iv
o
r
rp
cu
o
m
f
en
ng

t.
yi Co
op
notes concerning the battery types ⇒ page 3 . C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
General information about colour indicator:
Prote AG.
The general introduction of the “2-colour” display took place grad‐

ually in 2009. On the “2-colour” display, the colour indicator
»green« for the charge level is missing.
The colour indicator provides information on the electrolyte level
of the battery.
The battery charge can no longer be ascertained by means of the
colour indicator; the battery has to be checked for this
⇒ page 12 .
Before carrying out visual check, tap magic eye lightly and care‐
fully using handle of a screwdriver. The air bubbles, which can

influence the display, will dissipate when doing this. The colour
display of the magic eye will therefore be more accurate.
Note
♦ Visual check of electrolyte level from above with battery posi‐

tioned horizontally.
♦ Air bubbles can form under the sight glass, particularly when
a battery has been recharged, i.e. also when the battery has
been charged during normal vehicle operation. These falsify
the reading of the colour indicator.
♦ Since the colour indicator is only located in one battery cell,
the indicator also only applies to this battery cell. Determining
the exact condition of the battery is only possible by means of
a battery test ⇒ page 12 .
♦ The colour indicator can be located at various positions on the
battery. AG. Volkswagen AG d
agen oes
olksw not
V gu
2 different colour d bdisplays are possible:
y ara
rise nte
o eo
♦ »Black«, aut electrolyte level is OK.
h
ra
ss c
♦ »Light yellow«, electrolyte level too low The battery must be
ce
e
nl
pt
renewed.
du
an
itte
y li
erm
ab
ility
WARNING
ot p
wit
, is n
h re

hole
spec

es, in part or in w
t to the co

jump starting.
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.
2.5 Battery tester with printer - VAS 6161-

⇒ “2.5.1 General description - battery tester with printer VAS 6161
”, page 12
⇒ “2.5.2 Device description - battery tester with printer VAS 6161
. Volkswagen AG
”, page 13 swa
gen AG does
k not
y Vol gu
⇒ “2.5.3 Perform battery test with battery tester with printer
d b VAS ara
ise nte
6161 .”, page 13 tho
r eo
au ra
c
⇒ “2.5.4 Checking genuine Volkswagen battery”,
ss page 14
ce
le
un
pt
⇒ “2.5.5 Checking non-Volkswagen battery”, page 15
an
d
itte
y li
rm
ab
⇒ “2.5.6 Carrying out stock maintenance”, page 15
pe
ility
ot
⇒ “2.5.7 Comments concerning test print out”, page 16
wit
, is n
h re
hole
⇒ “2.5.8 Assessing test results”, page 16
spec
es, in part or in w
2.5.1 General description - battery tester with
t to the co
printer - VAS 6161-
rrectness of i
WARNING
l purpos
Danger of injury! Observe warning notices and safety regula‐
nform
ercia
tions ⇒ page 1 !
m
a
com
tion in
It is not necessary to remove or disconnect battery when using
r
te o
thi
battery tester with printer - VAS 6161- .
s
iva
do
r
rp
The battery tester with printer - VAS 6161- does not load the bat‐
cum
fo
tery any more. It works on the principle of dynamic conductance
en
ng
t.
yi
acquisition.
Co
Cop py
t. rig
gh
Every battery type is stored in the tester.
ht
pyri by
Vo
co lksw
by
cted
Data can be stored on an SD card.
agen
Prote AG.
The battery tester with printer - VAS 6161- can be updated via an
interface or an SD card, so that battery data from Volkswagen are
always up to date.
The integrated temperature sensor improves measurement qual‐
ity.
A 2D scanner is available as an option to read data directly from
the 2D code of the battery.
Note
Observe the operating manual ⇒ Operating manual of the battery

tester with printer - VAS 6161- .

2.5.2 Device description - battery tester with

printer - VAS 6161-
1 - Integrated printer
2 - Operating lever for paper compartment AG. Volkswagen AG d
agen oes
lksw not
3- Paper slot by
Vo gu
ara
ed
is nte
4- LCD screen with main menuuthor eo
a ra
s c
5- Control panel with ON/OFF
s button
ce
e
nl
pt
du
6 - Connection for battery test cable
an
itte
y li
erm
ab
7 - Memory card slot
ility
ot p
wit
8 - Infrared temperature sensor
, is n
h re
hole
9 - Data transmitter for PC
spec
es, in part or in w
t to the co
2.5.3 Perform battery test with battery tester
rrectness of i
with printer - VAS 6161- .
l purpos
WARNING
nf
ercia
orm
m
atio
m
tions ⇒ page 1 !
o
n in
or c
thi
te
sd
iva
o
r
rp
cu
Special tools and workshop equipment required
o
m
f
en
ng
t.
♦ Battery tester with printer - VAS 6161-
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Performing battery test:
WARNING

jump starting.
– Switch off ignition and all electrical consumers.

– Check the colour indicator in batteries with an inspection win‐
dow ⇒ page 6 .
– Switch tester on.
– Connect red terminal “+” of tester to positive terminal.

– Connect black terminal “-” of tester to negative terminal.
Note
Ensure test clamps have a good contact!
– Select one of the following tests:
Note
♦ Genuine Volkswagen battery test: all Genuine VW batteries

are to be tested with this, both during and after warranty.
♦ Non-Volkswagen battery test: batteries from all other manu‐
facturers are to be tested with this.
♦ Stock maintenance: for batteries in showroom and storage
vehicles requiring maintenance.
♦ Genuine Volkswagen battery ⇒ page 14 .

♦ Non-Volkswagen battery ⇒ page 15 .
♦ Stock maintenance ⇒ page 15 .
Note
♦ The test is completed after about 10 seconds.

♦ The result of the test is printed out by the printer.
♦ The tester requires no cooling phase before it is ready for the AG. Volkswagen AG d
agen oes
ksw
next measurement. by Vol not
gu
ara
d
rise nte
ho eo
2.5.4 Checking genuine Volkswagen battery ut ra
s a c
s
ce
le
un
pt
an
d
WARNING
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
Danger of explosion when checking and charging or slave/ spec

jump starting.
es, in part or in w
t to the co

rrectness of i
– Select “Genuine Volkswagen battery” in the menu.

l purpos
– Select “In vehicle” or “Outside vehicle”.

nform
ercia
– Select “On battery terminal” or “On jump-start point”.

m
– Scan in 2D code of battery or manually select battery type and

a
com
tio
amperage.
n in
r
te o
thi
– Measure temperature. Hold temperature sensor about 5 cm

s
iva
do
above one battery terminal until temperature stabilises.

r
rp
cum
fo
en
g
– Start test.
n
t.
yi Co
op py
– Print out test log if necessary.
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2.5.5 Checking non-Volkswagen battery
Note lks wage es n
o ot g
byV ua
ed ran
♦ The print-out
tho ris may vary depending on the software version.
tee
u or
a ac
♦ Observe
ss the operating manual ⇒ Operating manual of the
battery tester with printer - VAS 6161- .
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
WARNING
ot p
wit
is n
h re
ole,
spec
t to the co
jump starting.
rrectness
– Select “Non-Volkswagen battery” in the menu.
o
cial p
f inform
mer
atio
– Select battery type “Normal”, “AGM”, “2*6V” or “Gel”.
om
n
c
i
or
n
– Select “CCA”, “JIS”, “DIN”, “SAE”, “IEC” or “EN” norm.
thi
te
sd
va
– Select battery value.

i
o
pr
cum
r
fo
en
– Measure temperature. Hold temperature sensor about 5 cm

ng
t.
yi Co
above one battery terminal until temperature stabilises.
t. Cop py
rig
gh ht
yri
– Start test. p by
co Vo
by lksw
cted agen
– Print out test log if necessary. Prote AG.
2.5.6 Carrying out stock maintenance
WARNING

jump starting.
– Select “Stock maintenance” in the menu.

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

test printout by hand.
– Scan in vehicle identification number.

– Scan in 2D code of battery or select type and make manually
in menu.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
Amarok 2011 ut
ho ➤ , Amarok 2017 ➤ , Caddy 2004 ➤ , Caddy eo
ra 2011 ➤ , Caddy 2 ...
a
Electrical
s system - general information - Edition 01.2019 c
s
ce
e
nl
pt
du
an
– Measure temperature. Hold temperature sensor about 5 cm itte
y li
above terminal connection until temperature stabilises.
erm
ab
ility
ot p
– Start test.
wit
, is n
h re
– Print out test log if necessary.
hole
spec
2.5.7 Comments concerning test print out
es, in part or in w
t to the co
Note
rrectness of i
l purpos
♦ The print-out may vary depending on software version.

♦ The test printout is required for warranty claims.
nform
mercia
1- Check type.
at
om
ion
c
2- Battery test result
in t
or
his
ate
3- Measured voltage
do
priv
cum
or
4- Measured cold start value of battery.

f
en
ng
t.
yi Co
op
5- Nominal cold start value of battery selected on tester. C py
t. rig
gh ht
yri by
6- Measured temperature of battery. op Vo
by c lksw
cted agen
Prote
7- Fitting location of battery
AG.
8- Position of battery terminal clamp selected on tester.

9- Selected battery technology.
2.5.8 Assessing test results

Evaluating battery test results for guarantee and service tests
Battery test results Measure
Battery OK No measures on battery.
Battery OK - recharge. Charge battery ⇒ page 28 . In
case of discharging, look for
fault.
Perform current draw test Perform current draw test
⇒ page 19 . Fully charge bat‐
tery ⇒ page 28 and repeat
test.
Renew battery Disconnect battery and repeat
test. The result “Renew battery”
may be caused by a weak cable
contact.
Battery cell defective - renew. Renew battery.
Check connection. Connect cable directly to bat‐
tery and not to jump-start con‐
nection.
Battery dead Renew battery.
Evaluating battery test results for maintenance test
Battery OK No measure
Charge battery immediately. Charge battery fully
⇒ page 28 .
Mark as defective. Mark as defective.


Check tester connection. Disconnect battery and repeat
test. The result “Check tester
connection” may be caused by
a weak cable contact.
Check connection. Connect cable directly to bat‐
tery and not to jump-start con‐
nection.
Noises Wait until measured value ap‐
pears on display.
Battery dead Renew battery.
2.6 Battery tester DSS-7814 SET, MAN

TGE
2.6.1 Checking starter battery with batteryagen

AG. Volkswagen AG d
oes
ksw
tester DSS-7814 SET - 08.78024-0005-
ol not
V gu
d by ara
e is nte
or
au
th eo
ra
ss c
♦ Torque wrench - V.A.G 1331-
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
♦ Battery tester DSS-7814 SET - 08.78024-0005-
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Procedure
– Withdraw ignition key.
– If fitted, disconnect negative battery terminal of second battery
- A1- in engine compartment ⇒ Electrical system; Rep. gr.
27 ; Battery; Disconnecting and connecting batter .
– Move back left front seat.
– Remove left floor covering ⇒ General body repairs, interior;
Rep. gr. 70 ; Interior trim; Removing and installing floor cov‐
ering .
– Pull off cover -1- in direction of -arrow-.

– Visually inspect battery ⇒ page 7 .
– Connect red terminal -2- of battery tester DSS-7814 SET to

battery positive terminal -1-.
– Connect black terminal -4- of battery tester DSS-7814 SET to
battery negative terminal -3-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Connect current clamp -1- to negative wire -2-.
ility
ot p
wit
• Arrow -3- must point in direction of earth node on body.
, is n
h re
hole
– Check starter battery ⇒ Operating instructions of battery tester
spec
DSS-7814 SET .
es, in part or in w
t to the co
Specified torques
♦ Interior trim ⇒ General body repairs, interior; Rep. gr. 70 ;
rrectness of i
Trims, interior .
l purpos
♦ Battery; Assembly overview - battery ⇒ Electrical system;

Rep. gr. 27 ; Battery; Assembly overview - battery
nf
ercia
orm
m
atio
m
2.6.2 Checking second battery - A1- with bat‐

o
n in
or c
tery tester DSS-7814 SET -

thi
te
sd
a
08.78024-0005-
iv
o
r
rp
cu
o
m
f
en
ng

t.
yi Co
Cop py
♦ Battery tester DSS-7814 SET - 08.78024-0005-
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Procedure
– Withdraw ignition key.
– Visually inspect battery ⇒ page 7 .
– Connect red terminal -2- of battery tester DSS-7814 SET to
battery positive terminal -1-.
– Connect black terminal -4- of battery tester DSS-7814 SET to
battery negative terminal -3-.
– Check second battery - A1- ⇒ Operating instructions of battery
tester DSS-7814 SET .
On completion of test
– Disconnect battery tester DSS-7814 SET .
2.7 Current draw Vtest
olks
wage es n
ot g
by ua
ed ran
oris tee
WARNINGauth or
ac
ss
ce
le
It is not permissible to test or charge batteries whose magic

un
pt
an
d
eye shows light yellow. Do not slave/jump start the vehicle!

itte
y li
rm
ab
pe
ility
jump starting.
ot
wit
, is n
h re
hole
spec
es, in part or in w
Note t to the co
rrectness of i
♦ Make sure to set the correct charging mode on the charger so

l purpos
that the current draw test is not falsified.

♦ Battery charger - VAS 5095 A- , ⇒ page 29
nform
ercia
♦ Battery charger - VAS 5900- , ⇒ page 35

m
a
com
tion in

r
te o
thi

s
iva
do
r
rp
cum

fo
en
ng
t.
yi Co
♦ Battery tester DSS-7814 SET , ⇒ page 17 Cop py
ht. rig
rig ht
py by
o Vo
To quickly ascertain the state of discharged batteries, the battery by c lksw
cted agen
current draw test whilst charging helps to determine whether the Prote AG.
battery must be replaced or fully recharged.
Note
For battery tester with printer - VAS 6161- , the current draw test
must always be performed when the test result “Perform current
draw test” appears on the display.
Performing a current draw test whilst charging the battery will

quickly establish whether a partly or fully discharged battery
⇒ page 28 can be recharged to return it to a serviceable condi‐
tion.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
Amarok 2011 ➤ , Amarok 2017 ➤ , Caddy 2004 a➤
ut , Caddy 2011 ➤ , Caddy 2 ... ra
c
s
Electrical system - general information - Edition 01.2019 s
ce
le
un
pt
an
d
itte
Test requirements:
y li
rm
ab
pe
♦ When charging the battery, its temperature must be at least ≥
ility
ot
+10°C.
wit
, is n
h re
hole
♦ The charger must be capable of outputting a charge current of
spec
at least 30 A, as for example with VAS 5095A, VAS 5900, VAS
es, in part or in w
5903
t to the co
♦ The battery's current draw must be measured with a current
pick-up clamp, e.g. VAS 5051B/7, when charging with battery
rrectness of i
charger - VAS 5095A- . Battery charger - VAS 5900- and bat‐
tery charger - VAS 5903- display the current draw on the unit.
l purpos
Battery charger - VAS 5900- performs the current draw test
automatically with menu guidance.
nform
ercia
– Connect battery to battery charger and start charging proce‐
m
dure.
a
com
tion in
– Measure charge current of battery after 5 minutes. te o
r
thi
s
iva
Test result:
do
r
rp
cum
fo
If the current draw A is higher than 10% of the nominal capacity
en
ng
t.
yi
(e.g. > 6.1 A for a 61 Ah battery), fully charge battery and test
Co
op py
again.
t. C rig
gh ht
pyri by
Vo
– Battery is fully charged if charge current is greater than 10%
o
by c lksw
cted agen
of the nominal capacity. Prote AG.
– After 2 hours of battery resting time, perform a battery test

⇒ page 13 .
Renew battery if the charge current, in amperes, lies below 10%
of the rated capacity 5 minutes after the start of charging, (exam‐
ple for a 50 Ah battery < 5A) In the event of warranty and goodwill
gestures, fill out the battery test sheet.
2.8 No-load current measurement

⇒ “2.8.1 General description – no-load current measurement”,
page 20
⇒ “2.8.2 Inline measurement of no-load current”, page 23
⇒ “2.8.3 No-load current measurement on fuses”, page 24
2.8.1 General description – no-load current

measurement
Note
♦ The vehicle must not be de-energised in order to perform a

no-load current measurement (no reset at terminal 30).
♦ Also, for this purpose, do not disconnect the vehicle battery or
remove fuses. Otherwise, if a control unit fault occurs, it would
not be possible to trace it back.
Preparing the no-load current measurement:

– Recharge battery in vehicle for approx. one hour (do not dis‐
connect battery to do so).
– As long as battery is being recharged, read event memory.
– Check control units listed on diagnosis log printout against ac‐
tual equipment of vehicle (PR numbers). Does printout contain
all necessary control units? Control units that are not on the
list may not be in proper operating condition and may therefore
be a starting point for further investigation.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e
Amarok 2011 ➤ , Amarok t2017
ho
ris
➤ , Caddy 2004 ➤ , Caddy 2011 ➤ , nCaddy tee
or
2 ...
u
ssElectrical
a system - general information - Edition 01.2019
ac
ce
le
un
pt
– Determine which auxiliary components are installed, e. g. tow‐
an
d
itte
ing bracket, marten repellent system, radio system, DVD play‐
y li
rm
ab
er, two-way radio etc. If the measurement result shows a
pe
ility
higher no-load current than specified, these units need to be
ot
wit
, is n
checked first.
h re
hole
spec
– Prepare the no-load current measurement. For this purpose,
es, in part or in w
switch off radio TIM according to operating instructions (some
t to the co
radio models have several TIM timers), open all doors, bonnet,
tailgate, etc., close rotary latches, deactivate interior monitor‐
ing system, and enter anti-theft code to lock vehicle.
rrectness of i
– Perform two hour no-load current measurement. Thresholds:
l purpos
Phaeton and Touareg 40 mA, all other vehicles 20 mA. This
threshold applies to the lowest value of the trajectory. Small
peaks of up to 1 A (or up to 8 A for vehicles with air suspension
nform
ercia
or 12 A for Phaeton vehicles) are permissible for a duration of

m
1 second. Please note that such short current peaks may also
a
com
ti
occur when a door handle is touched or remote control key
on in
signals from other vehicles are received. Store the result of
r
te o
thi
long-term measurement.
s
iva
do
r
rp
c
Special note regarding Touareg vehicles: pick-up clamp must be
um
fo
en
g
connected to battery positive wire inside of battery box beneath

n
t.
yi Co
driver seat. Cop py
t. rig
gh ht
yri
As an alternative procedure, the Guided Functions mode of the p by
o Vo
by c lksw
vehicle diagnostic tester can also be used: Prote
cted AG.
agen
– Connect vehicle diagnostic tester ⇒ page 110 .

– On vehicle diagnostic tester , select “Guided Functions” mode.
– Using “GoTo” button, select “Functions/component” and then
the following menu options in succession:
♦ Body
♦ Electrical system
♦ 27 - Starter, current supply
♦ Electrical components
♦ A - battery
The calibration of the pick-up clamp may become lost during the
long-term measurement. The shape of the curve indicates wheth‐
er the specified no-load current is steadily maintained over the
entire period of the long-term measurement.
– In order to confirm the current value obtained in the last meas‐
urement, recalibrate the pick-up clamp, and perform brief
measurement of no-load current anew – this time in multimeter
mode. If the current value obtained from this measurement is
below 500 mA, it is necessary to confirm the measured value
by performing an “inline measurement of no-load current”
⇒ page 23 in order to eliminate the possibility for the meas‐
urement result to have been falsified through the effect of an
external magnetic field or the magnetic charge of the vehicle
body. The final evaluation of the no-load current is, therefore,
only possible after the “inline measurement of no-load cur‐
rent”. Please note that it is essential to ensure that the elec‐
trical circuit is under no circumstances interrupted.
– If the threshold value stated above is exceeded, search for
deviating current paths as described in “No-load current meas‐
urement on fuses” ⇒ page 24 . Please note that it is essential
to ensure that none of the fuses is removed prior to performing
the measurement.
– If a current flow through control units is detected, an additional
no-load current measurement on the CAN bus must be per‐
formed. When doing so, please note that a brief wake-up of
the CAN bus is possible when contact to the bus wiring is n AG. Volkswagen AG do
made. lkswage es n
o ot g
byV ua
– If the fault reason cannot be identified clearly, a technicalrire‐
se
d ran
tee
pair query is to be prepared before the control units are au re‐
tho
or
ac
moved or de-energised. In order to prevent repeat repairs,
ss it
is compulsory to perform a fault diagnosis to find out the true
ce
e
nl
pt
du
reason of the fault.
an
itte
y li
erm
ab
– Using technical product information valid for the respective
ility
ot p
vehicle as well as the update CD for the vehicle diagnostic
wit
tester , check if any components or software versions are in‐
, is n
h re
stalled in the vehicle that might cause battery discharge, and
hole
spec
check if any other faults can be detected.
es, in part or in w
t to the co
In order to determine the reason of an unexplained battery dis‐
charge, it might be helpful to ask the customer for cooperation.
Ask the customer to describe the circumstances under which the
rrectness of i
battery discharge occurs, or if any (recurring) unexpected behav‐
iour of the vehicle could be detected.
l purpos
♦ Duration of parking?
nf
ercia
♦ Time of day?
orm
m
♦ Weather conditions?
atio
om
n in
c
♦ Distance driven before parking? Duration of journey?

or
thi
te
sd
a
♦ Any inclination of vehicle?

iv
o
r
rp
cu
o
m
♦ Doors, windows, tailgate and rear window closed (sequence
f
en
ng
t.
yi
of operating doors, bonnet, tailgate etc.)?
Co
Cop py
t. rig
gh
♦ Lights, parking light, side lights switched on?
ht
pyri by
Vo
co lksw
by
♦ Ignition key removed?
cted agen
Prote AG.
♦ Switched on ignition by mistake when leaving vehicle? (For

vehicles with entry and start authorisation control unit: mes‐
sage in instrument cluster “Press and hold Start button” dis‐
played)?
♦ Function of radio/navigation/telephone system before outage
OK?
♦ Value on voltage display on last journey?
♦ Any problems when starting last time?
♦ Electrical equipment automatic switch-off active on last jour‐
ney (indicator in dash panel insert) (yes/no)?
♦ Any electrical consumers connected to 12-V socket?
♦ Faulty behaviour of any electrical consumers on last journey?
If yes, which ones?
♦ What did the driver do differently from the last time when park‐
ing?
♦ Any accessories installed (marten repellent system, amplifier,
telephone, two-way radio, …)?
♦ Any other conspicuous findings?

Note
♦ Explain to users of accessory radios and Travel Pilot DX4 that

the TIM function must not be permanently operated in 24 h
mode because of high current consumption.
. Volkswagen AG
gen AG
♦ Explain to users of auxiliary heaters that the vehicle must
kswbe
a does
not
Vol
moved sufficiently before and after operation on the
ed byauxiliary gu
ara
heater, as described in the ⇒ Owner's Manualtho. By rule of
ris nte
eo
thumb: do not heat more than you drive. s au ra
c
s
ce
le
un
pt
2.8.2 Inline measurement of no-load current
an
d
itte
y li
erm
ab
Due to the influence of external magnetic fields (vehicle body,
ility
ot p
workshop environment), inaccuracies of several 100 mA may oc‐
wit
is n
cur when measuring no-load current by means of a pick-up clamp.
h re
ole,
spec
For this reason, in order to confirm the result obtained from meas‐
urement with a pick-up clamp, an additional inline current meas‐
t to the co
urement must be performed on the battery earth cable using the
mA measuring range of the vehicle diagnostic tester without in‐
terrupting the circuit.
rrectne
Depending on the wires connected to the battery negative termi‐
nal clamp, two different measurement procedures apply:
ss o
cial p
f
“Measurement procedure 1” applies if battery negative terminal
inform
clamp with only one wire (earth strap) is connected to the battery
mer
negative terminal.
atio
om
n
1 - Black measuring cable to striker pin of door latch
c
i
or
n thi
te
2 - Vehicle diagnostic tester
sd
iva
o
pr
cum
r
3 - Red measuring cable with crocodile clip to battery negative

fo
en
ng
terminal clamp
t.
yi Co
Cop py
.
4 - Connection thread for earth cable to vehicle body
ht rig
rig ht
py by
co Vo
by lksw
cted agen
“Measurement procedure 2” applies if several earth wires are Prote AG.
connected directly to the battery negative terminal in addition to
the earth strap.
1 - Black measuring cable to striker pin of door latch
2 - Vehicle diagnostic tester
3 - Red test probe pressed onto battery negative terminal at front
edge
4 - Connection thread for earth cable to vehicle body
Note
♦ “Measurement procedure 1” is preferable because here it is

not necessary to hold the test probe by hand which eliminates
the risk of slipping off.
♦ If several wires are connected to the battery negative terminal
clamp, the “measurement procedure 2” must be applied, since
otherwise only the current flow through one earth wire will be
measured.
Preparing measurement as per procedures 1 and 2:
– Set vehicle diagnostic tester to “Test Instruments”, “URDI Cur‐

rent Measurement”. It is absolutely necessary to perform this
setting prior to the measurement, since the circuit will other‐
wise be interrupted.
– Pull off black test probe of URDI measuring cable, and extend
measuring cable using extension lead, 4 m - V.A.G 1594/31A-
-3-.
– Secure test probe -2- and crocodile clip of measuring cable -
V.A.G 1594/19- -1- to earth lead extension.
– Attach crocodile clip to door latch (striker pin) -4- from above.
Note
When connecting the measuring cables, ensure that the connec‐

tors are not under tension in order to prevent them from being
. Volkswagen AG
disconnected accidentally. swagen AG does
olk not
yV gu
edb ara
Measurement using methodh1: or
is nte
eo
aut ra
– Connect red test probe
ss of measuring cable to red crocodile c
clip.
ce
le
un
pt
an
d
itte
y li
– Securely attach red crocodile clip -1- to battery negative ter‐
rm
ab
pe
ility
minal clamp, and secure measuring cable against slipping off.
ot
wit
, is n
– Loosen threaded connection -2- of battery earth strap on ve‐
h re
hole
hicle body, and remove battery earth strap.
spec
es, in part or in w
– Read measured value.
t to the co
– After measurement, tighten threaded connections again to
specified torque. rrectness of i
Measurement using method 2:

l purpos
– Loosen securing nut of battery negative terminal clamp, but

do not remove battery negative terminal clamp.
nform
mercia
– Press red test probe -1- firmly onto battery negative terminal
a
com
tio
-2- so that it rests against the front edge.

n in
r
te o
thi
– Carefully lift battery negative terminal clamp -3- until it does

s
iva
do
not make any contact with battery negative terminal. When

r
rp
cum
doing so, it is essential to ensure that the test probe is firmly

fo
en
g
pressed onto battery negative terminal.

n
t.
yi Co
Cop py
– Read measured value. ht. rig
rig ht
py by
o Vo
– After measurement, reconnect battery terminal clamp, and by c lksw
cted agen
tighten threaded connection to specified torque ⇒ Electrical
Prote AG.
system; Rep. gr. 27 ; Disconnecting and connecting battery .
2.8.3 No-load current measurement on fuses

– Print out fuse assignment diagram contained in current flow
diagram in order to note the voltage values.
The following settings must be performed prior to carrying out the
current measurement in order to be able to observe the total no-
load current during the measurement:
♦ Set vehicle diagnostic tester to Multimeter mode.
♦ Calibrate 100 A pick-up clamp, and clamp it to battery negative
cable (if using a 50 A pick-up clamp, note that incorrect meas‐
urements might occur due to a fault in measurement amplifier).

♦ Switch hand-held multimeter - V.A.G 1526 E- to “V =” mode

(direct voltage measurement mode).
♦ Select thin and pointed test probes from auxiliary measuring
set - V.A.G 1594C- , and connect them.
– Hold test probes -1- against both fuse contacts -2-.
– Read measured value in mV, and enter it into fuse assignment
diagram.
– Convert entered measured voltage values into current values
as per table below.
Note
. Volkswagen AG
gen AG d
If the voltage is >Vo50 mV,
lksw
a
the fuse is not working.
oes
not
gy ua
db ran
rise tee
tho or
au ac
ss
Current in mA in terms of measured voltage:
ce
e
nl
pt
du
an
Meas‐ Mini Mini Mini Stand‐ Stand‐ Stand‐ Stand‐ Stand‐ Stand‐
itte
y li
erm
ured val‐ ard ard ard ard ard ard
ab
ility
ue
ot p
wit
, is n
mV 5 7.5 10 5 10 15 20 25 30
h re
hole
spec
0.1 6 10 14 7 13 23 30 47 62
es, in part or in w
t to the co
0.2 12 20 28 13 27 45 61 94 123
0.3 18 30 43 20 40 68 91 141 185
0.4 24 40 57 26 54 91 122 188 246
rrectness of i
0.5 30 50 71 33 67 113 152 235 308

l purpos
0.6 36 60 85 40 80 136 183 281 370

0.7 42 70 99 46 94 158 213 328 431
nf
ercia
orm
0.8 48 80 114 53 107 181 244 375 493

m
atio
m
0.9 54 90 128 59 120 204 274 422 554

o
n in
or c
thi
1.0 60 100 142 66 134 226 305 469 616

te
sd
iva
1.1 66 110 156 73 147 249 335 516 677

r
rp
cu
o
m
f
en
ng
1.2 72 120 171 79 161 272 366 563 739

t.
yi Co
op
1.3 78 130 185 86 174 294 396 610 801
C py
t. rig
gh ht
yri by
1.4 84 140 199 92 187 317 427 657 862
op Vo
by c lksw
cted agen
1.5 Prote
90 150 213 99 201 340 457 704 924
AG.
1.6 96 160 227 106 214 362 487 751 985

1.7 102 169 242 112 228 385 518 797 1047
1.8 108 179 256 119 241 407 548 844 1109
1.9 114 189 270 125 254 430 579 891 1170
2.0 120 199 284 132 268 453 609 938 1232
2.1 126 209 298 139 281 475 640 985 1293
2.2 132 219 313 145 294 498 670 1032 1355
2.3 138 229 327 152 308 521 701 1079 1417
2.4 144 239 341 158 321 543 731 1126 1478
2.5 150 249 355 165 335 566 762 1173 1540
2.6 156 259 369 172 348 589 792 1220 1601
2.7 162 269 384 178 361 611 823 1267 1663
2.8 168 279 398 185 375 634 853 1313 1725
2.9 174 289 412 192 388 656 884 1360 1786
AG. Volkswagen AG d
agen oes
Meas‐ Mini Mini Mini Stand‐
Vol
ksw Stand‐ Stand‐ Stand‐
not
g Stand‐ Stand‐
ured val‐ d by ard ard ard arduaran ard ard
ise
ue ho
r tee
aut or
ac
mV 5 7.5 ss10 5 10 15 20 25 30
ce
le
un
pt
3.0 180 299 426 198 401 679 914 1407 1848
an
d
itte
y li
3.1 186 309 rm 441 205 415 702 944 1454 1909
ab
pe
ility
3.2 192 319 455 211 428 724 975 1501 1971
ot
wit
, is n
3.3 198 329 469 218 442 747 1005 1548 2032
h re
hole
spec
3.4 204 339 483 225 455 770 1036 1595 2094
es, in part or in w
3.5 210 349 497 231 468 792 1066 1642 2156
t to the co
3.6 216 359 512 238 482 815 1097 1689 2217
3.7 222 369 526 244 495 837 1127 1736 2279
rrectness of i
3.8 228 379 540 251 509 860 1158 1782 2340
l purpos
3.9 234 389 554 258 522 883 1188 1829 2402
4.0 240 399 568 264 535 905 1219 1876 2464
nform
ercia
4.1 246 409 583 271 549 928 1249 1923 2525
m
a
com
tio
4.2 252 419 597 277 562 951 1280 1970 2587
n in
r
te o
thi
4.3 258 429 611 284 575 973 1310 2017 2648
s
iva
do
4.4 264 439 625 291 589 996 1341 2064 2710
r
rp
cum
fo
en
4.5 270 449 639 297 602 1019 1371 2111 2772
ng
t.
yi Co
op
4.6 276 459 654 304 616 1041 1401 2158 2833
C py
t. rig
gh ht
yri
4.7 282 469 668 310 629 1064 1432 2205 2895
p by
co Vo
by lksw
cted agen
4.8 288 479 682 317
Prote 642 1086
AG.
1462 2252 2956
4.9 294 488 696 324 656 1109 1493 2298 3018
5.0 300 498 711 330 669 1132 1523 2345 3080
5.1 306 508 725 337 683 1154 1554 2392 3141
5.2 312 518 739 343 696 1177 1584 2439 3203
5.3 318 528 753 350 709 1200 1615 2486 3264
5.4 324 538 767 357 723 1222 1645 2533 3326
5.5 330 548 782 363 736 1245 1676 2580 3387
5.6 336 558 796 370 749 1268 1706 2627 3449
5.7 342 568 810 376 763 1290 1737 2674 3511
5.8 348 578 824 383 776 1313 1767 2721 3572
5.9 354 588 838 390 790 1335 1798 2768 3634
6.0 360 598 853 396 803 1358 1828 2814 3695
6.1 366 608 867 403 816 1381 1858 2861 3757
6.2 372 618 881 409 830 1403 1889 2908 3819
6.3 378 628 895 416 843 1426 1919 2955 3880
6.4 384 638 909 423 857 1449 1950 3002 3942
6.5 390 648 924 429 870 1471 1980 3049 4003
6.6 369 658 938 436 883 1494 2011 3096 4065
6.7 402 668 952 442 897 1517 2041 3143 4127
6.8 408 678 966 449 910 1539 2072 3190 4188
6.9 414 688 981 456 923 1562 2102 3237 4250
7.0 420 698 995 462 937 1584 2133 3284 4311
7.1 426 708 1009 469 950 1607 2163 3330 4373
7.2 432 718 1023 475 964 1630 2194 3377 4434
7.3 438 728 1037 482 977 1652 2224 3424 4496

Meas‐ Mini Mini Mini Stand‐ Stand‐ Stand‐ Stand‐ Stand‐ Stand‐
ured val‐ ard ard ard ard ard ard
ue
mV 5 7.5 10 5 10 15 20 25 30
7.4 444 738 1052 489 990 1675 2255 3471 4558
7.5 450 748 1066 495 1004 1698 2285 3518 4619
7.6 456 758 1080 502 1017 1720 2315 3565 4681
7.7 462 768 1094 508 1030 1743 2343 3612 4742
7.8 468 778 1108 515 1044 1766 2376 3659 4804
7.9 474 788 1123 522 1057 1788 2407 3706 4866
8.0 480 798 1137 528 1071 1811 2437 3753 4927
8.1 486 807 1151 535 1084 1833 2468 3800 4989
8.2 492 817 1165 541 1097 1856 2498 3846 5050
8.3 498 827 1179 548 1111 1879 2529 3893 5112
8.4 504 837 1194 555 1124 1901 2559 3940 5174
8.5 510 847 1208 561 1138 1924 2590 3987 5235
8.6 516 857 1222 568 1151 1947 2620 4034 5297
8.7 522 867 1236 575 1164 1969 2651 4081 5358
8.8 528 877 1251 581 1178 1992 2681 4128 5420
8.9 534 887 agen1265
AG. Volkswag588
en AG
does1191 2015 2712 4175 5482
lksw not
9.0 540 y 897
Vo 1279 594 1204gu 2037 2742 4222 5543
db ara
se n
9.1 546thori 907 1293 601 1218 tee2060
or
2772 4269 5605
u ac
9.2 sa
s552 917 1307 608 1231 2082 2803 4316 5666
ce
le
9.3 558 927 1322 614 1245 2105 2833 4362 5728
un
pt
an
d
itte
9.4 564 937 1336 621 1258 2128 2864 4409 5789
y li
erm
ab
ility
9.5 570 947 1350 627 1271 2150 2894 4456 5851
ot p
wit
is n
9.6 576 957 1364 634 1285 2173 2925 4503 5913
h re
ole,
9.7 582 967 1378 641 1298 2196 2955 4550 5974
spec
9.8 588 977 1393 647 1312 2218 2986 4597 6036
t to the co
9.9 594 987 1407 654 1325 2241 3016 4644 6097
10 600 997 1421 660 1338 2263 3047 4691 6159
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.
3 Charging lkthe
swa
gebattery
es n
o ot g
yV ua
⇒ “3.1 Totally discharged
ise
db batteries”, page 28 ran
r tee
ho
⇒ “3.2 Batterys acharger
ut VAS 5095 A ”, page 29 or
ac
s
⇒ “3.3 Battery charger VAS 5900 ”, page 35
ce
e
nl
pt
du
an
itte
⇒ “3.4 Battery charger VAS 5900 A ”, page 47
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
⇒ “3.8 Midtronics INC 940 battery charger (USA/Canada only)”,
page 78
rrectness of i
⇒ “3.10 Solar charger module VAS 6102A ”, page 83
l purpos
3.1 Totally discharged batteries
nf
ercia
WARNING
orm
m
atio
m

o
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi
Caution
Co
Cop py
t. rig
gh ht
yri by
To prevent damage to the battery or to the vehicle, observe op Vo
by c lksw
notes concerning the battery types ⇒ page 3 . cted agen
Prote AG.
A battery is “completely discharged” if the open-circuit voltage is

less than 11.6 V.
WARNING

jump starting.
Caution
♦ Totally discharged batteries freeze prematurely.

♦ Frozen batteries should no longer be used.

olksw
agen AG
Amarok wag2011
en AG.➤
V
, Amarok 2017
does ➤ , Caddy 2004 ➤ , Caddy 2011 ➤ , Caddy 2 ...
olks not
d by V Electrical gsystem
ua - general information - Edition 01.2019
e ran
ris tee
utho or
a ac
ss
Note
ce
e
nl
pt
du
an
itte
♦ Totally discharged batteries in unregistered vehicles must be
y li
erm
ab
exchanged prior to delivery. Preliminary damage cannot be
ility
ot p
excluded.
wit
, is n
h re
♦ Batteries that have not been used for a long period of time
hole
spec
discharge themselves, e.g. those fitted in stored vehicles.
es, in part or in w
t to the co
♦ In totally discharged batteries, the electrolyte is comprised al‐
most entirely of water because the acid content is so low.
♦ Totally discharged batteries sulphate, that means, the entire
rrectness of i
plate surfaces of the battery harden.
l purpos
♦ If a battery is recharged shortly after it has totally lost its

charge, the sulphation will mostly dissipate.
nf
ercia
o
♦ If these batteries are not recharged, the plates continue to
rm
m
harden and the ability to recharge is reduced. The result of
atio
m
which is a reduction in the battery output.

o
n in
or c
thi
te
sd
a
– Measure no-load current of battery ⇒ page 20 .

iv
o
r
rp
cu
o
m
f
3.2 Battery charger - VAS 5095 A-

en
ng
t.
yi Co
Cop py
⇒ “3.2.1 General description - battery charger VAS 5095 A ”, page
t. rig
gh ht
yri
29
p by
co Vo
by lksw
cted agen
⇒ “3.2.2 Charging battery with battery charger VAS 5095 A ”, page
Prote AG.
30
⇒ “3.2.3 Charging exhaustively discharged battery with battery
charger VAS 5095 A ”, page 31
⇒ “3.2.4 Charging battery in support mode with battery charger
VAS 5095 A ”, page 32
⇒ “3.2.5 Charging battery in trickle charge mode with battery
charger VAS 5095 A ”, page 34
3.2.1 General description - battery charger -

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

The charge current must be read externally using a pick-up
clamp.
♦ Observe operating manual ⇒ Operating manual of the battery
charger - VAS 5095 A- .
The battery charger - VAS 5095- is suitable for charging all 12 V

batteries supplied by Volkswagen.
3. Charging the battery 29

The battery charger charges without peaks in amperage or volt‐

age. This will not adversely effect the on-board electronics. The
battery can remain in the vehicle while it is being charged and
need not be disconnected.
Battery charger - VAS 5095 A-
1 - ON / OFF switch (0 = charger OFF)
2 - Charge current indicator (I > 12 A)
3 - Charge current indicator, battery partially charged > 90%
4 - Trickle charge mode; lights up green when battery is fully
charged
5 - Malfunction indicator
6 - Support mode indicator
7 - Support mode/normal mode changer-over switch
n AG . Volkswage
8 - Charger cable, red terminalks“+”,
wageblack terminal “-” does n
n AG
ol ot g
yV u
9 - Battery type change-over edb switch (on base of charger unit) aran
ris tee
tho or
au ac
3.2.2 Charging battery with battery charger -
ss
ce
le
un
VAS 5095 A-
pt
an
d
itte
y li
erm
ab
ility
ot p
WARNING
wit
is n
h re
ole,

spec
t to the co

rrectne
♦ Battery charger - VAS 5095 A-

ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Caution
Always set battery type 2.4 V/C (volts/battery cell) when charg‐
ing! This applies for all batteries.
Note
The battery must have a temperature of at least 10°C.

WARNING

jump starting.
– Switch off ignition and all electrical equipment and then re‐
move ignition key.
– Check battery type setting on battery type change-over switch
⇒ page 29 . Must be set to 2.4 V/C (volts/battery cell).
– Connect red terminal clamp “+” of charger to positive terminal
of battery.
Note AG. Volkswagen AG d

agen oes
o lksw not
yV gu
♦ On vehicles installed with a start/stop system ised b and battery ara
nte
monitor control unit - J367- , the black tcharger
ho
r terminal clamp eo
“-” must be connected to the body earth.
ss au ra
c
ce
e
♦ If it is connected to the negative terminal of the battery, the

nl
pt
du
battery monitor control unit - J367- will be bridged. This could
an
itte
y li
result in malfunctions in the start/stop system.
erm
ab
ility
ot p
wit
– Connect black terminal clamp “-” of charger to negative termi‐
, is n
h re
nal of battery.
hole
spec
– Switch on charger ⇒ page 29 .
es, in part or in w
t to the co
The charge current indicators ⇒ page 30 -2- and -3- light up yel‐
low. When only the light emitting diode (LED) -3- lights up yellow,
battery is partially discharged (approx. 90%).
rrectness of i
If the green LED also lights up ⇒ page 30 -4-, the charger has
l purpos
switched to trickle charge mode. The battery is fully charged.

– Switch off charger ⇒ page 29 . nf
ercia
orm
– Remove charger terminals from battery terminal clamps.

m
atio
om
n in
c
3.2.3 Charging exhaustively discharged bat‐

or
thi
e
tery with battery charger - VAS 5095 A-

t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi
WARNING
Co
Cop py
t. rig
gh ht
yri
p by
o Vo
by c lksw
regulations ⇒ page 1 ! Prote
cted AG.
agen
The charger unit automatically recognises totally discharged bat‐

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

AG. Volkswagen AG d
agen oes
olksw not
yV gu
Amarok 2011 ➤ , Amarok 2017 ➤ , Caddy 2004is➤ e , Caddy 2011 ➤ , Caddy 2 ...
d b ara
nte
r
Electrical system - general information - Edition
ut 01.2019
ho eo
ra
s a c
s
ce
le
un
pt
an
d
Note
itte
y li
erm
ab
ility
ot p
♦ Follow instructions in chapter
wit
is n
⇒ “3.1 Totally discharged batteries”, page 28 .
h re
ole,
spec
t to the co
excluded.
♦ The battery voltage must be at least 0.6 V.
rrectne
WARNING
ss o
cial p
f in
form
mer
atio
om
n
c
i
or
n
jump starting.
thi
te
sd
va

i
o
pr
cum
r
fo
en
ng
t.
yi Co
op py
– Charge battery ⇒ page 30 . t. C rig
gh ht
pyri by
3.2.4 Charging battery in support mode with

o Vo
by c lksw
cted agen
Prote AG.
battery charger - VAS 5095 A-
Note
To avoid problems when updating or flashing the vehicle soft‐

ware, a charger capable of outputting a charge current of at least
70 A (such as e.g. the “VAS 5903”) should be used.
⇒ page 55
General notes:
The support mode provides the on-board supply with power when
the battery is removed or disconnected.
For further information, refer to ⇒ VAS 5095A operating manual .
The support mode is suitable in the following use cases:
♦ Support mode of on-board supplies without installed battery
♦ Power conservation when renewing the battery
♦ Ancillaries test without battery
WARNING


Electrical
en AG. V
system
olkswagen AG- general information - Edition 01.2019
ag does
ksw not
y Vol gu
b ara
ed
WARNING thoris nte
eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
jump starting.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
move ignition key.
rrectness of i
Caution
l purpos
♦ The terminal polarity protection in operating mode “charg‐

ing totally discharged batteries/support mode” is not ac‐
nf
ercia
o
tive. Connect battery charger terminal clamps correctly to
rm
battery terminals.
m
atio
om
n in
c
♦ It can cause sparks through a short-circuit.

or
thi
te
sd
a
♦ Danger of explosion
iv
o
r
rp
cu
o
m
♦ Ensure charger terminals are fitted securely.
f
en
ng
t.
yi Co
op
♦ Do not press START / STOP button if charger unit cables C py
t. rig
are connected incorrectly. The charger unit may be dam‐
gh ht
pyri by
aged.
o Vo
by c lksw
cted agen
Prote AG.
– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Removing

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

tween the positive terminal clamp of charger and the body
earth.
Also ensure there is no contact between individual battery ter‐
minal clamps.

clamp of vehicle battery.
Note
♦ On vehicles installed with a start/stop system and battery

monitor control unit - J367- , the black charger terminal clamp

nal clamp of vehicle battery.
– Check battery type setting on normal mode/support mode
change-over switch ⇒ page 29 . It must be switched on support
mode.
– Check that connections of charger terminals have correct po‐
larity.

– Switch on charger.
The battery charger starts with support mode.
End battery support mode:
– Switch off charger.
AG . Volkswage
– Disconnect black terminalksw
clamp
agen “-” of charger from
n AG d
oes negative
not
l
terminal clamp of vehicle
by Vo battery. gu
a d ran
ise
– Disconnect red ut
hoterminal clamp “+” of charger from positive e o
r te
terminal clamp
ss
a of vehicle battery. ra
c
ce
e
– Pull out mains plug of charger.

nl
pt
du
an
itte
y li
3.2.5 Charging battery in trickle charge mode
erm
ab
ility
with battery charger - VAS 5095 A-
ot p
wit
, is n
h re
hole
spec
WARNING
es, in part or in w
t to the co
rrectness of i
l purpos
WARNING
nform
ercia

m

at
om
ion
c

in t
or
his
e
jump starting.
at
do
priv

um
for
en
ng
t.
yi Co
Cop py
t. rig
In trickle charge mode the battery charger - VAS 5095 A- ensures
gh ht
pyri by
that the battery is charged correctly and is maintained in fully
co Vo
by lksw
cted
charged condition.
agen
Prote AG.
– Procedure same as for charging battery ⇒ page 30 .
Note
♦ When a battery is being charged in trickle charge mode and

an electrical consumer draws current from the battery, the
battery charger - VAS 5095 A- automatically compensates the
charge.
♦ The trickle charge can be continued for an unlimited period.
♦ The battery is always ready for use.

3.3 Battery charger - VAS 5900-

gen AG
. Volkswagen AG
d a oes
lksw not
⇒ “3.3.1 General description d-bbattery
yV
o
charger VAS 5900 ”, gu
ara
page 35 o
ir se nte
h eo
ut ra
⇒ “3.3.2 Charging battery
ss
a with battery charger VAS 5900 ”, page c
36
ce
e
nl
pt
du
an
⇒ “3.3.3 Charging battery in service mode with battery charger
itte
y li
VAS 5900 ”, page 38
erm
ab
ility
ot p
⇒ “3.3.4 Charging exhaustively discharged batteries with battery
wit
, is n
charger VAS 5900 ”, page 41
h re
hole
spec
es, in part or in w
VAS 5900 ”, page 44
t to the co
rrectness of i
l purpos
VAS 5900-
nform
ercia
WARNING
m
at
om
ion
c
in t
or
his
e
at
do
priv
cum
for
en
ng
t.
yi Co
op py
WARNING t. C rig
gh ht
pyri by
Vo
co
by lksw
cted agen
Prote
AG.

jump starting.

- VAS 5900- . For additional information refer to ⇒ operating in‐
structions for battery charger - VAS 5900- .
Note
♦ The effective charge current can be read directly on this bat‐

tery charger.
♦ Observe operating manual ⇒ Operating manual of the battery
charger - VAS 5900- .

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


VAS 5900-
WARNING

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
WARNING utho eo
ra
s a c
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
jump starting.
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Battery charger - VAS 5900-
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
Note
Prote AG.
move ignition key.
– Plug in mains plug of charger. The last selected type of battery
will appear on display.

– Set battery to respective operating mode with INFO .

In the display the symbol -1- for “standard charge for wet batter‐
ies” or symbol -2- for “standard charge for gel/absorbent glass
mat batteries” will appear.
– Set capacity (Ah) of battery to be charged, using correspond‐
ing button “Up” ↑ or “Down” ↓ .
of battery.
Note


nal of battery.
The charger unit recognises the voltage required for the connec‐
ted battery (6 V, 12 V or 24 V) and initiates the charging sequence
automatically.
At a charge condition of approx. 80 - 85% the battery charger

switches to the “final charge” mode. The fourth bar appears in
display -1-. The battery is ready for use.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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.

At a charge level of 100%, all bars appear on the display.
Note
♦ In the case of battery type “standard charge”, the parallel op‐

eration of electrical consumers while charging is possible. The
charging period will be longer.
♦ The battery charger will switch to trickle charge mode after
about 1-7 hours, depending on type of battery. To achieve a
100% charge, the battery should remain connected for this
period.
Possible faults and fault rectification:

1- Displayed battery voltage is not as per nominal voltage:
olkswagen AG
en AG. V
– Press and hold “Up” ↑ or “Down” ↓olkbutton
swa
g
until charging se‐
does
not
V
quence starts. ed by gu
ara
is nte
or eo
2- Displayed battery voltage
au is not as per nominal voltage –
th ra
charging process hass already started:
s c
ce
e
nl
pt
– Press START / STOP twice.
du
an
itte
y li
erm
– Press and hold “Up” ↑ or “Down” ↓ button until charging se‐
ab
ility
ot p
quence starts again.
wit
, is n
h re
3- Battery charger does not detect a battery when battery volt‐
hole
age is less than 2 V:
spec
es, in part or in w
Display remains unchanged.
t to the co
The battery type and ampere hours (Ah) as set is displayed.
rrectness of i
Ending battery charging sequence:
l purpos
– Press START / STOP .

– Disconnect black terminal clamp “-” of charger from negative
nf
ercia
terminal of battery.
orm
m
atio
– Disconnect red terminal clamp “+” of charger from positive

om
n in
or c
thi
te

sd
iva
o
r
rp
cu
o
m
f
en
ng
3.3.3 Charging battery in service mode with

t.
yi Co
op
battery charger - VAS 5900-
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
WARNING
AG.

Caution
The operating mode “service charge” is not permitted on VW

vehicles as the voltage peaks will damage the on-board elec‐
tronics.
If “service charge” operating mode is used nevertheless, the
battery must be disconnected from the onboard supply.

WARNING

jump starting.
Caution
When charging always set the battery charger to the correct

type of battery ⇒ operating instructions for battery charger -
VAS 5900- !
The “service mode” is suitable for:
♦ Wet batteries where the magic eye allows charging (magic
eye black or green)
AG. Volkswagen AG d
agen o
The operating mode “service charge olks
w (SERV)” is only usedeson
not
yV gu
sulphated batteries. The battery
ed b is charged at a voltage of ara
nte
is
> 14.4 V. This can resultthorin a partial reduction of the sulphated eo
layer. After charging,s always check the colour of the magic eye
au ra
c
before using the battery
s
⇒ page 9 .
ce
le
un
Special tools and workshop equipment required pt

an
d
itte
y li
erm
♦ Battery charger - VAS 5900- ab

ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
Note
te
sd
iva
o
pr
cum

r
fo
en
ng
t.
yi Co
op py
. C rig
ht ht
rig
move ignition key. py by
co Vo
by lksw
cted
– Plug in mains plug of charger. The last selected operating
agen
Prote AG.
mode will appear on display ⇒ page 35 .


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


nal of battery.
The charger unit recognises the voltage required for the connec‐ swa
gen AG
. Volkswagen AG
does
ted battery (6 V, 12 V or 24 V) and initiates the charging sequence y Volk not
gu
automatically. edb ara
ris nt ee
tho or
s au ac
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.

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

the battery charger switches to the “final charge” mode. The fourth
bar appears in display -1-. The battery is ready for use.

agen oes
olksw not
V gu
by
The success of the “service charge” depends on the isedseverity of ara
nte
the sulphation of the battery. ut
hor eo
ra
s a c
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
– Press and hold “Up” ↑ or “Down” ↓ button until charging se‐ ot
wit
quence starts.
, is n
h re
hole
2- Displayed battery voltage is not as per nominal voltage –
spec
charging process has already started:
es, in part or in w
t to the co
rrectness of i
quence starts.
l purpos

nform
ercia

m
a
com
t
The operating mode and ampere hours (Ah) as set are displayed.
ion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng

t.
yi Co
op
terminal of battery. C py
t. rig
gh ht
yri by
op Vo
by c lksw
terminal of battery. cted agen
Prote AG.
3.3.4 Charging exhaustively discharged bat‐

teries with battery charger - VAS 5900-
WARNING

WARNING

jump starting.

Caution

battery terminals.
♦ When charging always set the battery charger to the cor‐
rect type of battery ⇒ operating instructions for battery
charger - VAS 5900- !
♦ Totally discharged battery is not recognised by battery
charger ⇒ page 28 .
♦ Do not press START / STOP button if charger unit cables
aged.
Batteries with a voltage of less than 2 volts will not be recognised

automatically by battery charger - VAS 5900- .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
Note
h re
ole,
spec
t to the co
excluded. rrectne
♦ The battery must have a temperature of at least 10°C.
ss o
cial p
f in
form
mer
move ignition key.

atio
om

n
c
i
or

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.

– Use INFO to set battery to respective operating mode.

– Set capacity (Ah) of battery to be charged using corresponding
button “Up” ↑ or “Down” ↓ .
of battery. gen AG
. Volkswagen AG
d wa oes
olks not
byV gu
ara
ed nte
Note ris
tho eo
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
nal of battery.
– Press START / STOP for approx. 5 seconds. The menu
rrectness of i
“charging totally discharged batteries/support mode” will be
activated.
l purpos
– Press “Up” ↑ or “Down” ↓ button to set appropriate battery

voltage (6 V, 12 V or 24 V).
nform
mercia
a
com
tio
Note
n in
r
te o
thi
s
iva
If a button is not pressed within 5 seconds, the charger will return
do
r
rp
c
to the main menu (select operating mode).
um
fo
en
ng
t.
yi Co
op
– Confirm selected battery voltage with START / STOP .
C py
t. rig
gh ht
pyri by
Then follows the enquiry for "is charger cable terminal polarity
co Vo
by lksw
cted
correct".
agen
Prote AG.

larity.
– Confirm that connections of charger terminal clamps have
correct polarity with START / STOP .
Charger will start charging sequence for totally discharged bat‐
tery.


Note

70 A (such as e.g. the “VAS 5903”) should be used.
⇒ page 55
General notes:
For further information, refer to ⇒ VAS 5900 operating manual .
WARNING
lkswage es n
Danger of injury! Comply with the warningd bnotices
yV
o and safety ot g
ua
regulations ⇒ page 1 ! o
ir se
ran
tee
th or
au ac
ss
ce
e
nl
pt
du
WARNING
an
itte
y li
erm
ab
It is not permissible to test or charge batteries whose magic ility
ot p
eye shows light yellow. Do not slave/jump start the vehicle! wit
, is n
h re
hole

spec
jump starting.
es, in part or in w
t to the co

rrectness of i
l purpos
move ignition key.

nform
ercia
Caution
m
at
om

ion
c

in t
or
his

ate
do
riv
battery terminals.
p
cum
for

en
ng
t.
yi Co
op py
♦ Danger of explosion t. C rig
gh ht
pyri by
♦ Ensure charger terminals are fitted securely.
co Vo
by lksw
cted agen
Prote AG.
aged.
– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Battery;

Removing and installing battery .


Caution

earth.
minal clamps.

Note

battery monitor control unit - J367- will be bridged. This couldswagen AG. Vo
lkswagen AG
does
result in malfunctions in the start/stop system. by
Vol
k not
gu
ara
ed nte
ris
ho eo
– Connect black terminal clamp “-” of charger to negative
au
t termi‐ ra
c
nal clamp of vehicle battery. ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
activated.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
l purpos
nf
ercia
o
rm
m
correct".
atio
om
n in
c

or
thi
e
larity.
t
sd
iva
o
r
rp
cu

o
m
f
en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
c by lksw
cted agen
Prote AG.
terminal clamp of vehicle battery.

AG. Volkswagen AG d
agen oes
ksw
3.3.6 Charging battery in trickle charge mode ol not
y V gu
d b ara
ise
with battery charger - VAS 5900- r nte
tho eo
au ra
ss c
ce
e
nl
pt
du
Note
an
itte
y li
erm
ab
♦ When a battery is being charged in the trickle charge mode
ility
ot p
and an electrical consumer draws current from the battery, the
wit
, is n
battery charger - VAS 5900- automatically compensates the
h re
hole
charge.
spec
es, in part or in w
t to the co
rrectness of i
♦ Observe battery manufacturer's maintenance instructions. l purpos
WARNING
nf
ercia
or
m
m
atio
m
o
n in
or c
thi
te
sd
iva
o
r
rp
cu
WARNING
o
m
f
en
ng
t.
yi Co
op
C py
t. rig
gh
ht
pyri by
Vo
co lksw
by
cted
agen
Prote AG.
jump starting.
When the battery is fully charged the battery charger - VAS 5900-
switches to trickle charge mode.

3.4 Battery charger - VAS 5900 A-

⇒ “3.4.1 General description - battery charger VAS 5900 A ”, page
47
⇒ “3.4.2 Charging battery with battery charger VAS 5900 A ”, page
48
⇒ “3.4.3 Charging totally discharged battery with battery charger
VAS 5900 A ”, page 49
VAS 5900 A ”, page 52
⇒ “3.4.5 Mains supply mode with battery charger VAS 5900 A ”,
page 53

VAS 5900 A-
WARNING


- VAS 5900 A- . For additional information refer to ⇒ operating
wage
instructions for battery
olks charger - VAS 5900 A-
es n.
o
V t gu
by ara
Product characteristics
ris
ed nte
tho eo
♦ Fully
ss
auautomatic charging using the Plug & Charge feature.
ra
c
ce
e
♦ Simple user guidance and maximum operational safety thanks

nl
pt
du
an
to the animated graphical display. All functions and charging

itte
y li
data can be configured, read and are clearly presented on the

erm
ab
display.
ility
ot p
wit
, is n
♦ Automatic pre-selection of battery voltage (6 V, 12 V and 24 V).

h re
hole
spec
♦ Robust and compact housing for flexible use in the workshop.

es, in part or in w
t to the co
♦ Pluggable charging and power supply cables (in different

lengths).
♦ Edge protection for high stability and protection against paint‐
rrectness of i
work damage.
l purpos
♦ For charging or trickle-charging conventional lead-acid, lead-

calcium/silver, or absorbent glass mat batteries (AGM, MF) as
nform
ercia
well as of maintenance-free lead-gel batteries without having

to disconnect the batteries from the vehicle’s electrical system.
m
at
om
io
♦ Can be used on batteries with capacities of 3 to 350 Ah.

n
c
in t
or
his
e
♦ Optional USB interface for software updates of the battery

at
do
riv
charging system ensures a long-term and future-proof use.

p
cum
for
en
g
♦ Based on the active inverter technology.

n
t.
yi Co
op py
♦ Full protection of the vehicle, the onboard electronics and bat‐
. C rig
ht ht
rig
tery thanks to electronics protection, short-circuit protection,
py by
co Vo
electronic inverse polarity protection, safety shut-off and ther‐
by lksw
cted agen
Prote
mal overload protection.
AG.
Applications
♦ Charging: automatic charging and buffering of parallel con‐
sumers during the restricted service time.

♦ Diagnosis and software update: in buffer mode, the parallel

consumers are supplied with power during the diagnosis or
during software updates.
♦ Battery change: in support mode, the user settings in the ve‐
hicle are retained, when the battery is renewed.
♦ In power supply mode, an external power supply without any
support from the battery is provided.
♦ In refresh mode, totally discharged batteries are regenerated.
n AG. Volkswagen A ge G do
swa es n
Operating unit on battery charger
by
Vo-l VAS 5900 A-
k ot g
ua
ed ran
1 - Graphic display ris tee
tho or
au ac
2 - Menu button ss
ce
e
nl
pt
du
3 - Up/Down buttons
an
itte
y li
erm
ab
4 - Stop/start button
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
VAS 5900 A-
l purpos
nf
ercia
o
rm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Sequence of operations
– Connect battery charger - VAS 5900 A- to mains supply.
Charging mode is available as standard once charging unit has
been connected to mains supply.
– Select Ah setting or battery type using Menu button.
– Use Up/Down buttons to enter value (e.g. 100 Ah or wet bat‐
tery type).
– Connect red charging cable from battery charger - VAS 5900
A- to positive terminal of battery.
Battery removed
– Connect black charging cable from battery charger - VAS 5900
A- to negative terminal of battery.
Battery installed in vehicle
A- to dedicated negative jump-start connection with battery in
situ.

Battery charger automatically detects that battery is connected

and starts the charging process after 5 seconds.
If battery voltage was not detected correctly, e.g. in event of ex‐
haustively discharged battery, select battery voltage within 5
seconds as follows:
– Set correct battery voltage using Up/Down buttons.
Note
To prevent damage to the components, always ensure that the

battery voltage is set correctly.
– Confirm selection with Stop/Start button.

If selection window for battery voltage does not appear, battery is
exhaustively discharged. In this case, perform action on exhaus‐
tively discharged battery using battery charger - VAS 5900 A-
⇒ page 49 .
Note
Do not disconnect charging cable during charging. Danger of

damage to plug sockets and connectors.
Ascending bars -1- indicate the charge level of the battery, e.g. 3
bars denote a charge level of 80%.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
Once all 4 bars -1- are displayed permanently, the charge level
ce
le
un
pt
is 100%.
an
d
itte
y li
Battery can remain connected to battery charger - VAS 5900 A-

erm
ab
ility
for as long as necessary.

ot p
wit
is n
If required, interrupt/continue charging process

h re
ole,
spec
– Press Stop/Start button to interrupt charging process.

t to the co
– Press Stop/Start button to continue charging process.

Ending charging process
rrectne
– Press Stop/Start button to end charging process.

s
– Disconnect red charging cable from positive terminal of bat‐

s o
tery.
cial p
f inform
mer
– Disconnect black charging cable from negative terminal of

atio
battery and/or jump-start connection.

om
n
c
i
or
n thi
e
3.4.3 Charging totally discharged battery with

t
sd
iva
o
r

p
cum
r
fo
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
49
cted agen
Prote AG.
3. Charging the battery
Refresh mode serves as a means of charging the battery if ex‐

haustive discharge is likely to have extended over a longer period
of time (e.g.: battery sulphated).
WARNING

WARNING

jump starting.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
Caution aut
ho eo
ra
ss c
ce
le

un
pt

an
d
itte
y li

rm
ab
battery terminals.
pe
ility
ot
wit
, is n

h re

hole
spec
charger - VAS 5900 A- !

es, in part or in w
t to the co

rrectness of i

l purpos
aged.
nform
mercia
Caution
com
tion in
r
te o
thi
The refresh charge mode is not permitted on VW vehicles as

s
iva
the voltage peaks will damage the onboard electronics.

do
r
rp
cum
fo
If refresh charge mode is used nevertheless, the battery must

en
ng
t.
yi
be disconnected from the onboard supply.
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.


Note
♦ Follow instructions in chapter ⇒ page 28 .


– Select refresh mode using Up/Down buttons.
– Select Ah setting or battery type using Menu button.
– Use Up/Down buttons to enter value (e.g. 100 VAh or wet bat‐
AG. olkswagen AG d
tery type). lkswagen oes
n o ot g
yV ua
– Connect red charging cable from ed battery charger - VAS 5900
b ran
ris tee
ut
ho
or
sa ac
– Connect black chargingscable from battery charger - VAS 5900
ce
e
A- to negative terminal of battery.

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
seconds as follows:
es, in part or in w
t to the co
rrectness of i
Note
l purpos

nf
ercia
orm
m

atio
om
n in
c
If selection window for battery voltage does not appear, battery is

or
thi
e
exhaustively discharged with a voltage of under 2 volts. A corre‐

t
sd
iva
sponding warning appears.

o
r
rp
cu
o
m
f
en
ng
If battery charging is still desired despite the battery being ex‐

t.
yi Co
haustively discharged: Cop py
t. rig
gh ht
yri
– Press OK in warning message using Stop/Start button. p by
o Vo
by c lksw
cted agen
– In next selection window that appears, set correct battery volt‐
Prote AG.
age using Up/Down buttons.
Note


Note
Do not disconnect charging cable during charging. Danger of

damage to plug sockets and connectors.
Ascending bars -1- indicate the charge level

agen
AG. Vof
olkthe
swagbattery,
en AG e.g. 3
does
bars denote a charge level of 80%.
Volksw not
g y ua
db ran
rise tee
tho or
s au ac
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
Once all 4 bars -1- are displayed permanently, the charge level
is 100%.
rrectness of i
Battery can remain connected to battery charger - VAS 5900 A-
l purpos
for as long as necessary.

If required, interrupt/continue refresh charging process
nform
ercia
– Press Stop/Start button to interrupt charging process.

m
at
om
– Press Stop/Start button to continue charging process. ion

c
in t
or
his
e
Ending refresh charging process

at
do
priv
– Press Stop/Start button to end charging process.

um
for
en
ng
t.
yi
Co
Cop py
tery.
t. rig
gh ht
pyri by
Vo
o
– Disconnect black charging cable from negative terminal on
c by lksw
cted agen
battery. Prote AG.

Backup power supply mode serves exclusively as a means of re‐

lieving the load on the battery during diagnosis or a software
update on the vehicle. Over a longer period of time, the consumed
current must be lower than the maximum output current of the
charging unit as otherwise the battery will discharge. Backup
power supply mode is not suitable for fully charging the battery.

– Select backup power supply mode using Up/Down buttons.
A- to dedicated negative jump-start connection.
seconds as follows:
Note


If selection window for battery voltage does not appear,AG. Volbattery isG
kswagen A
exhaustively discharged with a voltage ofounder agen
2 volts. In this does no
lksw
case, backup power supply mode is not d b permissible. Replace‐
yV t gu
ara
ment of the battery is recommended. orise nte
e th or
s au ac
s
ce
le
Note
un
pt
an
d
itte
y li
erm
Do not disconnect charging cable during backup power supply. ab

ility
Danger of damage to plug sockets and connectors.
ot p
wit
is n
h re
ole,
If required, interrupt/continue backup power supply

spec
– Press Stop/Start button to interrupt backup power supply.

t to the co
– Press Stop/Start button to continue backup power supply.

rrectne
Ending backup power supply

– Press Stop/Start button to end backup power supply.
ss o

cial p
f in
tery.
form
mer
atio
– Disconnect black charging cable from negative jump-start con‐

om
nection.
n
c
i
or
n thi
e
3.4.5 Mains supply mode with battery charger

t
sd
iva
o
pr
- VAS 5900 A-
um
r
fo
en
ng
t.
yi Co
Special tools and workshop equipment required Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen
Amarok 2011 ➤ , Amarok ksw 2017 ➤ , Caddy 2004
agen AG do
es n ➤ , Caddy 2011 ➤ , Caddy 2 ...
Vol ot g
Electrical system
d b- general information - Edition 01.2019
y ua
ra
e nte
ris
tho eo
♦ Battery chargers a-u VAS 5900 A- 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
Mains supply mode serves as a means of supplying power to the

electronics in the vehicle when the battery is removed. Since only
nf
ercia
the battery cables of the vehicle are connected to the battery
orm
charger - VAS 5900 A- , the battery voltage detection function is
m
atio
m
not available.
o
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
– Select mains supply mode using Up/Down buttons.

t.
yi Co
Cop py
t.
– Set vehicle electrical system voltage with Menu button.
rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note

vehicle electrical system voltage is set correctly.

A- to positive battery cable of vehicle.
A- to negative battery cable of vehicle.
Caution

earth.
minal clamps.
– Start mains supply mode with Stop/Start button.

A security question appears on the display to determine whether
the charging cables are connected correctly.
– Confirm security question with Stop/Start button and start
external power supply of vehicle electronics.
Ending mains supply mode
– Press Stop/Start button to end mains supply mode.
– Disconnect red charging cable from positive battery cable of
vehicle.
– Disconnect black charging cable from negative battery cable
of vehicle.


⇒ “3.5.1 General description - battery charger VAS 5903 ”,
page 55
⇒ “3.5.2 Charging battery with battery charger VAS 5903 ”, page
56
⇒ “3.5.3 Charging battery in refresh charge mode with battery
⇒ “3.5.4 Charging totally discharged battery with battery charger
VAS 5903 ”, page 61
VAS 5903 ”, page 64

VAS 5903-
WARNING

WARNING

jump starting. G. Volkswagen nA AG do
wage es n
yV
olks ot g
ua
b
ed ran
oris tee
th or
au
This chapter describes
ss the basic
functions of the battery charger ac
- VAS 5903- . For additional information refer to ⇒ operating in‐
ce
e
nl
pt
du

an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
hole
Observe operating manual ⇒ Operating manual of the battery

spec
charger - VAS 5903- .

es, in part or in w
t to the co

rrectness of i

l purpos
1 - Display
nform
ercia
2 - Adjustment button “Up” ↑

m
at
3 - Adjustment button “Down” ↓

om
ion
c
in t
r
4 - START / STOP
o
his
ate
do
riv
5 - INFO
p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

wage
3.5.2 Charging battery with battery charger - lks es n
o ot g
byV ua
VAS 5903-
d ran
ir se tee
tho
u or
a ac
ss
ce
le
WARNING
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
WARNING
t to the co
rrectne
jump starting.
ss o
cial p
f
inform
mer
atio
om
n
c
i
or
n thi
e

t
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.
Note
move ignition key.


In the display the symbol -1- for “standard charge for wet batter‐
ies” or symbol -2- for “standard charge for gel/absorbent glass
mat batteries” will appear.
of battery.
Note
On vehicles installed with start/stop system and battery monitor

control unit - J367- , the black charger terminal clamp - must be
connected to the body earth. Connecting it to the negative termi‐
nal of the battery will cause start/stop system to malfunction. wagen AG. Volkswagen AG doe
ks s no
Vol t gu
d by ara
– Connect black terminal clamp “-” of charger to negative
ris
e termi‐ nte
nal of battery. utho eo
ra
a c
ss
ce
le
un
pt
an
d
itte
automatically.
y li
rm
ab
pe
ility
ot
At a charge condition of approx. 80 - 85% the battery charger
wit
, is n
switches to the “final charge” mode. The fourth bar appears in
h re
hole
display -1-. The battery is ready for use.
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.

Note
♦ In the case of battery type “standard charge”, the parallel op‐

eration of electrical consumers while charging is possible. The
charging period will be longer. n AG. Volkswagen AG do
lkswage es n
o ot g
yV
♦ The battery charger will switch to trickle charge mode after
ir se
d b ua
ran
about 1-7 hours, depending on type of battery. To achieve
tho a tee
or
100% charge, the battery should remain connected ss
afor
u
this ac
period.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
quence starts.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
quence starts again.

nform
ercia

m
at
om
i
on
c
in t
or
The battery type and ampere hours (Ah) as set is displayed.
his
ate
do
riv

p
cum
for
en
ng
t.
– Press START / STOP . Cop
yi Co
py
t. rig
gh ht
pyri by
co Vo
by lksw
cted agen
Prote AG.
3.5.3 Charging battery in refresh charge

mode with battery charger - VAS 5903-
WARNING

WARNING

jump starting.

Caution
The operating mode “refresh charge” is not permitted on VW

vehicles as the voltage peaks will damage the onboard elec‐
tronics.
If “refresh charge” operating mode is used nevertheless,n Athe
G. Volkswagen AG d
lkswage
battery must be disconnected from the onboard supply. oes
not
Vo gu
by ara
ed nte
oris eo
th
au ra
c
ss
Caution
ce
le
un
pt
an
d
itte
When charging always set the battery charger to the correct
y li
rm
ab
type of battery ⇒ operating instructions for battery charger -
pe
ility
VAS 5903- !
ot
wit
, is n
h re
The “refresh charge” mode is suitable for:
hole
spec
♦ Wet batteries, where distilled water can be replenished.
es, in part or in w
t to the co
Do not use operating mode “refresh charge” with maintenance-
free wet batteries.
rrectness of i
l purpos
The “refresh charge (refr)” operating mode is only used on bat‐

teries presumed to be defective (e.g. sulphation). The battery will
be charged to maximum specific gravity and the plates will be
nform
ercia
reactivated (dissipation of sulphur layer).

m
a
com
t
ion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
move ignition key.


In the display the symbol -1- for “refresh charge for wet batteries”
or symbol -2- for “refresh charge for gel/absorbent glass mat bat‐
of battery.
Note

nal of the battery will cause start/stop system to malfunction.

nal of battery.
automatically.
olkswagen AG
en AG. V
At a charge condition of approx. 80 - 85% of the battery ovoltage,
ksw
ag does
not
V l
the battery charger switches to the “final charge” mode.ed
b The fourth
y gu
ara
bar appears in display -1-. The battery is ready for
ho
risuse. nte
eo
t
au ra
c
ss
ce
le
Note
un
pt
an
d
itte
y li
rm
ab
The success of the “refresh charge” depends on the severity of
pe
ility
the sulphation of the battery.
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
quence starts. rrectness of i
l purpos

nform
ercia

m
a
com
quence starts.
ion in
r
te o

thi
s
iva

do
r
rp
cum
fo

en
ng
t.
yi Co
op
The operating mode and ampere hours (Ah) as set are displayed. C py
t. rig
gh ht
yri
p by
o Vo
by c lksw
cted agen
Prote AG.


AG. Volkswagen AG d
agen oes
olksw not
yV g
Amarok 2011 s➤ ed , Amarok 2017 ➤ , Caddy 2004 ➤ u,aCaddy
b ran 2011 ➤ , Caddy 2 ...
ri tee
tho Electrical system - general information
o - Edition 01.2019
au ra
c
ss
3.5.4 Charging totally discharged battery with
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
WARNING
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
WARNING
l purpos

nform
ercia

m
at
om
jump starting.
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Caution Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
ing totally discharged batteries/support mode” is not ac‐ Prote AG.
battery terminals.
charger - VAS 5903- !
aged.


Note

excluded.
move ignition key.
AG. Volkswagen
– Plug in mains plug of charger.
wage The last selecteddoperating
n AG o
es n
olks
mode will appear ond bdisplay
y V ⇒ page 55 . ot g
ua
e ran
ris tee
utho 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.


of battery.
Note

nal of the battery will cause start/stop system to malfunction.

nal of battery.
“charging totally discharged batteries/support mode” will be n AG. Volkswagen AG do
activated. olkswage es n
o V t gu
by ara
– Press “Up” ↑ or “Down” ↓ button to set appropriateise battery
d
nte
or
voltage (6 V, 12 V or 24 V). au
th eo
ra
ss c
ce
le
un
pt
Note
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
correct".
rrectne
larity.
s
s o
cial p
f
inform
mer
Charger will start charging sequence for totally discharged bat‐

atio
tery.
om
n
c
i
or

thi
te
sd
va

i
o
pr
cum
r
fo
en
ng

t.
yi Co
op
terminal of battery. C py
t. rig
gh ht
yri
p by
co Vo
by lksw
terminal of battery. Prote
cted AG.
agen


Note
A charger with a charge current of at least 70A is required if the

software is updated or flashed in a vehicle to prevent problems
during updating and flashing.
General notes:
For further information, refer to ⇒ VAS 5903 operating manual .
WARNING
swage es n
Danger of injury! Comply with the warning notices and safety byV
olk ot g
ua
regulations ⇒ page 1 ! ir se
d ran
tee
tho
u or
a ac
ss
ce
e
nl
pt
du
WARNING
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
jump starting.
es, in part or in w
t to the co
rrectness of i
move ignition key.
l purpos
nf
Caution
ercia
orm
m
atio

om
n in

or c
thi

te
sd
a
battery terminals.
iv
o
r
rp
cu
o

f
en
ng
t.
yi Co
op
♦ Danger of explosion
C py
t. rig
gh ht
yri by
♦ Ensure charger terminals are fitted securely. cop Vo
by lksw
cted agen
Prote
AG.

aged.


Electrical
gen AG
. Vsystem
olkswage-ngeneral
AG d information - Edition 01.2019
wa oes
olks not
byV gu
ara
ed nte
ris
Caution tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
earth.
y li
erm
ab
ility
ot p
wit
minal clamps. , is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Note
l purpos

nform
ercia

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
or

f
en
ng
t.
nal clamp of vehicle battery.
yi Co
Cop py
t. rig
– Press START / STOP for approx. 5 seconds. The menu gh ht
pyri by
co Vo
by lksw
cted
activated.
agen
Prote AG.

Note


correct".
larity.


with battery charger - VAS 5903-
Note
♦ When a battery is being charged in the trickle charge mode

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

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or
WARNING aut
h eo
ra
ss c
ce
le

un
pt
an
d
itte
y li
rm
ab
pe
ility
jump starting.
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
When the battery is fully charged the battery charger - VAS 5903-
switches to trickle charge mode.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.


page 67
67

VAS 5906-
Battery charger - VAS 5906- has been specially developed for
charging in vehicle on-board supply during vehicle presentation.
It has an automatic charging characteristic for starter batteries, 3
to 300 AH.
The maximum charging voltage 14.4 V is not exceeded. All elec‐
trical loads are supported by up to 30 A by the trickle charging.
For sustained operation, battery charger - VAS 5906- changes to
trickle charging once battery - A- is fully charged.
The battery charger - VAS 5906- starts fully automatically and
does not require any settings. All that is required is to connect
terminal clamps and mains cable.
For additional information, refer to ⇒ Operating instructions for
battery charger - VAS 5906- .
Overview - controls
1- Charge level display 25%
2- Charge level display 50%
wage es n
3- Charge level displayolks
y V 75%
ot g
b ua
ed ran
4- Charge level
tho
rdisplay
is 100% tee
or
au ac
5- Display ready
ss
ce
e
nl
pt
6- START/STOP button and Setup button for interrupting and

du
an
itte
y li
resuming charging process. Used to enter the Setup menu

erm
ab
and select type of characteristic (press for 10 seconds)

ility
ot p
wit
7- Malfunction display.
, is n
h re
hole
spec

es, in part or in w
t to the co
VAS 5906-
rrectness of i
Note
l purpos

nf
ercia
70 A (such as e.g. the “VAS 5903”) should be used. ⇒ page 55

rm
m
atio
om
n in
or c
thi
WARNING
te
sd
iva
o
r
rp
cu

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

WARNING
Do not test or charge batteries - A- whose magic eye is »col‐

ourless/light yellow«. Do not slave/jump start the vehicle!
jump starting.
These batteries - A- must be replaced.

Procedure
– Switch off ignition and all electrical consumers, and withdraw
ignition key.
– Place charger - VAS 5906- in engine compartment or under
vehicle. . Volkswag AG en AG
agen do
– Connect battery charger
yV
w es n
olks - VAS 5906- to mains supply.
ot g
b ua
ed ra
Battery charger h-orVAS
is 5906- is in no-load operation - “ready”
nte in‐
eo
dicator is on.s aut ra
c s
– Connect red terminal clamp (+) to positive terminal of battery
ce
e
nl
pt
du
- A- .
an
itte
y li
erm
ab
ility
ot p
Note
wit
, is n
h re
hole
In vehicles with start/stop function and battery monitor control unit

spec
- J367- fitted, the black terminal clamp (-) must be connected to

es, in part or in w
t to the co
body earth. Connecting it to the negative terminal of the battery's

- A- will cause start/stop system to malfunction.
rrectness of i
– Connect black terminal clamp (-) to negative terminal of bat‐

tery - A- /negative connection point.
l purpos
Charging starts after approximately 2 seconds.

nform
ercia
Number of LEDs lit indicates charge level of battery - A- . Battery

- A- has been charged up once all lights are lit.
m
at
om
ion
c
When battery - A- is fully charged, battery charger - VAS 5906-

in t
or
automatically switches over to trickle charging.

his
ate
do
priv
cum
or
Caution
f
en
ng
t.
yi Co
Cop py
Danger of sparking if charging terminals are removed too soon.
t. rig
gh ht
yri by
Terminate charging by pressing START/STOP button. cop Vo
by lksw
cted agen
Prote AG.

Ending battery - A- charging process

– Press START/STOP button.
– Remove charger terminals from battery terminal clamps.
– Disconnect battery charger - VAS 5906- from mains supply.

page 69
⇒ “3.7.2 Auto mode on battery charger VAS 5908 ”, page 70
72
VAS 5908 ”, page 74
⇒ “3.7.5 VAS I-CHECK current draw test with battery charger VAS
5908 ”, page 75
3.7.1 General description

swage
n AG. Volk-sw
battery
agen AG charger -
does
VAS 5908- olk not
y V gu
d b ara
e is nte
or
Battery chargerau-thVAS 5908- has the following operating modes:
eo
ra
ss c
♦ AUTO MODE , trickle charge with automatic load detection (bat‐ ce
le
un
pt
tery or electrical consumer) ⇒ page 70 an
d
itte
y li
erm
♦ CHARGE MODE , battery charging with adjustable parameters

ab
ility
⇒ page 72
ot p
wit
is n
♦ EPS MODE , external power supply (support mode)

h re
ole,
⇒ page 74
spec
♦ I-CHECK , current draw test with short circuit test between cells
t to the co
⇒ page 75
Technical data
rrectne
♦ Input voltage: 100-240 VAC

ss
♦ Output voltage: 14.4 VDC (13.2 VDC with trickle charge)

o
cial p
f inform
♦ Charge current: 90 A (max. 105 A)

mer
atio
♦ Weight: 8.2 kg
om
n
c
i
or
Replacement parts
thi
te
sd
va
♦ Charger cable 5 m - VAS 5908/1-

i
o
pr
cum
r
fo
en
♦ Charger coupling - VAS 5908/2-

ng
t.
yi Co
op py
For additional information, refer to ⇒ Operating instructions for t. C rig
gh ht
battery charger - VAS 5908- . pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen o
Amarok 2011 ➤ , VAmarok olks
w
2017 ➤ , Caddy 2004 es n
ot➤
gu
, Caddy 2011 ➤ , Caddy 2 ...
by
Electrical system
rised - general information - Edition 01.2019
ara
nt ee
tho or
au ac
Equipment overview
ss of battery charger - VAS 5908-
ce
le
un
1 - “ON/OFF” mains switch
pt
an
d
itte
y li
2 - Mains cable connection
erm
ab
ility
ot p
3 - ▲ button for menu selection
wit
is n
h re
ole,
4 - ENTER button for menu selection or start
spec
5 - ▼ button for menu selection
t to the co
6 - Battery charger clamp connection + (red clamp)
rrectne
7 - Battery charger clamp connection - (black clamp)
8 - RS232 communication interface, 9-pin
ss o
9 - Signal interface, 25-pin
cial p
f inform
10 - Display for menu selection
mer
atio
m
11 - LED display for displaying operating and equipment status

o
n
c
i
or
n thi
LED display -11-
te
sd
iva
o
r
The LED display on the front of the equipment serves to indicate

p
cum
r
fo
the operating and equipment statuses. The relevance of the flash‐
en
ng
t.
yi
ing or lit green, amber or red LEDs in the various operating
Co
op py
statuses is listed in a table ⇒ Operating instructions battery
t. C rig
gh ht
yri
charger - VAS 5908- , 8) Attachment for LED and remote indicator p by
co Vo
signals .
by lksw
cted agen
Prote AG.
Equipment menu
In the equipment menu, various parameters and basic settings
can be predefined to safeguard measured values and determine
the activation and deactivation behaviour of the battery charger -
VAS 5908- .
– Switch on battery charger - VAS 5908- .
– Using buttons ▲▼ , choose menu line »MENU« and confirm
with ENTER button.
– Using buttons ▲▼ , choose sub-menu »EQUIPMENT MENU«
and confirm with ENTER button.
For further information about the equipment menu, see ⇒ Oper‐
ating instructions for battery charger - VAS 5908- .
3.7.2 Auto mode on battery charger - VAS

5908-
»AUTO MODE« serves to maintain the voltage in the vehicle
electrical system (trickle charge) during flashing or diagnostic
work. In »AUTO MODE«, the battery charger - VAS 5908- auto‐
matically detects whether a battery or an electrical consumer with
resistive load is connected by means of integrated load detection.

Starting supply process
Note
If the charger clamps are connected to an electrical consumer or

battery before the charger is switched on, the battery charger -
VAS 5908- starts trickling charging in »AUTO MODE« automati‐
cally once it is switched on.

– Using buttons ▲▼ , choose AUTO MODE and confirm with EN- . Volkswage
AG n AG d
TER button. lksw
agen oes
n
Vo ot g
by ua
– Connect red terminal clamp “+” to positive terminal
ris
ed of vehicle ran
tee
battery. ut
ho or
a ac
ss
ce
e
nl
pt
du
Note
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
– On vehicles with start/stop system, fit the black charger clamp
“-” to body earth.
l purpos
– On vehicles without start/stop system, fit the black charger

clamp “-” to the negative terminal of the vehicle battery.
nform
ercia
OR
m
at
om
io
– Fit the charger clamps with correct polarity to an electric con‐

n
c
in t
r
sumer with resistive load.

o
his
ate
do
riv
– Using buttons ▲▼ , choose menu START and confirm with EN-

p
cum
or
TER button to start the supply.

f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
Note py by
co Vo
by lksw
cted agen
Prote AG.
The battery charger - VAS 5908- adapts the current and voltage
thresholds automatically for auto mode.
Ending supply process

– Using buttons ▲▼ , choose menu STOP and confirm with EN-
TER button to stop the supply.

– Switch off battery charger - VAS 5908- .

– Disconnect black charger clamp “-” of battery charger from
negative terminal of vehicle battery or electrical consumer.
– Disconnect red charger clamp “+” of battery charger from pos‐
itive terminal of vehicle battery or electrical consumer.

VAS 5908-
WARNING

WARNING
Do not test or charge batteries - A- whose magic eye is »col‐

ourless/light yellow«. Do not slave/jump start the vehicle!
jump starting.
Note
♦ Follow instructions in chapter »Exhaustively discharged bat‐

teries« ⇒ page 28 .
♦ Totally discharged batteries in unregistered vehicles must be . Volkswagen AG
exchanged prior to delivery. Preliminary damage cannot be ksw
agen
AG does
excluded. by
Vol not
gu
ara
d
ise nte
♦ The battery must have a temperature of at least t10°C.
ho
r eo
u ra
sa c
♦ The minimum voltage “Uesp” of the battery to be
s charged must
ce
le
be at least 5 V.
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
Charging battery
s
iva
do
r
rp
cum
fo
move ignition key.

en
ng
t.
yi Co
op
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
72
cted agen
Prote
Rep. gr.27 - Starter, current supply, CCS
AG.
– Connect red terminal clamp “+” to positive terminal of vehicle

battery.
Note


clamp “-” to the negative terminal of the vehicle battery.
– Using buttons ▲▼ , choose CHARGE MODE and confirm with
ENTER button.
Note
AG. Volkswagen AG d
agen oes
lksw not
♦ The battery charger - dVAS by
V 5908- adapts the current and
o gvolt‐
ua
age thresholds automatically
orise for charge mode. ran
tee
th or
u
♦ Predefine different
ss
a current and voltage thresholds in the ac
charging menu if necessary ⇒ page 73 .
ce
e
nl
pt
du
an
itte
y li
Ending battery charging process

erm
ab
ility
ot p
– Switch off battery charger - VAS 5908- .

wit
, is n
h re
– Disconnect black charger clamp “-” of battery charger from

hole
spec
negative terminal of vehicle battery.

es, in part or in w
t to the co

itive terminal of vehicle battery.
rrectness of i
l purpos
Note
nf
ercia
For sustained operation, the battery charger - VAS 5908- auto‐

rm
m
matically changes to trickle charging once the battery is fully

atio
m
charged.
o
n in
or c
thi
te
sd
a
Charging menu
iv
o
r
rp
cu
o
The battery charger adapts the current and voltage thresholds

f
en
ng
t.
yi
automatically for charge mode. The parameters for charging
Co
op py
mode can also be set manually.
. C rig
ht ht
rig by
py
co Vo
by lksw
cted agen
with ENTER button. Prote AG.
– Using buttons ▲▼ , choose sub-menu »CHARGING MENU«

and confirm with ENTER button.
For further information about the charging menu, see ⇒ Operating
instructions for battery charger - VAS 5908- .


Support or backup mode (»EPS MODE«, external power supply)
serves to supply the vehicle electrical system with power if the
battery is disconnected or removed.
AG. Volkswagen AG d
agen oes
Note yV
olksw not
gu
d b ara
ise nte
r
A charger with a charge current
ut
ho of at least 70 A is required if the eo
ra
software is updated or sflashed in a vehicle to prevent problems
s a c
during updating and flashing.
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
Caution
rrectness of i
In »EPS MODE«, only a resistive load (electrical consumer)
l purpos
may be supplied.
»EPS MODE« may not be used if a battery is connected.
nf
ercia
or
Before using »EPS MODE«, disconnect or remove the battery.
m
m
atio
om
n in
or c
thi

te
sd
iva
o
r
rp

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

move ignition key.
– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Removing
and installing battery .
Caution
Make absolutely sure that the red charger clamp does not
come into contact with the body earth.
Make absolutely sure that the battery terminal clamps do not
come into contact with each other.


Note


clamp “-” to the negative terminal clamp of the vehicle battery.
Note
♦ The battery charger - VAS 5908- adapts the current and volt‐
age thresholds automatically for support mode.
♦ Predefine different current and voltage thresholds in the EPS
menu if necessary ⇒ page 75 . AG. Volkswagen AG d
agen oes
olksw not
yV gu
– Using buttons ▲▼ , choose EPS sMODE
i ed b and confirm with EN- ara
nte
TER button. or eo
h
aut ra
s c
Ending backup power supply s
ce
le
un
– Switch off battery charger - VAS 5908- . pt

an
d
itte
y li
erm
– Disconnect black charger clamp “-” of battery charger from ab

ility
ot p
negative terminal clamp of vehicle battery. wit

is n
h re
ole,
spec
itive terminal clamp of vehicle battery.

t to the co

EPS menu
rrectne
The battery charger adapts the current and voltage thresholds

automatically for support mode. The parameters for support mode
s
can also be set manually.

s o
cial p

inform
with ENTER button.

mer
atio
m
– Using buttons ▲▼ , choose sub-menu »EPS MENU« and con‐

o
n
c
i
or
firm with ENTER button.

thi
te
sd
va
For further information on the EPS menu, see ⇒ Operating in‐

i
o
pr
cum
r

fo
en
ng
t.
yi Co
3.7.5 VAS I-CHECK current draw test with Cop py
t. rig
gh ht
battery charger - VAS 5908- pyri by
Vo
o
by c lksw
cted agen
Prote
The current draw test serves as a means of quickly appraising the
AG.
condition of a discharged battery. Based on the result of the cur‐

rent draw test, it is possible to determine whether the battery must
be renewed or fully charged.

Note
For the battery current draw test, take measures to ensure that
the battery is testing without electrical consumers attached in
parallel.

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
Perform current draw test pt

du
an
itte
y li
– Disconnect both battery terminal clamps so as not to falsify the
erm
ab
ility
result from electrical consumers within the vehicle ⇒ Electrical
ot p
system; Rep. gr. 27 ; Battery; Disconnecting and connecting

wit
, is n
h re
battery .
hole
spec
– Switch on battery charger - VAS 5908- and connect to battery

es, in part or in w
t to the co
with correct polarity using charger clamps.

– Using buttons ▲▼ , choose menu line »AUTO MODE« and
confirm with ENTER button (display flashes).
rrectness of i
– Using buttons ▲▼ , choose I-CHECK and confirm with ENTER

l purpos
button.
– Activate battery capacity input »Qbat:« by pressing ENTER
nf
ercia
or
button (flashes).
m
m
atio
m
– Using buttons ▲▼ , set capacity (Ah) of battery to be tested and

o
n in
or c
confirm with ENTER button.

thi
te
sd
iva
– Using buttons ▲▼ , choose menu line »TEST START« and

o
r
rp
cu
o
confirm with ENTER button to start the current draw test. Note
f
en
ng
t.
yi
possible connection error messages ⇒ page 77 .
Co
Cop py
t. rig
gh
While current draw test is running, »TEST« flashes in display.
ht
pyri by
Button lock is activated, active test can only be interrupted by re‐
co Vo
by lksw
cted agen
moving charger clamps. Note possible abort error messages Prote AG.
⇒ page 77 .
End of test with result 'Current draw I less than 100%' (battery
defective)
If the current draw »I« is <100% at the end of the test, the current
supply to the battery is interrupted and »FILL IN WARRANTY
APPLICATION« appears in the display.
– Using buttons ▲▼ , choose »OK« and confirm with ENTER but‐
ton to display the test results.
The current draw percentage is displayed in the results windows
under »I«. The displayed data can be copied over to the battery
test sheet.
– Using buttons ▲▼ , choose »TEST END« and confirm with
ENTER button to stop the current draw test.

End of test with result 'Current draw I greater than 100%' (battery
in order but insufficiently charged)
If the current draw »I« is >100% at the end of the test, the current
supply to charge the battery is continued.
– Using buttons ▲▼ , choose »RESULT« and confirm with EN-
TER button to display the test results.
The current draw percentage is displayed in the results windows

under »I«.
– Using buttons ▲▼ , choose »OK« or »TEST END« and confirm
with ENTER button to change to “I-Check charge mode” and
continue charging the battery.
In I-Check charging mode, »CHARGING« flashes in the display
until the battery is fully charged. Once the charging process is
complete, the equipment switches automatically to trickle charge.
»TRICKLE« flashes in the display.
Note
♦ While the battery is being charged in “I-Check charging mode”,

the short circuit between cells test is automatically active.
♦ When the short circuit between cells test is active, the battery
charge is interrupted twice for approx. 30 seconds in order to
perform a voltage measurement.
♦ If the short circuit between cells test is positive, the charging
process is interrupted and »CELL SHORT CIRCUIT« is dis‐
played.
Connection error messages

♦ »APPLICATION ERROR - CONTACT« = no battery detected
. Volkswagen AG
and no battery connected. swa
gen AG does
k not
Vol gu
♦ »APPLICATION ERROR - POLARITY ed REVERSAL« = battery
by ara
nte
oris
was connected with polarity reversal. eo
th
au ra
♦ »APPLICATION ERROR - EXHAUSTIVE
ss DISCHARGE« = c
ce
e
voltage level of connected battery is below the activation volt‐

nl
pt
du
age limit (Uesp) as defined in the charging menu.

an
itte
y li
erm
ab
Abort error messages

ility
ot p
wit
♦ »APPLICATION ABORT - CONTACT« = battery was discon‐

, is n
h re
nected during the test.

hole
spec
♦ »APPLICATION ABORT - SHORT CIRCUIT« = short circuit

es, in part or in w
t to the co
determined in battery cables.

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

3.8 Midtronics INC 940 battery charger

(USA/Canada only)
⇒ “1.2 Warning notices and safety regulations”, page 1
⇒ “3.8.1 General description of Midtronics INC 940 battery charg‐
. Volkswagen AG
er”, page 78 swa
gen AG does
k not
Vol gu
by
⇒ “3.8.2 Charging battery with sMidtronics INC 940”, page 79 ara
ed nte
ri
ho eo
⇒ “3.8.3 Rectifying problemsau with Midtronics INC 940 battery
t ra
c
charger”, page 81 ss
ce
e
nl
pt
du
3.8.1 General description of Midtronics INC
an
itte
y li
erm
940 battery charger
ab
ility
ot p
wit
Batteries in VW vehicles are only allowed to be charged with bat‐
, is n
h re
tery chargers approved by VW. In the USA/Canada, it is permitted
hole
spec
for the Midtronics INC 940 battery charger to be used.
es, in part or in w
t to the co
The Midtronics INC 940 battery charger combines battery charg‐
ing with a charge condition check and a battery test.
The following charging and analysis procedures apply to all bat‐
rrectness of i
teries, all battery installation locations (engine compartment or
l purpos
luggage compartment) and battery application purposes (starter

battery or second/convenience battery).
nf
ercia
Always comply with the safety regulations, the regulations for
or
setting up the battery charger, the display menu/display buttons,
m
m
atio
LEDs and the operating procedures described in the ⇒ operating
om
n in
manual INC 940 .
or c
thi
te
Read through ⇒ operating manual INC 940 carefully.

sd
iva
o
r
rp
cu
Refer to ⇒ Self-study programme No. ; Vehicle batteries for more

o
m
f
en
ng
information.
t.
yi Co
Cop py
t. rig
gh ht
yri by
WARNING op Vo
by c lksw
cted agen
Prote AG.
tions ⇒ page 1 !
No naked flames, sparking or smoking in the vicinity of batter‐
ies.
Battery charger must be switched off before cables are con‐
nected or disconnected.
Do not remove cell plugs during charging.
Overcharging sulphated batteries can lead to explosions.
Do not store precision tools in rooms where batteries are
charged, because corrosion can ensue due to chemical reac‐
tions.
WARNING

jump starting.

3.8.2 Charging battery with Midtronics INC

940
AG. Volkswagen AG d
agen oes
olksw not
yV gu
Note ised b ara
nte
or eo
h
ut ra
To avoid problems when updating or flashing the vehicle soft‐ c
s a
s
ce
le
un
pt
70 A (such as e.g. the “VAS 5903”) should be used. ⇒ page 55
an
d
itte
y li
erm
ab
ility
Prerequisites:
ot p
wit
is n
h re
ole,
WARNING
spec
t to the co
rrectne
jump starting.
s
s o
cial p
f inform
mer
INC 940 initial set-up performed (dealership number, date/time)
atio
m
⇒ Operating manual INC 940 .

o
n
c
i
or
n
– Check general information ⇒ page 78 .
thi
te
sd
iva
– Open bonnet or cover for other installation location of battery.

pr
cum
r
fo
en
ng
– Perform visual check of battery ⇒ page 7 .

t.
yi Co
Cop py
– Determine whether battery type is “Standard” (wet battery) or ht. rig
rig ht
“AGM” (absorbent glass mat battery).
py by
co Vo
by lksw
cted agen
– Close all vehicle doors.
Prote AG.
Note
♦ Battery temperature must be at least 10°C.

♦ For additional information, refer to the ⇒ operating manual
INC 940 .
Perform charging procedure:

– Switch off all electrical consumers.
– Switch off ignition and remove ignition key.
– Connect red terminal clamp “+” of charger unit to positive ter‐
minal on battery.
Note
In vehicles with start/stop function and battery monitor control unit

- J367- fitted, black terminal clamp “-” must be connected to body
earth. Connecting it to the negative terminal of the battery will
cause start/stop system to malfunction.
– Connect black terminal clamp “–” of battery charger to nega‐

tive terminal.
– Connect Midtronics INC 940 battery charger to an earthed
socket.

– Set “ON/OFF” switch of Midtronics INC 940 battery charger to

“ON”.
– Select “Automatic” or “Manual” charging mode
– Select test “In vehicle” or “Outside vehicle”.
– Select battery type “Standard”
wage
n AGor
. Vo“AGM” (absorbent
lkswagen AG
does glass
s
mat). yV
olk not
gu b ara
ed n
– Select test type
tho
ris “Warranty” or “Miscellaneous”. Note additional
tee
or
details (depending
s au on type of test). ac
s
ce
e
nl
pt
du
an
Note
itte
y li
erm
ab
ility
ot p
♦ For additional information, refer to the ⇒ operating manual
wit
, is n
INC 940 .
h re
hole
spec
♦ If necessary, make a note of menu items required for “War‐
es, in part or in w
ranty” test type ⇒ Warranty service circular .
t to the co
The Midtronics INC 940 battery charger tests the battery and
starts the charging process. Display then shows one of three re‐
rrectness of i
sults, as well as approximate charging time.
l purpos
Result: Measures:
Battery OK Battery can be returned to op‐
nf
ercia
eration. orm
m
atio
m
Charging required ♦ Test found low charge level.

o
n in
or c
♦ Charging starts and approx‐

thi
te
sd
a
imate charging duration is

iv
o
r
rp
cu
displayed.
o
m
f
en
ng
t.
♦ Achieved cold-start per‐
yi Co
op py
formance and remaining
t. C rig
gh ht
yri
charging time are displayed,
p by
o Vo
and are updated regularly.
c by lksw
cted agen
Prote AG.
Renew battery Battery defective. Charging

procedure is interrupted. Re‐
new battery.
Note
If the Midtronics INC 940 shows fault messages or text displays

other than those listed above, please refer to ⇒ page 81 .
WARNING
Stop charging if battery is liberating a lot of gas. Press “Stop”

button on front.
When charging and testing process has finished, Midtronics INC

940 battery charger displays “Battery good” or “Renew battery”
and total charging time.
There are three possible messages depending on individual cir‐
cumstance (printout for warranty, repair job, evaluation and filing):
♦ Generate test code (only possible after automatic charging
and test).
♦ Print last test result (for warranty).

♦ Display last test results.
Note
For additional information, refer to the ⇒ operating manual INC

940 .
3.8.3 Rectifying problems with Midtronics INC

940 battery charger
Under certain circumstances, the display may show errors or
messages according to status.
The most frequent display messages are listed below, together
with suggested solutions.
AG. Volkswagen AG d
agen oes
Note Volksw not
gu
by ara
d
rise nte
For messages not listed here, please refer to ⇒ operating
utho manual eo
ra
INC 940 . ss a c
ce
le
un
pt
an
d
Display message Measure

itte
y li
erm
ab
Check connection. – Check whether terminals of
ility
ot p
battery charger are firmly
wit
is n
connected to battery termi‐
h re
ole,
nals.
spec
– Check that battery terminal
t to the co
bolts are tightened accord‐
ing to regulations and are
free of corrosion.
rrectne
Terminals connected? Safety function of tester.
– Connect terminals to battery
ss
before starting charging pro‐
o
cial p
f i
cedure.
nform
mer
System noise – Switch off all electrical con‐
atio
m
sumers.
o
n
c
i
or
n thi
– Wait until all electrical loads
te
sd
va
monitored by on-board sup‐

i
o
pr
cum
ply control unit have switch‐

r
fo
en
ng
ed off.
t.
yi Co
Cop py
t. rig
– Withdraw ignition key. gh ht
pyri by
Vo
co lksw
by
– Disconnect any suspect
cted agen
Prote AG.
electrical equipment not
connected to on-board sup‐
ply as standard.
Wait a few minutes and repeat charging procedure ⇒ page 79 .
3.9 Battery charger Fronius Acctiva Profes‐

sional 35A, MAN TGE
3.9.1 General description of battery charger

Fronius Acctiva Professional 35A
The battery charger Fronius Acctiva Professional 35 A has been
approved for all MAN vehicles.

The battery charger Fronius Acctiva Professional 35 A both

charges the battery and monitors the charge level.
Comply with the safety regulations, the regulations for setting up
the battery charger, the display menu/display buttons, LEDs and
the operating procedures described in the ⇒ operating manual of
the battery charger Fronius Acctiva Professional 35A .
Read the ⇒ operating manual of the battery charger Fronius Ac‐
ctiva Professional 35A carefully.
WARNING

Keep bare flames and sparks away from batteries and do not
smoke in their vicinity.
Battery charger must be switched off before cables are con‐
nected or disconnected.
Do not remove cell plugs during charging.
Overcharging sulphated batteries can lead to explosions.
Do not store precision tools in rooms where batteries are
charged, because corrosion can ensue due to chemical reac‐
tions.
lkswage es n
o ot g
yV ua
Product characteristics ir se
d b ran
tee
tho
or
♦ Fully automatic charging using the Plug & Charge aufeature. ac
ss
ce
le
♦ Simple user guidance and maximum operational safety thanks

un
pt
to the animated graphical display. All functions and charging
an
d
itte
y li
data can be configured, read and are clearly presented on the
erm
ab
display.
ility
ot p
wit
is n
♦ Automatic pre-selection of battery voltage (6 V, 12 V and 24 V).
h re
ole,
spec
♦ Robust and compact housing for flexible use in the workshop.
t to the co
♦ Pluggable charging and power supply cables (in different
lengths).
♦ Edge protection for high stability and protection against paint‐
work damage. rrectne
♦ For charging or trickle-charging conventional lead-acid, lead-

ss o
calcium/silver, or absorbent glass mat batteries (AGM, MF) as

cial p
f in
well as of maintenance-free lead-gel batteries without having

form
mer
to disconnect the batteries from the vehicle’s electrical system.

atio
m
♦ Can be used on batteries with capacities of 3 to 350 Ah.

o
n
c
i
or
n thi
e
♦ Optional USB interface for software updates of the battery

t
sd
va
charging system ensures a long-term and future-proof use.

i
o
pr
cum
r
fo
♦ Based on the active inverter technology.

en
ng
t.
yi Co
op py
♦ Full protection of the vehicle, the onboard electronics and bat‐ t. C rig
gh ht
tery thanks to electronics protection, short-circuit protection, yri
p by
o Vo
electronic inverse polarity protection, safety shut-off and ther‐
c by lksw
cted agen
mal overload protection.
Prote AG.
Applications
♦ Charging: automatic charging and buffering of parallel con‐
sumers during the restricted service time.
♦ Diagnosis and software update: in buffer mode, the parallel
consumers are supplied with power during the diagnosis or

during software updates. In this case, the battery charging

systems provides a current of up to 35 A.
♦ Battery change: in support mode, the user settings in the ve‐
hicle are retained, when the battery is renewed.
♦ In power supply mode, an external power supply without any
support from the battery is provided.
♦ In refresh mode, totally discharged batteries are regenerated.
3.9.2 Charging battery using battery charger

Fronius Acctiva Professional 35A
♦ Battery charger Fronius Acctiva Professional 35 A -
80.99642-0003-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
Procedure
ce
le
un
pt
an
d
– Connect battery charger ⇒ Electrical system; Rep. gr. 27 ;

itte
y li
Battery; Charging battery .
rm
ab
pe
ility
ot
– For further procedure, refer to ⇒ operating manual of battery
wit
, is n
charger Fronius Acctiva Professional 35A .
h re
hole
spec
3.10 Solar charger module - VAS 6102A-
es, in part or in w
t to the co
⇒ “3.10.1 Charging battery in trickle charge mode with solar panel
VAS 6102A ”, page 83
rrectness of i
l purpos
with solar panel - VAS 6102A-

Solar panel VAS 6102A
nform
ercia
General description:
m
a
com
tion in
Solar panel - VAS 6102A- supports onboard supply and prevents

r
te o
thi
spontaneous discharging of battery.

s
iva
do
r
Solar panel - VAS 6102A- achieves max. voltage of 14.3 V and a

rp
cum
fo
charge current of max. 255 mA.

en
ng
t.
yi Co
op
Solar charger module - VAS 6102A- is allowed to be used for C py
t. rig
gh
charging all rechargeable lead or lead gel batteries.
ht
pyri by
Vo
co lksw
by
Solar charger module - VAS 6102A- is connected to diagnostic cted agen
Prote AG.
connection in vehicle.
A green LED is integrated in the frame to indicate its function. The
brighter the LED, the higher the charging current.
Integrated electronics prevent battery overcharging.

– Secure solar panel - VAS 6102A- on interior mirror -1-.

– Place underside on dash panel -2-. AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
is nte
Note hor eo
aut ra
ss c
Solar charger module - VAS 6102A- is not allowed to lie fully on
ce
e
nl
pt
dash panel. It is only allowed to be positioned with the bottom du
an
itte
edge for support. Placing it fully on the surface can result in dis‐
y li
erm
ab
colouration of the dash panel.
ility
ot p
wit
, is n
– Pull attachment string tight so that solar charger module - VAS
h re
hole
6102A- is positioned close to windscreen.
spec
es, in part or in w
– Connect solar panel - VAS 6102A- to diagnostic connection of
t to the co
vehicle. Connect in same way as vehicle diagnostic tester
⇒ page 110 .
rrectness of i
– Check function of solar panel - VAS 6102A- . Green LED in‐
dicates that solar panel - VAS 6102A- is operative.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

4 Alternator
⇒ “4.1 Checking function of poly V-belt pulley with freewheel”,
page 85
4.1 Checking function of poly V-belt pulley

with freewheel
♦ Multipoint adapter - T10474-
♦ Multipoint adapter - 3400-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
Distinguishing between different versions of decoupler pulleys
es, in part or in w
t to the co
with freewheel:
There are different types of decoupler pulleys with freewheel.
rrectness of i
Before removing the decoupler pulley with freewheel, it must be
determined which special tool must be used.
l purpos
-A- decoupler pulley with freewheel, small; use adapter -T10474-

nform
ercia
-B- decoupler pulley with freewheel, large; use adapter -3400-

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4. Alternator 85
Belt drive without air conditioner compressor

1- Tensioning pulley
2- Alternator pulley
3- Vane pump
4- Poly V-belt
5- Crankshaft pulley
Belt drive with air conditioner compressor

1- Crankshaft pulley
AG. Volkswagen AG d
2- Tensioning pulley lksw
agen oes
not
Vo gu
by
3- Alternator pulley rise
d ara
nte
tho eo
4- Vane pump s au ra
c
s
ce
le
5- Air conditioner compressor pulley

un
pt
an
d
itte
6- Poly V-belt
y li
rm
ab
pe
ility
7- Idler roller
ot
wit
, is n
Functional check
h re
hole
spec
– Remove protective cap (if applicable) from poly V-belt pulley

es, in part or in w
with freewheel.
t to the co
– Insert multipoint adapter - 3400- or multipoint adapter - 3400-

into poly V-belt pulley with freewheel.
rrectness of i
– Fit 17 mm spanner onto multipoint adapter .

l purpos
Note
nform
mercia
Counterhold the outer race of the poly V-belt pulley with freewheel
com
tion in
by hand in order to prevent it from turning.

r
te o
thi
s
iva
do
♦ Using spanner, turn multipoint adapter »clockwise«. Free‐

r
rp
cum
wheel must turn freely with slight resistance.

fo
en
ng
t.
yi Co
♦ Using spanner, turn multipoint adapter »anti-clockwise«. It t. Cop py
must not be possible to turn freewheel in anti-clockwise direc‐
rig
gh ht
yri by
tion. cop Vo
by lksw
cted agen
Prote
If both tests deliver positive results, the function of the poly V-belt
AG.
pulley with freewheel is OK. If not, pulley must be renewed ⇒

Electrical system; Rep. gr. 27 ; Alternator; Removing and instal‐
ling poly V-belt pulley .

5 Cruise control system (CCS)

⇒ “5.1 General description - cruise control system (CCS)”,
page 87
⇒ “5.2 Activating and deactivating cruise control system (CCS)”,
page 87
. Volkswagen AG
gen AG
5.1 General description - cruise control olksys‐
swa does
not
yV gu
tem (CCS) d b ara
ise nte
or h eo
ut ra
The functions of the cruise control system are scontrolled
sa by the c
engine control unit.
ce
le
un
pt
an
d
– The cruise control system can be activated and deactivated
itte
y li
⇒ page 87 . erm
ab
ility
ot p
Fault detection and fault display:
wit
is n
h re
ole,
Faults on the CCS are output via the engine control unit.
spec
For fault finding, use vehicle diagnosis, testing and information
t to the co
system - VAS 5051B- or vehicle diagnosis and service information
system - VAS 5052 A- in “Guided Fault Finding” mode.
rrectne
5.2 Activating and deactivating cruise con‐
trol system (CCS)
ss o
cial p
f
inform
mer
– Select operating mode “Guided Fault Finding” in vehicle diag‐
atio
nosis tester .
om
n
c
i
or
n
thi
te
sd
iva
o
pr
cum
r
♦ Drive
fo
en
ng
t.
yi Co
♦ Engine code ht. Cop py
rig
rig ht
♦ 01 - Self-diagnosis compatible systems py by
co Vo
by lksw
cted agen
♦ Engine management/diesel direct injection and glow plug sys‐ Prote AG.
tem
♦ Functions
♦ Activating and deactivating cruise control system (CCS)
5. Cruise control system (CCS) 87

. gen AG Volkswa
Amarok 2011 ➤ , Amarok 2017 ➤ , Caddy 2004 ➤ , Caddy gen AG
Volk2011
swa ➤ , Caddy 2 ... does no
t gu
ed
by ara
ris nte
utho eo
ra
a c
ss
90 – Gauges, instruments
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
88 Rep. gr.90 - Gauges, instruments

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e
Amarok 2011 ➤ , Amarok hor2017
is
➤ , Caddy 2004 ➤ , Caddy 2011 ➤nt,eeCaddy 2 ...
ut or
ss a Electrical system - general information - Edition a01.2019
c
ce
e
nl
pt
du
an
92 – Windscreen wash/wipe system
itte
y li
erm
ab
ility
ot p
wit
, is n
1 Washer fluid line hose couplings
h re
hole
spec
The following hose coupling types are used to connect the hoses
es, in part or in w
t to the co
to pumps and spray jets and/or as coupling points:
⇒ “1.1 Hose couplings - windscreen and rear window washer
system”, page 89
rrectness of i
⇒ “1.2 Hose couplings - windscreen and rear window washer
l purpos
system”, page 90
⇒ “1.3 Hose couplings - headlight washer system”, page 91
nf
ercia
orm
1.1 Hose couplings - windscreen and rear
m
atio
om
window washer system
n in
or c
thi
te
sd
a
– Pull the two coupling sections apart (no securing device) to

iv
o
r
rp
cu
loosen the connection.
o
m
f
en
ng
t.
yi
– To secure the connection, push the two coupling sections to‐
Co
op py
gether, until you hear and feel them engage. t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– To loosen the connection, rotate the lock ring -1- 90° -arrow-
and pull off the hose connection.
– To secure the connection, push on the hose connection and
rotate the lock ring -1- -arrow- until it engages.
– To loosen the connection, pull up the lock ring -1- by approx‐

imately 1 mm -arrow- and pull off the hose connection.
– To secure connection, attach hose connection and press in
clip -1- until it engages.
1. Washer fluid line hose couplings 89

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

window washer system
♦ Hot air blower - VAS 1978/14A- or
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
♦ Hot-air blower - V.A.G 1416- 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
ercia
The connections of washer fluid hoses on pumps and spray jets

of the windscreen and rear window washer system are not equip‐
m
a
com
ti
ped with hose couplings. The washer fluid hoses are pushed
on in
directly onto hose connections of the corresponding components.

r
te o
thi
s
iva
It can be helpful to heat the hose ends with hot air blower in order
do
r
rp
to ease the procedure of releasing or securing washer fluid hoses.

um
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
90 Rep. gr.92 - Windscreen wash/wipe system

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

tem
– To loosen the connection, push the lock ring -1- -arrow- and
pull off the hose connection.
– To secure the connection, push and hold the lock ring
-arrow- and push on the hose connection. Check proper en‐
gagement of securing clips by attempting to pull them off
without pressing them.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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.
1. Washer fluid line hose couplings 91

Amarok 2011 ➤ , Amarok 2017 ➤ , Caddy AG2004 ➤ag,eCaddy
. Volksw n AG d 2011 ➤ , Caddy 2 ...
Electrical system - general informationagen
ksw - Edition 01.2019
oes
ol not
V gu
by ara
ed nte
oris eo
th
2 Hose repair ss
au ra
c
ce
e
nl
⇒ “2.1 General description - hose repair”, page 92
pt
du
an
itte
y li
⇒ “2.2 Repairing smooth pipe”, page 92
erm
ab
ility
ot p
⇒ “2.3 Repairing corrugated pipe”, page 92
wit
, is n
h re
2.1 General description - hose repair
hole
spec
es, in part or in w
A new repair concept has been developed for repair work on wash
t to the co
system hoses. Various connectors, special EPDM hoses (ethyl‐
ene-propylene-diene monomer) and heat-shrink hose are avail‐
able as spare parts.
rrectness of i
♦ Refer to the ⇒ Electronic Parts Catalogue (ETKA) for spare
l purpos
parts.
♦ Replacement parts are available for repair of both smooth and
nform
ercia
corrugated pipes.
m
at
om
2.2 Repairing smooth pipe
ion
c
in t
or
his
e
Smooth pipe with a diameter or 5x1 mm or 6x1 mm can be re‐

at
do
riv
paired with EPDM hose.

p
cum
for
en
g
– Cut damaged section (cuts straight through pipe) out of the

n
t.
yi Co
smooth pipe to be repaired. ht. Cop py
rig
rig ht
– In the ⇒ Electronic Parts Catalogue (ETKA) , select the ap‐ py by
co Vo
propriate EPDM hose -2- and cable ties.
by lksw
cted agen
Prote AG.
– Cut EPDM hose -2- to size so that smooth-type pipe ends
-1- and -3- can be inserted approx. 10 mm into EPDM hose
-2-.
– Secure repair position on both sides with cable ties -1-.
2.3 Repairing corrugated pipe

♦ Hot air blower - VAS 5179- or

♦ Hot air blower - V.A.G 1416- or
♦ Hot-air blower - VAS 1978/14A- 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
Note
l purpos
♦ Repair points must not be subjected to pulling or bending

forces.
nform
ercia
♦ If the damaged section is longer than 20 mm, a new piece of

m
corrugated pipe must be used and the procedure described
at
om
i
below must be performed twice.
on
c
in t
or
his
ate
– Cut damaged piece (cuts straight through pipe) out of the cor‐
do
priv
rugated pipe to be repaired. cum

for
en
ng
t.
– In ⇒ Electronic Parts Catalogue (ETKA) , select appropriate
yi Co
op py
connecting pieces -2- and -3- and appropriate heat-shrink t. C rig
gh ht
hose. yri
p by
co Vo
by lksw
cted
– Heat end of corrugated pipe -1- with hot air blower.
agen
Prote AG.
– Push connecting piece -2- into corrugated pipe -1- -arrow A-.
– Heat end of corrugated pipe -4- with hot air blower.
– Push connecting piece -3- into corrugated pipe -4- -arrow B-.
2. Hose repair 93
– Cut heat-shrink hose so that ends of corrugated pipe are each

covered by about 20 mm -dimension x- of heat-shrink hose.
– Push heat-shrink hose on both sides over corrugated pipe
-x- and connect connection pieces.
– Heat heat-shrink hose on both sides with hot air blower to se‐
cure section to be repaired. gen AG
. Volkswagen AG
wa does
olks not
byV gu
ara
ed nte
ris
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

94 – Lights, bulbs, switches - exterior

1 Operation and safety notes for gas
discharge lamps
If repair work is done on headlights with gas discharge bulbs, fol‐
lowing instructions must be observed:
♦ Notes on dangerous high voltage/currents ⇒ page 95
♦ Notes on pressure, temperature, radiation/arcs ⇒ page 96
♦ Assembly notes for gas discharge bulbs ⇒ page 97
♦ Disposal regulations for gas discharge bulbs ⇒ page 97
AG. Volkswagen AG d
♦ Safety glasses agen oes
olksw not
V gu
by ara
♦ Gloves rised
nte
ho eo
aut ra
ss c
WARNING
ce
le
un
pt
an
d
itte
It is absolutely necessary to disconnect the battery earth strap
y li
erm
ab
before working on parts of the gas discharge headlights
ility
ot p
marked with yellow high voltage symbols.
wit
is n
h re
Then switch dipped beam on and off again. This will eliminate
ole,
spec
any possible residual voltage.
t to the co
The gas discharge lamp control unit must never be operated
without a gas discharge lamp.
Due to the high voltage (above 28000 V when igniting the gas
rrectne
discharge bulb) and high temperatures, the gas discharge bulb
must only be operated in the headlight housing.
ss o
cial p
f inform
mer
WARNING atio
om
n
c
i
or
♦ Never change bulbs if you are not familiar with the appro‐
thi
te
priate procedures, safety precautions and tools.

sd
iva
o
pr
cum
r
fo
en
ng
t.
yi
Notes on dangerous high voltage and current
Co
Cop py
t. rig
gh ht
pyri by
Vo
o
WARNING by c lksw
cted agen
Prote AG.
Control units for light system, connectors and components per‐

taining to bulb holders conduct lethally high voltage.
Operating the control unit and the starter unit is permitted only
with the bulb fitted.
1. Operation and safety notes for gas discharge lamps 95

WARNING AG. Volkswagen AG d

agen oes
olksw not
V gu
• Switch off ignition and all electrical equipment ed by and then ara
nte
remove ignition key. horis
eo
aut ra
• When working on headlight system,s ensure that there is
s c
ce
e
no voltage in any components, including the dissipation of
nl
pt
du
residual voltage after the headlights are switched off.
an
itte
y li
erm
ab
• Residual voltage can be dissipated by turning the dipped
ility
ot p
beam on and then off again after withdrawing the ignition
wit
, is n
key.
h re
hole
spec
• When working on the headlight system, ensure that the
es, in part or in w
lights cannot be switched on.
t to the co
Notes on pressure, temperature, radiation/arcs
rrectness of i
l purpos
WARNING
nf
ercia
• The bulbs may be operated in the headlight housing only
or
(protection against contact due to very hot bulbs, absorp‐
m
m
atio
tion of UV radiation, avoidance of dazzling light, protection
om
n in
against explosion).
or c
thi
te
• The glass of the bulbs can become very hot - danger of
sd
iva
o
r
burns!
rp
cu
o
m
f
en
ng
• Avoid looking directly into the collimated beam as the UV

t.
yi Co
op
radiation from the gas discharge bulb is about 2.5 times C py
t. rig
greater than from normal halogen bulbs.
gh ht
pyri by
Vo
o
by c lksw
• Never look directly into the light beam (danger of glare); cted agen
Prote AG.
otherwise vision may be impaired for a substantial length
of time.
WARNING
• Avoid contact with burst glass bulbs.

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

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

electrical consumer.
♦ Switch off ignition and all electrical equipment and then
remove ignition key.
♦ Do not touch the bulb glass with bare fingers. Use clean
fabric gloves. When the light bulb is switched on, the heat
would vaporise the oil of the finger prints which would then
settle on the reflector, impairing the brightness of the
headlight.
♦ A light bulb must always be renewed with a bulb of the
same sort. The designation appears on the base of the
bulb or on the bulb glass.
♦ Properly engage connectors during installation and the
connection is seated tightly.
Disposal regulations for gas discharge bulbs
WARNING
• Gas discharge bulbs must be disposed of as hazardous

waste; never dispose of gas discharge bulbs as consumer
waste.
• Gas discharge bulbs contain metallic mercury (Hg) and
traces of thallium; never destroy these bulbs.
Volkswagen AG
• These components must be recycled in thekscorrect
wage
n AGman‐
.
does
ner according to national law. by
Vol not
gu
ara
d
ise nte
• Only dispose of in containers intended
ho
r for this purpose at eo
ut
an authorised collection point.ss a ra
c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Operation and safety notes for gas discharge lamps 97

96 – Lights, bulbs, switches - interior

1 Immobiliser
⇒ “1.1 General description - immobiliser”, page 98
⇒ “1.2 Online system test”, page 99
⇒ “1.3 Immobiliser control unit J362 ”, page 99
⇒ “1.4 Engine control unit J623 ”, page 99
⇒ “1.5 Immobiliser reader coil”, page 99
⇒ “1.6 Replacement ignition key”, page 100
⇒ “1.7 Ignition key - variable code transponder”, page 100
⇒ “1.8 New lock set”, page 100
⇒ “1.9 New identity on renewing all components”, page 101
1.1 General description - immobiliser

These chapters contain further information about immobilisation
in the following vehicles:
♦ Amarok, from MY 2011
♦ Caddy, from MY 2016
♦ Transporter/Multivan, from MY 2016 wage
es n
olks ot g
byV ua
d ran
ir se tee
Note utho
or
a ac
ss
Additional information:
ce
le
un
pt
an
d
itte
⇒ Current flow diagrams, Electrical fault finding and Fitting loca‐ y li

erm
ab
tions ility
ot p
wit
is n
The 4th generation immobiliser provides online and download

h re
ole,
capabilities. The main component of the fourth generation immo‐

spec
biliser is a central database, in which all of the theft-relevant data

t to the co
from the participating control units is stored. Adapting the control

units associated with the immobiliser is not possible without an
online link to this database.
rrectne
Access to the central database is by means of the ODIS vehicle

diagnosis tester. The user needs a personal ID and password for
s
authentication.
s o
cial p
f i
Online connection check via online system test ⇒ page 99 .

nform
mer
Important features of fourth immobiliser generation:

atio
om
n
c
♦ There is no PIN request of the immobiliser components by fax

i
or
n thi
nor provisional activation of the components.

te
sd
iva
o
pr
♦ All components associated with the immobiliser must be adap‐

um
r
fo
ted online.
en
ng
t.
yi Co
op
♦ All ignition keys (including re-ordered ones) are pre-coded to
C py
t. rig
gh
a specific vehicle in the factory and can only be adapted to this
ht
pyri by
Vo
o
vehicle.
c by lksw
cted agen
Prote AG.
♦ The relevant vehicle identification number must be specified
when re-ordering ignition keys.
♦ It is no longer possible to adapt components of other brands
for use in Volkswagen vehicles.
98 Rep. gr.96 - Lights, bulbs, switches - interior

Immobiliser components:
♦ Immobiliser control unit - J362- ⇒ page 99
♦ Engine control unit - J623- ⇒ page 99
♦ Ignition key ⇒ page 100
Fault detection and fault display:
The immobiliser is equipped with self-diagnosis, which makes
fault finding easier.
For fault finding, use the systems described in chapter “Vehicle
diagnosis, testing and information system” in “Guided Fault Find‐
ing” mode ⇒ page 110 .
1.2 Online system test

The following processes are performed with this test program:
♦ System test for online connection
♦ User authorisation check (personal ID and password)
♦ Test for correct line connection to Volkswagen database
Prerequisite for this is the online connection g(network
en AG. V connection)
olkswagen AG
does
swa
of the tester ⇒ Vehicle diagnostic tester.
yV
olk not
gu b ara
ed nte
ris
1.3 Immobiliser control unit - J362- au
tho e or
ac
ss
The immobiliser control unit - J362- is integrated in the dash panel
ce
e
nl
insert and cannot be replaced individually.
pt
du
an
itte
y li
In the event of a defective control unit, the whole dash panel insert
erm
ab
must be renewed ⇒ Rep. gr. 96 ; Removing and installing im‐
ility
ot p
mobiliser control unit .
wit
, is n
h re
hole
Adapting new immobiliser control unit

spec
es, in part or in w
A new immobiliser control unit - J362- is adapted via the “Adapt t to the co
immobiliser” ⇒ Vehicle diagnostic tester function.
If a new immobiliser control unit - J362- is installed, all ignition
rrectness of i
keys must be adapted ⇒ page 100

l purpos
1.4 Engine control unit - J623-

The engine control unit - J623- is a component linked to the im‐
nform
ercia
mobiliser. Removing and installing ⇒ Rep. gr. 23 ; Engine control

m
unit; Removing and installing engine control unit - J623- .

at
om
ion
c
Adapting new engine control unit to immobiliser

in t
or
his
ate
A new engine control unit - J623- is adapted after coding using

do
priv
the “Adapt engine control unit” ⇒ Vehicle diagnostic tester func‐

um
for
tion.
en
ng
t.
yi Co
op py
1.5 Immobiliser reader coil
t. C rig
gh ht
pyri by
Vo
o
by c lksw
The immobiliser reader coil - D2- is joined to the lock cylinder and Prote
cted agen
cannot be renewed individually.
AG.
If reader coil is defective, lock cylinder must be renewed ⇒ Rep.

gr. 96 ; Switch module of steering column; Removing and instal‐
ling lock cylinder .
1. Immobiliser 99
1.6 Replacement ignition key
Note

vehicle.
Adapting ignition key to immobiliser

Adapt new or additional ignition keys to immobiliser control unit -
J362- via “Adapting keys” ⇒ Vehicle diagnostic tester function.
Note
♦ If one new key is adapted to the immobiliser, then all other

(even old) keys belonging to the vehicle must be adapted
anew.
♦ If the whole set of keys or a control unit associated with the
immobiliser is replaced, the “New ID” function must be called
up ⇒ page 101 .
1.7 Ignition key - variable code transponder

agen oes
o lksw not
All ignition keys by(including re-ordered ones) are pre-coded to
V
♦ ed
gu
ara
a specific vehicle
horis
in the factory and can only be adapted nte
to
e this
vehicle.s aut or
ac
s
ce
e
nl
pt
du

an
itte
y li
erm
ab
ility
The variable or rolling code transponder is integrated in the igni‐

ot p
wit
tion key and cannot be renewed individually.

, is n
h re
hole
In the event of a defective rolling code transponder, the ignition

spec
key must be replaced and then adapted to the immobiliser control

es, in part or in w
t to the co
unit - J362- via the “Adapting keys” function ⇒ Vehicle diagnostic

tester.
1.8 New lock set

rrectness of i
l purpos
Note
nf
ercia
or

m
m
atio

om
n in
vehicle.
or c
thi
te

sd
iva
o
r

rp
cu
o
m
f
en
ng
t.
yi Co
Adapting new lock set to immobiliser Cop py
t. rig
gh ht
yri
To adapt a new lock set, the new lock set, the old immobiliser p by
o Vo
by c
control unit - J362- and the old engine control unit - J623- must
lksw
cted agen
Prote
be installed.
AG.
⇒ Vehicle diagnostic tester is used to adapt a new lock set.

With this program, the immobiliser control unit - J362- and engine
control unit - J623- receive the data associated with the new keys.
1.9 New identity on renewing all compo‐

nents
Note

vehicle.
Adapting new immobiliser group

To adapt a new immobiliser group, a new immobiliser control unit
- J362- , a new engine control unit - J623- and a new lock set must
be installed.
⇒ Vehicle diagnostic tester is used to adapt a new lock set.
This program performs all of the processes required for adapting
a new key set to the new immobiliser components.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Immobiliser 101
2 12 V socket lksw
agen
AG. Volkswagen AG d
oes
not
Vo gu
y
⇒ “2.1 Removing and installing 12 V socket ”, page 102 rise d b ara
nte
tho eo
⇒ “2.2 Removing and installing socket illumination bulb
s a L42 ”,
u ra
c
page 104 s
ce
le
un
pt
2.1 Removing and installing 12 V socket
an
d
itte
y li
erm
ab
ility
ot p
Caution
wit
is n
h re
ole,
spec
If excessive force is exerted on sockets without illumination, urposes, in part or in wh
the retaining sleeve may be damaged.
t to the co
Only illuminated sockets (cigarette lighter) can be removed
with the puller T 40148.
rrectne
The puller does not manage to release the locking lugs of
sockets without illuminated retaining sleeve.
ss o
Usually sockets without illumination cannot be removed with‐
cial p
f in
out being damaged.
form
mer
atio
om
n
c
i
or
n thi
e
Note
t
sd
iva
o
pr
cum
r
fo
The illustrations apply to all vehicle models; for this reason, they
en
ng
t.
yi
do not show the original vehicle environment.
Co
Cop py
t. rig
gh ht
yri by
Special tools and workshop equipment required cop Vo
by lksw
cted agen
Prote AG.
♦ Puller - T40148-
Removing
– Remove knurled nut from puller and take top section of puller
off.
– Insert the bottom part of the puller in the socket so that the 2
retaining tabs on the puller engage in the detent openings of
the socket -arrow-. If necessary, turn the bottom part of the
puller back and forth a little in the socket until the puller en‐
gages in the detent openings of the socket.

– Fit puller - T40148- -1- in place and place it onto socket as

shown.
– Turn knurled nut of puller in -direction of arrow A- so that sock‐

et is pulled out of its mounting in -direction of arrow B-.
– Remove socket and release and disconnect connector.
. Volkswagen AG
– Release locking lugs of puller by pressing spindlek-1- swa in direc‐
gen AG does
tion of -arrow B-. Then, release press tool -2-byby V turning it
ol not
gu
ara
slightly to left -arrow A- and take puller out
ris of socket.
ed nte
tho eo
s au ra
c
s
Note
ce
e
nl
pt
du
an
itte
y li
When pulling out the puller, ensure that its locking lugs are not
erm
ab
spread.
ility
ot p
wit
, is n
h re
hole
spec
Caution
es, in part or in w
t to the co
The cigarette lighter might be ejected out of the socket after
the heating phase.
rrectness of i
When inserting the puller, the socket retaining springs are

pressed apart, and the retaining force of the cigarette lighter is
l purpos
reduced.
After removing socket, carefully press together retaining
nform
ercia
springs and check if cigarette lighter remains in removal posi‐

m
tion after the heating phase.

at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. 12 V socket 103
– Carefully press retaining springs of socket together -arrows-.

– Check if cigarette lighter remains in removal position after
heating phase and ensure it is not ejected into vehicle interior.
Installing
– Attach connector to socket and engage it.
– Push socket into its mounting slot until it latches into place.
Note
♦ In some socket brackets, the installation position of the socket agen

AG. Volkswagen AG d
is prescribed by a groove. Volksw
oes
not
gu
d by ara
♦ When installing, align the socket to the groove in theosocket
ris
e nte
eo
bracket. aut
h
ra
ss c
ce
e
nl
pt
du
an
2.2 Removing and installing socket illumi‐
itte
y li
erm
ab
nation bulb - L42-
ility
ot p
wit
, is n
The removal of the socket illumination bulb - L42- is performed in
h re
the same way as the removal of the cigarette lighter illumination
hole
spec
bulb - L28- ⇒ page 109 .
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
Amarok 2011 horis➤ , Amarok 2017 ➤ , Caddy 2004 ➤ , Caddy
nte
e o 2011 ➤ , Caddy 2 ...
aut Electrical system - general information ra - Edition 01.2019
ss c
ce
e
nl
pt
du
an
3 Cigarette lighter - U1-
itte
y li
erm
ab
ility
ot p
⇒ “3.1 General description - cigarette lighter U1 ”, page 105
wit
, is n
h re
⇒ “3.2 Assembly overview - cigarette lighter U1 ”, page 105
hole
spec
⇒ “3.3 Removing and installing cigarette lighter socket ”,
es, in part or in w
t to the co
page 106
⇒ “3.4 Removing and installing cigarette lighter illumination bulb
L28 ”, page 109
rrectness of i
3.1 General description - cigarette lighter -
l purpos
U1-
nf
ercia
o
The following descriptions apply to the rear left cigarette lighter -
rm
m
U3- , rear right cigarette lighter - U7- , rear cigarette lighter - U9- ,
atio
m
12 V socket 2 - U18- , 12 V socket 3 - U19- , 12 V socket 4 - U20- ,

o
n in
c
cigarette lighter 2 - U25- and 12 V socket 5 - U26- so far as they

or
thi
e
are illuminated.
t
sd
iva
o
r
rp
cu
o
m
f
en
ng
Caution
t.
yi Co
Cop py
ht. rig
If excessive force is exerted on sockets without illumination, rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Only illuminated sockets (cigarette lighter) can be removed
with the puller T 40148.
The puller does not manage to release the locking lugs of
out being damaged.
On some vehicles, the illumination is not provided by a light bulb,

but by an LED (light-emitting diode), depending on the equipment
level. This LED is permanently attached to the retaining sleeve
and cannot be renewed separately.
Retaining sleeves with a light bulb are available in different ver‐
sions. On the one version, the light bulb can be replaced sepa‐
rately; on the other version, the light bulb cannot be replaced
separately. In this case, the bulb carrier has to be replaced to‐
gether with the light bulb.
Depending on the space requirement, the vehicles are equipped
with various electric sockets and cigarette lighter sockets. They
differ in length and have different electrical connections. In the
case of electric sockets or cigarette lighter sockets with wiring
harness, it may be necessary to perform additional work in order
to gain access to the connector.
3.2 Assembly overview - cigarette lighter - U1-
3. Cigarette lighter U1 105

1 - Cigarette lighter socket with

wiring harness
2 - Cigarette lighter
3 - Electric socket
4 - Cigarette lighter socket
5 - Retaining sleeve
6 - Light bulb W 5 12V,
1.2 watts
7 - Bulb carrier
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
3.3 Removing and installing cigarette lighter
spec
es, in part or in w
socket
t to the co
rrectness of i
Note
l purpos
The removal and installation procedure is the same for all sockets
and is therefore described here only for the cigarette lighter sock‐
nf
ercia
et.
orm
m
atio
om
n in
c
Caution
or
thi
te
sd
iva
If excessive force is exerted on sockets without illumination,

r
rp
cu
o

f
en
ng
t.
yi Co
op
Only illuminated sockets (cigarette lighter) can be removed C py
ht. rig
with the puller T 40148. rig ht
py by
co Vo
by lksw
The puller does not manage to release the locking lugs of Prote
cted AG.
agen
out being damaged.

AG. Volkswagen AG d
Special tools and workshop equipment required ksw
agen oes
not
Vol
y gu
♦ Puller - T 40148- ise
d b ara
nte
or eo
th
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
Removing:
s
– Remove cigarette lighter, cigarette lighter dummy etc. from
s o
socket.
cial p
f inform
mer
atio
m
Note
o
n
c
i
or
n thi
e
For reasons of clarity, the socket is removed in the illustration.

t
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi
Caution
Co
Cop py
t. rig
gh ht
yri by
The socket or the retaining sleeve can be damaged. cop Vo
by lksw
cted agen
Prote
Ensure that the puller is seated correctly in the socket, other‐
AG.
wise the retaining lugs of the spring pin will not be released.
– Push puller -arrow- into socket so that locking lugs -1- engage
in recesses -2-.
– Pull grip -3- in -direction of arrow- to release locking lugs of

retaining sleeve.
– Pull socket out of retaining sleeve using puller.
Caution
The socket wiring can be damaged.

Pull out the socket only as far as the connected wiring allows.

Depending on the fitting location, it is recommended to use the

thrust piece 40148/1 -2- with the knurled nut -1-.
Caution
When using the thrust piece, ensure that no surrounding com‐

ponents are damaged.
– Release and disconnect connector from socket.
Note
Depending on the space requirement, the vehicles are equipped

with various electric sockets and cigarette lighter sockets. They
differ in length and have different electrical connections. In the
case of electric sockets or cigarette lighter sockets with wiring
harness, it may be necessary to perform additional work in order
to gain access to the connector.
– Release locking lugs of puller by pressing spindle -1- in direc‐

tion of -arrow B-. Then, release press tool -2- by turning it
slightly to left -arrow A- and take puller out of socket.
Note
When pulling out the puller, ensure that its locking lugs are not
spread.
Caution
AG. Volkswagen AG d
agen oes
olksw not
The cigarette lighter mighted b be ejected out of the socket after
y V gu
ara
the heating phase. horis nte
eo
ut ra
a
When inserting thess puller, the socket retaining springs are c
pressed apart, and the retaining force of the cigarette lighter is
ce
le
un
pt
reduced.
an
d
itte
y li
rm
ab
After removing socket, carefully press together retaining

pe
ility
springs and check if cigarette lighter remains in removal posi‐

ot
wit
tion after the heating phase.

, is n
h re
hole
spec
es, in part or in w
t to the co
– Carefully press together retaining springs of socket -arrows-.

– Check if cigarette lighter remains in removal position after
rrectness of i
heating phase and ensure it is not ejected into vehicle interior.

l purpos
Installing:
Install in the reverse order of removal.
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.

3.4 Removing and installing cigarette lighter

illumination bulb - L28-
Note
♦ On some vehicles, the illumination is not provided by a light

bulb, but by an LED (light-emitting diode), depending on the
equipment level. This LED is permanently attached to the re‐
taining sleeve and cannot be renewed separately.
♦ Retaining sleeves with a light bulb are available in different
versions. On the one version,Gthe light bulb can be replaced
. Volkswagen AG
separately; on the other waversion,
gen A the light bulb
doe cannot be re‐
placed separately. olkthis case, the bulb carriers n
VIn
s
has
ot g to be
y ua
db
replaced together
or
ise with the light bulb. ran
te
th eo
s au ra
c
Removing: s
ce
le
un
pt
– Remove socket ⇒ page 106 .
an
d
itte
y li
rm
ab
– Press retaining lugs -arrows- and remove spring pin with bulb
pe
ility
carrier.
ot
wit
, is n
h re
– Unclip bulb carrier from spring pin.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
– Separate bulb carrier parts -A- and -B-.

com
tion in
r
– Open part -B- of bulb carrier.

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.
– Pull out bulb -1- in -direction of arrow-.

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

the same sort.
♦ The designation is indicated on the base of the bulb or on the
bulb glass.

Amarok 2011 ➤ , Amarok 2017 ➤ , Caddy 2004 ➤ , Caddy 2011 AG.➤
Vol,ksCaddy
wagen A2 ...
Electrical system - general information - Edition 01.2019 agen G do
es n
olksw ot
V gu
by ara
ed nte
oris eo
97 – Wiring
th
au ra
c
ss
ce
le
un
pt
an
d
itte
1 Vehicle diagnosis, testing and infor‐
y li
rm
ab
pe
mation systems
ility
ot
wit
, is n
h re
⇒ “1.1 General description - vehicle diagnosis, testing and infor‐
hole
spec
mation system”, page 110
es, in part or in w
t to the co
⇒ “1.2 Connecting vehicle diagnostic tester ”, page 110
1.1 General description - vehicle diagnosis,
rrectness of i
testing and information system l purpos
WARNING
nform
ercia
♦ During testing or measuring operations using a vehicle di‐

m
a
agnostic information system there is a risk of serious or
com
tion in
even fatal injury!
r
te o
thi
s
♦ If the vehicle diagnostic information system is situated in
iva
do
r
the activation area of an airbag during testing or measur‐

rp
cum
fo
ing operations, serious or even fatal injury may result if an
en
ng
t.
yi
airbag is triggered!
Co
Cop py
ht. rig
♦ During testing and measuring operations, work together
rig ht
py by
Vo
with a person who can operate the vehicle diagnosis and
co lksw
by
cted agen
information system from one of the back seats. Prote AG.
Note
♦ All the operations described, e.g. adaptation, coding, etc. can

be performed using the vehicle diagnostic tester .
♦ All work procedures can be found in “guided fault finding” and
“guided functions” modes.
♦ Observe the current operating instructions for the vehicle di‐
agnosis, testing and information system to be connected.
♦ Additional information:
⇒ Self-study programme No. 202 ; Vehicle diagnostic, testing

and information system VAS 5051
⇒ Self-study programme No. 256 ; VAS 5052
⇒ Self-study programme No. 294 ; Online connection of VAS
5051
⇒ Self-study programme No. 295 ; Diagnosis with VAS 5051,
VAS 5052 or VAS 5053
1.2 Connecting vehicle diagnostic tester
Note
Observe the latest operating instructions for the vehicle diagnos‐

tic tester , which are displayed after selecting the “Administration”
and “Operating Manual” buttons.
110 Rep. gr.97 - Wiring


♦ Vehicle diagnostic tester
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
♦ Diagnostic cable - VAS 5051/6A- (5 m)
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
♦ Diagnostic cable - VAS 5051/5A- (3 m)

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

– Apply handbrake.
– Vehicles with automatic gearbox, move selector lever to posi‐
tion “P” or “N”.
– Vehicles with manual gearbox, move gear lever to neutral po‐
sition.
1. Vehicle diagnosis, testing and information systems 111

– With ignition switched off, connect vehicle diagnostic tester

using diagnosis cable - VAS 5051/6A- or diagnosis cable -
VAS 5051/5A- to diagnostic connection -enlargement- of ve‐
hicle.
Exemplary illustration of diagnostic connection
– Switch on ignition.
– Switch off all electrical consumers.
Note
All other and the following vehicle diagnosis, testing and informa‐
tion systems or vehicle diagnosis and service information sys‐
tems are connected accordingly in the sequence described
above.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

2 Wiring harness and connector re‐

pairs
⇒ “2.1 General notes concerning repairs to vehicle electrical sys‐
tem”, page 113
⇒ “2.2 Wiring harness repair set”, page 116
⇒ “2.3 Tool descriptions”, page 119
⇒ “2.4 Repairs to electrical wiring harnesses”, page 122
⇒ “2.5 Repairs to fibre optic cables”, page 144
⇒ “2.7 Repairing connector housings and connectors”,
page 164
⇒ “2.8 Releasing and dismantling connector housings”,
page 168
n AG. Volkswagen A
2.1 GeneralVolnotes
ksw
age concerningG repairs
does
not
gu
to ve‐
hicle
ise electrical system
by ara
d
nte
or
th eo
au ra
c
ss
Caution
ce
le
un
pt
an
d
itte
To disconnect and connect the battery, the procedure descri‐

y li
erm
ab
bed in the workshop manual should be strictly adhered to ⇒
ility
ot p
Electrical system; Rep. gr. 27 ; Disconnecting and connecting

wit
is n
battery . h re
ole,
spec
t to the co
WARNING
rrectne
Some tools are equipped with a tool safety device.

This must be pushed over the tip of the tool after use in order
s
to protect the tip and prevent injuries to personnel.

s 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.
2. Wiring harness and connector repairs 113

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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.

♦ Observe the latest notes in the respective workshop manual

when carrying out repairs.
♦ Observe country-specific regulations.
♦ Always disconnect the battery earth strap before working on
the electrical system. Disconnecting the battery earth strap
(open circuit) provides a safe working environment for repairs
to the electrical system. The battery positive wire need only be
disconnected for removal of the battery.
♦ Before starting a repair, it is important to identify and rectify
the cause of damage (e.g. sharp edges on body panels, de‐
fective electrical consumers, corrosion, etc.).
♦ For additional information, e.g. removal and installation of in‐
dividual components, refer to the relevant workshop manual.
♦ Soldering is not permitted for repairs to vehicle wiring.
♦ Wiring harness and connector repairs to onboard supply sys‐
tem may be carried out using wiring harness repair set - VAS
1978 B- and previous versions only. Only use yellow wires
from wiring harness repair set - VAS 1978 B- .
AG. gen AG Volkswa
♦ Wiring harness repairs may not be integrated agen
ksw in the vehicle's
does
ol not
own wiring harness and must be marked
ed by V with the use of yellow gu
ara
adhesive tape. This indicates ahprevious
oris repair. nte
e t or
au ac
♦ Crimp connectors may never ss be repaired. If necessary, route
a cable parallel to the defective one. After crimping, the crimp
ce
e
nl
pt
du
connector has to be shrink fitted using the hot air blower in
an
itte
y li
order to prevent any ingress of moisture.
erm
ab
ility
ot p
♦ It is essential that the supplementary notes are observed re‐
wit
garding repairs to wiring harnesses in airbag systems and belt
, is n
h re
tensioners, fibre optic cables, CAN bus lines, aerial cables and
hole
spec
wiring with cross sections up to 0.35 mm2 ⇒ page 122 .
es, in part or in w
t to the co
♦ Carry out a function test after every repair. It may be necessary
to read and delete the event memory and/or to reset the sys‐
tems.
♦ If possible, do not loosen any earth wires from the body (dan‐ rrectness of i
l purpos
ger of corrosion).
♦ Wiring harness repair set - VAS 1978 B- and previous versions
nf
ercia
do not cover all wiring cross sections that occur in the vehicle.
orm
If the required wiring cross section is not available, use the

m
atio
m
next largest one.

o
n in
or c
♦ Screened wires can be repaired. Wiring for camera systems

thi
te
sd
a
are the exception. If damaged they must be replaced com‐

iv
o
r
plete.
rp
cu
o
m
f
en
ng
t.
♦ Heat resistant wiring can be found in various places in the ve‐
yi Co
op
hicle, mainly in the engine compartment. Heat resistant wiring
C py
ht. rig
can be identified by its slightly matt and softer insulation. To
rig ht
py by
o Vo
repair these wires, only heat resistant wiring may be used. by c lksw
cted agen
Prote AG.

2.2 Wiring harness repair set

⇒ “2.2.1 Wiring harness repair set VAS 1978 ”, page 116
⇒ “2.2.2 Upgrade kit VAS 1978/50 ”, page 116
⇒ “2.2.3 Wiring harness repair set VAS 1978A ”, page 116
⇒ “2.2.4 Release tool set VAS 1978/35 ”, page 117
⇒ “2.2.5 Wiring harness repair set VAS 631 001 ”, page 117
⇒ “2.2.6 Wiring harness repair set VAS 631 003 ”, page 117
2.2.1 Wiring harness repair set - VAS 1978-

Wiring harness repair set - VAS 1978- allows optimal repair qual‐
ity to be achieved in the area of vehicle n Aelectrics.
G. VolkswagUsing
en AG the tools,
repairs to connectors and wiring l wage circuits can be carried
ksopen
does
not out.
o
To do this, complete repair by V sections with contacts already
wire gu
ara
ed
crimped on are used and horis joined to the vehicle's own wiring har‐ nte
eo
ness with the aid ofs acrimp
ut connectors. A special set of pliers with ra
c
3 different crimp recesses
s and a hot air blower for shrinking the
ce
le
crimp connectors make a perfect electrical connection.

un
pt
an
d
itte
y li
rm
ab
pe
ility
Note
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
⇒ Operating instructions Wiring harness repair set - VAS 1978-
2.2.2 Upgrade kit - VAS 1978/50-

rrectness of i
Upgrade kit - VAS 1978/50- is required to bring “old” wiring har‐

l purpos
ness repair set - VAS 1978- up to the latest standard of wiring

harness repair set - VAS 1978A- . The upgrade kit comprises of
nform
ercia
4 assembly and 10 release tools, a new set of crimping pliers for

crimp connectors with head adapter 0.35 - 2.5 mm2 -VAS
m
a
com
1978/1-1- , 4.0 - 6.0 mm2 -VAS 1978/2 A- and head adapter for
ion in
JPT contacts - VAS 1978/9-1- . Also included are new stickers, a

r
te o
thi
new set of operating instructions, crimp connectors for

s
iva
do
0.35 mm2 cable cross-section and a roll of black felt adhesive

r
rp
cum
tape.
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2.2.3 Wiring harness repair set - VAS 1978A-
The new wiring harness repair set - VAS 1978A- allows optimal
repair quality to be achieved in the area of vehicle electrics. Using
the new pliers, repairs to connectors and wiring open circuits can
be carried out. To do this, complete repair wire sections with con‐
tacts already crimped on are used and joined to the vehicle's own
wiring harness with the aid of four different types of crimp con‐
nectors. A new set of crimping pliers with head adapters and a
hot air blower for shrinking the crimp connectors make a perfect
electrical connection.
Note
⇒ Operating instructions Wiring harness repair set - VAS 1978A-

wage es n
Amarok
yV
olks 2011 ➤ , Amarok 2017 ot➤
gu , Caddy 2004 ➤ , Caddy 2011 ➤ , Caddy 2 ...
b
ir se
d Electrical system
ara
nte - general information - Edition 01.2019
tho eo
au r ac
2.2.4 ss Release tool set - VAS 1978/35-
ce
e
nl
pt
du
an
Release tool set - VAS 1978/35- serves as a means of releasing
itte
y li
various primary and secondary locking devices in Group vehicles.
erm
ab
The set comprises 26 different tools with which, for example,
ility
ot p
round connector systems, flat contacts with 1 or 2 fasteners and
wit
, is n
also single wire seals can be released or installed.
h re
hole
spec
Allocation of the correct release tool to the respective locking
es, in part or in w
mechanisms can be gleaned from the table in the ⇒ Operating
t to the co
instructions of -VAS 1978/35- .
rrectness of i
l purpos
nf
ercia
o
2.2.5 Wiring harness repair set - VAS 631
rm
m
atio
001-
om
n in
or c
thi
Wiring harness repair set - VAS 631 001- allows optimal repair
te
sd
a
quality to be achieved in the area of vehicle electrics. Using the

iv
o
r
rp
cu
wiring harness repair set, repairs to aluminium wiring in the area
o
m
f
en
ng
of the wiring connectors and in the event of wiring open circuits

t.
yi Co
can be carried out. To do this, copper repair wires (by the metre) Cop py
. rig
as well as complete copper repair wires with pre-crimped contacts
t
gh ht
yri by
are used. Connection to the vehicle's wiring harness is carried out
cop Vo
by lksw
using three different butt connectors according to the thickness cted agen
Prote AG.
of the wire.
The wiring harness repair set - VAS 631 001- for aluminium wires
comprises the following parts:
♦ Hand pliers without crimp adapter and positioner -VAS 631
001/1-
♦ Crimp adapter and positioner for 2.5-mm2 aluminium wires -
VAS 631 001/2-
♦ Crimp adapter and positioner for 4-mm2 aluminium wires -VAS
631 001/3-
♦ Crimp adapter and positioner for 6-mm2 aluminium wires -VAS
631 001/4-
♦ Aluminium wire strippers -VAS 631 001/5-
Caution
Only use the corresponding butt connectors with heat-shrink

hose for repairs to aluminium wires ⇒ Electronic parts cata‐
logue (ETKA) .
Note
⇒ Operating instructions Wiring harness repair set - VAS 631

001-
2.2.6 Wiring harness repair set - VAS 631

003-
Wiring harness repair set - VAS 631 003- allows optimal repair
quality to be achieved in the area of vehicle electrics. With this
wiring harness repair set, repairs to 10-mm2 and 16-mm2 wires

can be carried out in the area of the connections and in the event
of wiring open circuits. To do this, repair wires (by the metre) as
well as complete repair wires with pre-crimped/pre-fitted contacts
are used. Connection to the vehicle's wiring harness is carried out
using two different butt connectors according to the thickness of
the wire.
The wiring harness repair set - VAS 631 003- for 10-mm2 and 16-
mm2 wires comprises the following parts:
♦ Case with inserts -VAS 631 003/1-
♦ Crimping pliers -VAS 631 003/2- n AG. Volkswagen AG do
lkswage es n
o ot g
yV
♦ Wire strippers -VAS 631 003/3- d b ua
ran
ir se tee
ho
♦ Wire cutters -VAS 631 003/4- aut or
ac
ss
♦ Crimp adapter for 10-mm2 wires -VAS 631 003/5-
ce
e
nl
pt
du
an
itte
♦ Crimp adapter for 16-mm2 wires -VAS 631 003/6-
y li
erm
ab
ility
ot p
wit
, is n
Note
h re
hole
spec
es, in part or in w
t to the co
⇒ Operating instructions Wiring harness repair set - VAS 631
003-
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
co lksw
by
cted agen
Prote AG.

2.3 Tool descriptions

⇒ “2.3.1 Special pliers with insert”, page 119
⇒ “2.3.2 Release tools for contacts”, page 119
⇒ “2.3.3 Assembly tools for single wire seals”, page 120
⇒ “2.3.4 Wire stripper VAS 1978/3 ”, page 120
⇒ “2.3.5 Hot air blower VAS 1978/14A ”, page 121
⇒ “2.3.6 Crimping pliers VAS 1978/1A ”, page 121 AG. Volkswagen AG d
agen oes
lksw not
2.3.1 Special pliers with insert
o
byV gu
ara
ed
ris nte
o eo
The special pliers without insert - VAS 1978/1-
aut
h
with insert for spe‐ ra
cial pliers - VAS 1978/2- is part of theswiring harness repair set -
s c
ce
le
VAS 1978- and is used to crimp connectors during wiring harness

un
pt
repairs.
an
d
itte
y li
rm
ab
Colour allocation of crimp connectors to crimp recess:
pe
ility
ot
wit
, is n
Colour of crimp Colour of crimp re‐ Wiring cross section
h re
connector cess
hole
spec
Yellow Yellow
es, in part or in w
0.35 mm2
t to the co
Red Red 0.5 mm2 - 1.0 mm2
blue blue 1.5 mm2 - 2.5 mm2
rrectness of i
Yellow Yellow 4.0 mm2 - 6.0 mm2
l purpos
nform
Note
mercia
a
♦ As an alternative, the connectors can also be crimped with
com
tion in
crimping pliers (base tool) - VAS 1978/1-2- in conjunction with
r
te o
thi
head adapters -VAS 1978/1-1- or -VAS 1978/2A-
s
iva
⇒ page 121 .
do
r
rp
cum
fo
♦ It is essential to ensure that the correct crimp recess is chosen

en
ng
t.
yi
for the crimp connector being used ⇒ page 119 .
Co
Cop py
ht. rig
♦ The insulation on the wires must not be crimped.
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2.3.2 Release tools for contacts

The various release tools serve as a means of detaching the dif‐
ferent contacts from the connector housings without damage.
A selection of release tools is included in the wiring harness repair
set - VAS 1978- and wiring harness repair set - VAS 1978A- . The
complete set of release tools is included in release tool set - VAS
1978/35- ⇒ page 117 .
WARNING
Some tools are equipped with a tool safety device.

This must be pushed over the tip of the tool after use in order
to protect the tip and prevent injuries to personnel.
Releasing and dismantling connector housings ⇒ page 168 .

2.3.3 Assembly tools for single wire seals

The assembly tools serve as a means of sliding the single wire
seals fully into the connector housing without damage and there‐
by assure complete sealing between single wire and connector
housing.
4 assembly tools for single wire seals are included in each wiring
harness repair set - VAS 1978 B- and previous versions.
Installing single wire seals ⇒ page 165 .
2.3.4 Wire stripper - VAS 1978/3-

Wire strippers - VAS 1978/3- serve as a means agen
Aof stripping
G. Volkswageninsu‐
AG do
lation off wires and cutting wires in theVocorrect
lksw manner. es n
ot g
y ua
db ran
Wire strippers - VAS 1978/3- are
ho
riincluded
se in wiring harness repair tee
set - VAS 1978 B- and previous
aut versions. or
ac
ss
The wire strippers have an adjustable limit stop within the pliers
ce
e
nl
pt
du
jaws, with which the desired length of insulation to be removed
an
itte
y li
can be adjusted.
erm
ab
ility
ot p
Stripping:
wit
, is n
h re
– Set sliding stop in jaws of pliers to desired insulation stripping
hole
length.
spec
es, in part or in w
– Insert end of wire from front onto stop into jaws of pliers and t to the co
press pliers together fully.
rrectness of i
– Open pliers again and remove stripped insulation from end of

l purpos
wire.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
op
– If necessary, cut wire with cutting part on upper side of wire
C py
t. rig
gh
strippers.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2.3.5 Hot air blower - VAS 1978/14A-
Caution
When shrink-fitting crimp connections, make sure not to dam‐

age any other wiring, plastic parts or insulating material with
the hot nozzle of the hot air blower.
Close attention to operating instructions for hot air blower is
essential!
The hot air blower - VAS 1978/14A- is used in conjunction with

shrink element for hot air blower - VAS 1978/15- to shrink fit the . Volkswage
crimp connectors. After crimping, the crimp connector has wato
gebe
n AG n AG d
oes
shrink fitted using the hot air blower in order to prevent olksingress
any
V
not
gu
by ara
of moisture. ris
ed
nte
tho eo
s au ra
c
Hot air blower - VAS 1978/14A- is includeds in wiring harness re‐
ce
e
pair set - VAS 1978 B- and previous versions.

nl
pt
du
an
itte
y li
Shrink fit crimp connectors using hot air blower - VAS 1978/14A-
erm
ab
⇒ page 140 , or ⇒ page 142 .
ility
ot p
wit
, is n
h re
2.3.6 Crimping pliers - VAS 1978/1A-
hole
spec
es, in part or in w
Crimping pliers - VAS 1978/1A- or crimping pliers (base tool) -
t to the co
VAS 1978/1-2- together with head adapter 0.35 - 2.5 mm² - VAS
1978/1-1- or head adapter 4.0 - 6.0 mm² - VAS 1978/2 A- are used
to squeeze together crimp connectors from the wiring harness
rrectness of i
repair sets.
l purpos
Crimping connectors using crimping pliers - VAS 1978/1A-

⇒ page 142 .
nf
ercia
The following heads adapters are available for crimping pliers
orm
(base tool) - VAS 1978/1-2- :
m
atio
om
n in
♦ Head adapter 0.35 mm2 - 2.5 mm2 - VAS 1978/1-1-
or c
thi
te
sd
♦ Head adapter 4.0 mm2 - 6.0 mm2 - VAS 1978/2A-
iva
o
r
rp
cu
o
♦ Head adapter for JPT contacts - VAS 1978/9-1-

f
en
ng
t.
yi Co
op
In conjunction with head adapter for JPT contacts - VAS C py
ht. rig
1978/9-1- , the crimping pliers are used to crimp contacts to single rig ht
py by
wires during repairs to wiring with cross sections up to
co Vo
by lksw
cted
0.35 mm2 ⇒ page 127 .
agen
Prote AG.
Interchanging head adapter:

– Open crimping pliers fully.
– Disengage both locking pins -arrows- from main body of crimp‐

ing pliers.

– Insert required head adapter in main body of crimping pliers

from above -arrow-.
lkswage es n
o ot g
byV ua
d ran
ir se
– Lock head adapter by pressing pins -arrows- into main body
tho tee
or
of crimping pliers. ss
au ac
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
2.4 Repairs to electrical wiring harnesses
l purpos
⇒ “2.4.1 Notes on repairs to airbag and belt tensioner wiring”,
nf
ercia
page 122
orm
m
atio
⇒ “2.4.2 Repairing CAN bus wiring”, page 124
om
n in
c
⇒ “2.4.3 Repair of Flexray wires with sheath”, page 125

or
thi
te
sd
a
⇒ “2.4.4 Repair of Flexray wires without sheath”, page 126

iv
o
r
rp
cu
o
m
⇒ “2.4.5 Renewal of aerial wiring”, page 127
f
en
ng
t.
yi Co
op
⇒ “2.4.6 Repairs to electrical wiring with cross sections up to 0.35
C py
t. rig
gh
mm2 ”, page 127
ht
pyri by
Vo
co lksw
by
⇒ “2.4.7 Repairs to 10-mm2 or 16-mm2 wires with single butt
cted agen
Prote AG.
connector”, page 130
⇒ “2.4.8 Repairs to 2.5 mm2, 4 mm2 or 6 mm2 aluminium wires
with single butt connector”, page 135
⇒ “2.4.9 Wiring open circuit with one repair position”, page 140
⇒ “2.4.10 Wiring open circuit with two repair positions”,
page 142
2.4.1 Notes on repairs to airbag and belt ten‐

sioner wiring
In addition to the general notes on repairs to wiring harnesses,
the following instructions must be observed on how to repair wir‐
ing in airbag system and belt tensioners:

WARNING
♦ The airbag system and belt tensioner may fail.

♦ Faulty repairs to the airbag and seat belt tensioning sys‐
tem can cause malfunctions in the passenger protection
system.
♦ For repairs to airbag and belt tensioner wiring harnesses,
only contacts, connectors and wiring designed specifically
for this purpose may be used ⇒ Electronic Parts Cata‐
logue (ETKA) .
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
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Note
♦ Wires from airbag and belt tensioner wiring harness are only
allowed to be repaired using the wiring harness repair set -
VAS 1978 B- and previous versions.
♦ Adhere to general instructions concerning repairs to vehicle
electrical system ⇒ page 113 .
♦ Observe vehicle stickers indicating high voltage components.
Before carrying out repairs, discharge residual voltage ⇒
General body repairs, interior; Rep. gr. 69 ; Occupant safety .
♦ For wiring in the airbag system and belt tensioners, repairs
may be performed at 2 locations as a maximum. The more the
repairs there are in the wiring, the greater the resistance and
this can trigger faults in the self-diagnosis of the system.
♦ To avoid corrosion, the crimp connectors are always to be
shrink-fitted when performing airbag or belt tensioner wiring
harness repairs.
AG. Volkswagen AG d
agen
♦ Do not incorporate the repaired wiring back in the Vvehicle's
olks
w oes
not
own wiring harness. Mark the repair position clearly
db
y
with yel‐ gu
ara
ise
low insulating tape. thor nte
eo
au ra
♦ Repairs in the airbag or belt tensioner area
ss should not be more c
ce
e
than 30 cm from the next connector housing. Together with

nl
pt
du
the yellow insulating tape, this gives a clear indication of re‐
an
itte
y li
pairs that have already been carried out.
erm
ab
ility
ot p
♦ In series production, the wires leading to the triggering units
wit
, is n
(airbags) are twisted with a length of lay of 20 mm ± 5 mm.
h re
This length of lay is ensured in series production by means of
hole
spec
standard-part numbers for pairs of wires and must be adhered
es, in part or in w
to under all circumstances when sections of twisted wires are
t to the co
repaired.
♦ During repairs, the wiring to the triggering units (airbags) must
rrectness of i
have the same length. When wires -1- and -2- are entwined,
the twine spacing of A = 20 mm ± 5 must be adhered to without
l purpos
fail.
♦ There must not be any section of wiring, for example in the
nf
ercia
vicinity of crimp connectors -arrow-, longer than B = 100 mm

rm
with the wires not twisted.

m
atio
om
n in
or c
thi
te
2.4.2 Repairing CAN bus wiring

sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Note Cop py
t. rig
gh ht
pyri by
Adhere to general instructions concerning repairs to vehicle elec‐
o Vo
by c lksw
cted agen
trical system ⇒ page 113 . Prote AG.

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

0.35 mm2 or 0.5 mm2 is used for CAN bus wiring.
♦ Colour codes of CAN bus wiring: agen
AG. Volkswagen AG d
oes
olksw not
V gu
Powertrain CAN, high wire Orange/black d by ara
rise nte
o
Convenience CAN, high wire Orange/green
auth eo
ra
s c
Infotainment CAN, high wire Orange/violet
s
ce
e
nl
pt
du
CAN low wire, (all) orange/brown
an
itte
y li
erm
ab
♦ Repairs to CAN bus wiring can be carried out either with sec‐
ility
ot p
tions of repair wiring with the correct cross section or with
wit
entwined wires “green/yellow” or “white/yellow” from the Elec‐ , is n
h re
tronic Parts Catalogue ⇒ Electronic Parts Catalogue (ETKA) .
hole
spec
es, in part or in w
♦ When repairs are performed, both CAN bus wires must have
t to the co
the same length. When twisting the wires -1- and -2- together,
the lay length must be A = 20 mm.
rrectness of i
♦ There must not be any section of wiring, for example in the
vicinity of crimp connectors -arrow-, longer than B = 50 mm
l purpos
with the wires not twisted.

♦ Mark the repair position with yellow insulation tape to make it
nform
ercia
easy to identify.
m
at
om
io
2.4.3 Repair of Flexray wires with sheath
n
c
in t
or
his
ate
do
priv
cum
Note
for
en
ng
t.
yi Co
op
♦ The repair of Flexray wires with sheath may only be carried
C py
t. rig
gh
out using Flexray wires with sheath from the electronic parts
ht
pyri by
Vo
catalogue ⇒ Electronic parts catalogue (ETKA) .
co lksw
by
cted agen
Prote AG.
electrical system
⇒ “2.1 General notes concerning repairs to vehicle electrical
system”, page 113 .
A two core sheathed cable -1 and 2- with a cross section of

0.35 mm2 is used as a Flexray wire.

♦ In the event of repair, both cores must have exactly the same
length.
♦ When twisting the wires -1 and 2- together, the length of each
complete twist must be -A- = 30 mm.
♦ In this case, no section of the wire may be longer than -B- =
50 mm without a twist, e.g. in the area of the crimp connectors
-arrow-.
♦ The maximum wire length with the sheath removed is -C- =
100 mm.
♦ The area of repair is to be protected against environmental
influences by suitable means. To do this, a crimp connector
with heat-shrink hose and internal adhesive over the untwisted
repair area is to be used as well as waterproof insulating tape
over the wire section stripped of sheath.
♦ The repair area is to be marked by suitable means, e.g. with
yellow insulating tape.
♦ For repairs to two core wires, the same specifications as for
repairs to single core wires are to be adhered to.
♦ In addition, both repair areas -arrows- are to be opposed by
one twist length -A- = 30 mm in relation to each other.
♦ The crimping of cable ends with connectors is to be carried out
analogously.
1 - Repair area in stripped section
n AG. Volkswagen A
2 - Repair area with connector-attached
olks
wage cable ends G does no
V t gu
by ara
C - Maximum stripped length
ris
ed = 100 mm nte
tho eo
s au ra
c
2.4.4 Repair of Flexray wires without sheath
s
ce
le
un
pt
an
d
itte
y li
erm
ab
Note
ility
ot p
wit
is n
♦ The repair of Flexray wires without sheath may only be carried

h re
ole,
out using Flexray wires without sheath listed in the electronic

spec
parts catalogue ⇒ Electronic parts catalogue (ETKA) .

t to the co

electrical system
⇒ “2.1 General notes concerning repairs to vehicle electrical
rrectne
system”, page 113 .

ss
A twisted two core unsheathed cable -1- and -2- with a cross sec‐
o
cial p
tion of 0.35 mm2 is used as a Flexray wire

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

♦ In the event of repair, both Flexray wires must have exactly

the same length.
♦ When twisting the wires -1 and 2- together, the length of each
complete twist must be -A- = 20 mm.
♦ In this case, no section of the wire may be longer than -B- =
40 mm without a twist, e.g. in the area of the crimp connectors
-arrow-.
♦ The repair area is to be marked by suitable means, e.g. with
yellow insulating tape.
♦ During the repair of both Flexray wires, the same specifica‐
tions as for the repair of one Flexray wire are to be adhered
to.
♦ In addition, both repair areas are to be opposed by one twist
length -A- = 20 mm in relation to each other.
♦ The crimping of cable ends with connectors is to be carried out
analogously.
1 - Repair area in wiring harness
2 - Repair area with connector-attached cable ends
2.4.5 Renewal of aerial wiring

A new approach to repair work on aerial wires has been devel‐
oped ⇒ page 150 .
Now connecting wires in different lengths and various adapter
cables are available as replacement parts instead of a complete
aerial wire.
♦ Replacement parts can be found in the ⇒ Parts catalogue
(ETKA): Special catalogue; Electrical connections; Genuinen AG. Volkswagen A
accessories; Subgroup 35 from illustration No. 035-20 . wage
olks
G do
es n
o V t gu
by ara
♦ These genuine parts are suitable for all aerial rwires
ise
d and wire
nte
diameters which may need to be replaced. utho eo
ra
a c
ss
♦ The connector housings for aerial cables are only available as ce
le
un
replacement parts in one colour. However, they can be used pt

an
d
for all colours of aerial connector.

itte
y li
erm
ab
♦ No provision has been made for replacement of individual
ility
ot p
aerial connectors in the event of repair.

wit
is n
h re
ole,
♦ The wires can be used retroactively for all VW models, with all
spec
installed aerial wire diameters.

t to the co
♦ All adapter and connection wires are suitable for all transmitter
and receiver signals.
rrectne
♦ This repair method can also be used for testing or retrofitting.

Assembly overview - aerial wire ⇒ page 151 .
ss o
Installing a new aerial wire ⇒ page 151 .

cial p
f inform
2.4.6 Repairs to electrical wiring with cross

mer
atio
m
sections up to 0.35 mm2

o
n
c
i
or
n thi
te
sd
iva
o
r
Note
p
cum
r
fo
en
ng
t.
yi Co
Adhere to general instructions concerning repairs to vehicle elec‐ Cop py
trical system ⇒ page 113 .
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Special tools and workshop equipment required Prote AG.

♦ Crimping pliers, complete - VAS 1978/1 A-

♦ Head adapter 0.35 mm² - 2.5 mm² - VAS 1978/1-1-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
For repairs to wiring with cross sections up to 0.35hor 2
mm , it is es‐ eo
ut ra
sential that contacts are crimped on using crimping
ss a pliers for JPT c
contacts - VAS 1978/9A- or crimping pliers (base tool) - VAS
ce
e
nl
pt
1978/1-2- with attached head adapter for JPT contacts - VAS
du
an
itte
1978/9-1- . Due to the low current strength of these wires in the
y li
erm
ab
micro and thousandths range, incorrectly crimped contacts cause
ility
ot p
electrical resistances and result in faults or failure in the respec‐
wit
, is n
tive system. The most common applications of these contacts are:
h re
hole
♦ Lambda probe
spec
es, in part or in w
t to the co
♦ Engine speed sender
♦ Air mass meter
rrectness of i
With the use of crimping pliers for JPT contacts - VAS 1978/9A-
or crimping pliers (base tool) - VAS 1978/1-2- with attached head
l purpos
adapter for JPT contacts - VAS 1978/9-1- , the correct connection

between crimp contact, wire and single wire seal is assured. The
nf
tool is only to be used for the application described.
ercia
orm
m
atio
om
n in
Note
or c
thi
te
sd
a
Crimped to the repair wiring are normal contacts and gold-plated

iv
o
r
rp
cu
contacts. The repair contact must always be the same type as the
o
m
f
en
ng
contact installed in the factory.

t.
yi Co
Cop py
t. rig
gh ht
Crimping on new contact with single wire seal yri
p by
o Vo
by c lksw
cted
– Insert head adapter for JPT contacts - VAS 1978/9-1- in crimp‐
agen
Prote AG.
ing pliers (base tool) - VAS 1978/1-2- ⇒ page 121 .
– Connect single wire seal to repair wire -arrow-.
Note
When doing this, the small diameter of the single wire seal must
face the contact to be crimped on.

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

– Open crimping pliers again and remove stripped insulation
from end of wire.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
– Push single wire seal towards stripped wire end until it is flush
an
itte
with wiring insulation.
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
– Insert new crimp contact into mounting of crimping pliers

or
-arrow-.
m
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

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

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

cation of pressure on the wire and single wire seal in the contact.
Furthermore, there is a stamp on the rear that indicates the cor‐
rect tool was used in the correct manner to carry out the crimping
process.
AG. Volkswagen AG d
agen oes
o lksw not
2.4.7 Repairs to 10-mm or 16-mm wires with ise
d by V2 2 gu
ara
nte
single butt connector or eo
th
au ra
ss c
ce
e
nl
pt
du
an
♦ Hot air blower - VAS 1978/14A- from wiring harness repair set
itte
y li
erm
- VAS 1978 B-
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
♦ Shrink element for hot air blower - VAS 1978/15A- from wiring
m
atio
m
harness repair set - VAS 1978 B-

o
n in
or c
♦ Wiring harness repair set - VAS 631 003-

thi
te
sd
iva
o
r
rp
cu
o
m
f
Note
en
ng
t.
yi Co
Cop py
t. rig
♦ Repair wires (by the metre) with a cross section of 10 mm2 or
gh ht
pyri by
16 mm2 are available for the repair.
co Vo
by lksw
cted agen
Prote AG.
♦ Furthermore, single repair wires with a crimped/attached con‐
tact are available for repair work.

Procedure
– Attach the crimping anvil and crimping stamp relevant to the
wire thickness to the crimping pliers as follows:
– Open crimping pliers from wiring harness repair set - VAS 631
003- .
– Pull out locking pin -1- in direction of arrow -A- as far as it will
go.
– Open adapter -2- in direction of arrow -B-.
– Insert crimping stamp -1- until it is heard to engage in mounting

-2- on adapter -arrow A-.
– Insert crimping anvil -3- until it is heard to engage in mounting
-4- of crimping pliers -arrow B-. . Volkswage n AG n AG d
wage oes
Volks not
gu
by ara
ed nte
oris eo
th
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Close adapter -1- in direction of arrow -A-.

– Insert locking pin -2- onto stop in direction of arrow -B-.
– Clear the wire to be repaired about 20 cm either side of the
repair position.
Caution
Risk of damage to electrical wiring.

♦ Carefully lay wrapped wiring harnesses aside.
– If necessary, cut through wrapping of wiring harness with a

knife.
– Cut out or through damaged section of wire with wire cutters
from wiring harness repair set - VAS 631 003- .

agen oes
olksw not
y V gu
d b ara
♦ If, after the damaged wire has been orisecut out, both ends of the nte
eo
vehicle's own wiring are too short
aut for a repair using single butt
h
ra
connectors, use a piece of yellow
ss repair wire of the appropriate c
ce
length with two crimp connectors.
le
un
pt
an
d
itte
♦ When repairing a single wire with crimped/attached contact,
y li
erm
ab
lay the yellow repair wire next to the damaged single wire of
ility
ot p
the vehicle and cut to the required length.
wit
is n
h re
ole,
spec
– Set the adjustable stop in the wire strippers from wiring har‐
ness repair set - VAS 631 003- to the length that needs to be
t to the co
stripped.
♦ 10 mm2 wires: 14 mm rrectne
♦ 16 mm2 wires: 16.5 mm
ss
– Place end of wire from front onto stop into jaws of pliers and
o
cial p
press pliers together fully.

inform
mer

atio
m
wire.
o
n
c
i
or
• Insulation must be cut cleanly and removed from the wire

thi
te
sd
iva
o
r
• Do not leave any insulation on the stripped wires

p
cum
r
fo
en
ng
• Single wires must not be damaged

t.
yi Co
Cop py
t.
– Choose butt connector and heat-shrink hose from wiring har‐
rig
gh ht
yri by
ness repair set - VAS 631 003- relevant for the repair. cop Vo
by lksw
cted agen
Prote
– Push heat-shrink hose onto one of the wires.
AG.

– Position butt connector -1- with first crimping point centrally on

crimping anvil -2-.
• Dimension -a- must be even on both sides
– Turn quick-action lever -3- in anti-clockwise direction -arrow-
until butt connector -1- is secure.
– Insert wire -2- with stripped end into butt connector -1- as far
as stop -arrow-.
• All single wires must be pushed into the butt connector
– Close and open the crimping pliers several times until the
crimping anvil moves downwards automatically toagthe
AG. Volksw en Astart
agen G do
position. V olksw es n
ot
by gu
ara
ed nte
oris eo
th
Note au ra
c
ss
ce
le
un
pt
The insulation on the wires must not be crimped.

an
d
itte
y li
erm
ab
– Crimping the wire with butt connector on the other side as de‐
ility
ot p
scribed.
wit
is n
h re
ole,
spec
– Pull out locking pin in direction of arrow -A- as far as it will go.
t to the co
– Open adapter in direction of arrow -B-.

– Remove crimped butt connector.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
Correct crimping result

um
r
fo
en
ng
t.
yi
A - 10 mm2, star crimp
Co
Cop py
ht. rig
B - 16 mm2, B crimp
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

After crimping, the heat-shrink hose over the butt connector has
to be shrink fitted using the hot air blower in order to prevent any
ingress of moisture.
– Place shrink element for hot air blower - VAS 1978/15A- on
hot air blower - VAS 1978/14A- .
Caution
Risk of damaging adjacent components.

♦ When shrink-fitting the hose, take care not to damage any
other wiring, plastic parts or insulating material with the hot
nozzle of the hot air blower.
♦ Close attention to operating instructions for hot air blower
is essential! AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
o eo
– Position heat-shrink hose -1- centrally over butt connectorauth
ra
-2- by feeling contours. ss c
ce
le
un
pt
• Dimension -a- must be approximately even on both sides.
an
d
itte
y li
erm
– Heat up heat-shrink hose using hot air blower along a straight
ab
ility
line, working from centre outwards, until it is sealed completely
ot p
wit
and adhesive escapes from the ends.
is n
h re
ole,
• This is how the finished repair point should look -3-.
spec
t to the co
rrectness o
Note
cial p
f inform
mer
♦ Ensure that, where several wires have to be repaired, the butt
atio
m
connectors are not directly adjacent to each other. To prevent

o
n
c
the circumference of the wiring harness from becoming to
i
or
n thi
great, position the butt connectors so they are offset slightly.
te
sd
iva
o
r
♦ If the repair position was already wrapped, this section has to

p
cum
r
fo
be wrapped again with yellow adhesive tape once the repair en

ng
t.
yi
has been carried out.
Co
Cop py
t. rig
gh
♦ Attach the repaired wiring harness with a cable tie, if neces‐
ht
pyri by
Vo
sary, to prevent it from generating noise when the vehicle is in
co lksw
by
cted agen
motion. Prote AG.

Premature release
– Push lever -1- downwards -arrow A-.
– Turn quick-action lever -2- in clockwise direction -arrow B- until
crimping anvil is in the start position.
If premature release is not possible by hand:
– Push lever -1- downwards -arrow
olks
wA-.
age es n
ot g
V
by ua
– Place wrench from wiring ris harness
ed repair set - VAS 631 003- rante
on bolt -3- on rear. utho eo
ra
a c
ss
– Turn wrench in anti-clockwise direction -arrow C- until crimp‐
ce
e
nl
ing anvil is in the start position.
pt
du
an
itte
y li
erm
ab
Caution
ility
ot p
wit
, is n
h re
Do not use the butt connector after premature release.
hole
spec
es, in part or in w
t to the co
2.4.8 Repairs to 2.5 mm2, 4 mm2 or 6 mm2
rrectness of i
aluminium wires with single butt connec‐
l purpos
tor
nf
ercia
orm
♦ Hot air blower - VAS 1978/14A- from wiring harness repair set
m
atio
m
- VAS 1978 B-
o
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Shrink element for hot air blower - VAS 1978/15A- from wiring
harness repair set - VAS 1978 B-
♦ Wiring harness repair set - VAS 631 001-
Note
♦ Copper repair wires (by the metre) with a cross section of 2.5
mm2, 4 mm2 or 6 mm2 are available for repair.
♦ Furthermore, single copper repair wires with crimped contacts
are available for repair work.

Procedure
– Choose the crimping anvil, crimping stamp and contact posi‐
tioner with contact locking mechanism relevant to the wire
thickness and attach to the hand pliers as follows:
– Open hand pliers from wiring harness repair set - VAS 631
001- .
go. AG. Volkswagen AG d
agen oes
olksw not
– Open support -2- in direction of arrow -B-. d by V gu
ara
rise nte
tho eo
au ra
ss c
ce
e
nl
– Place crimping anvil -1- in hand pliers in such a way that
pt
du
an
crimping anvil -1- is flush with front of pliers.
itte
y li
erm
ab
– Secure crimping anvil with pins -2- -arrow A- and tighten
ility
ot p
knurled screw by hand.
wit
, is n
h re
– Insert crimping stamp -3- that corresponds with crimping anvil
hole
spec
into support.
es, in part or in w
t to the co
– Secure crimping stamp with pins -4- -arrow B- and tighten
knurled screw by hand.
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
– Close adapter -1- in direction of arrow -A-.

t.
yi Co
Cop py
– Insert locking pin -2- onto stop in direction of arrow -B-.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Insert contact locking mechanism -1- in contact positioner

-2-.
– Locate contact positioner with contact locking mechanism on
hand pliers -5- and push hole in contact positioner -2- over
knurled screw -4-.
. Volkswagen AG
does gen AG
– Screw in knurled screwV-3-
olks and tighten by hand.
wa not
y gu
db a
– Clear the wire to oberis repaired about 20 cm either side of thentee
e ra
repair position.auth or
a
ss c
ce
e
nl
pt
Caution
du
an
itte
y li
erm
ab
Risk of damage to electrical wiring.
ility
ot p
wit
♦ Carefully lay wrapped wiring harnesses aside.
, is n
h re
hole
spec
es, in part or in w
– If necessary, cut through wrapping of wiring harness with a
t to the co
knife.
rrectness of i
– Cut out damaged section of wire with wire strippers from wiring
harness repair set - VAS 631 001- .
l purpos
Note
nform
mercia
at
If, after the damaged wire has been cut out, both ends of the ve‐
om
ion
hicle's own wiring are too short for a repair using single butt
c
in t
or
connectors, use a piece of yellow copper repair wire of the ap‐ his
ate
propriate length with two crimp connectors.

do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
– Insert end of wire from front into matching adapter (relevant to
co Vo
by lksw
cted agen
wire thickness) in jaws of pliers as far as it will go. Prote AG.
– Press the pliers together completely.

wire.
• Insulation must be cut cleanly and removed from the wire
• Do not leave any insulation on the stripped wires
• Single wires must not be damaged
– Choose butt connector and heat-shrink hose from wiring har‐
ness repair set - VAS 631 001- relevant for the repair.
– Push heat-shrink hose onto one of the wires.

– Insert butt connector -1- in contact positioner -2-.

• Butt connector -1- must be flush with contact positioner -2-
-arrow A-
– Push contact locking mechanism -3- as far as stop in direction
of arrow -B- and, in doing so, secure butt connector -1-.
• Lugs -4- on butt connector -1- must engage in groove -5- on
contact locking mechanism -3-
– Insert wire -2- with stripped end into butt connector -1- as far
as stop -arrow-.
• All single wires must be pushed into the butt connector.
• End of insulation should be no further than front edge of insu‐
lation crimp.
– Close hand pliers until hand pliers open again automatically.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
– Turn contact ulocking
tho
mechanism -2- onto stop in direction ofe or
-arrow-. ss a ac
ce
e
nl
– Remove butt connector -1- from contact positioner -3-.

pt
du
an
itte
y li
– Rotate hand pliers for 2nd crimping

erm
ab
ility
ot p
– Crimping the wire with butt connector on the other side as de‐
wit
, is n
scribed.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
go.
nform
ercia
– Open support -2- in direction of arrow -B-.

m
– Remove crimped butt connector.

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.

n G do AGElectrical
. Volkswagensystem
A
- general information - Edition 01.2019
wage es n
Volks ot g
Correct crimping result ed by ua
ran
oris tee
• End of wire must protrude
auth 0.1 mm-1.0 mm at front edge of wire or
ac
crimp, dimension -a-.
ss
ce
e
nl
pt
• End of insulation must not be crimped with wire crimp.
du
an
itte
y li
• Insulation should end no further than front edge of insulation
erm
ab
ility
crimp -arrows-.
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
After crimping, the heat-shrink hose over the butt connector has
to be shrink fitted using the hot air blower in order to prevent any
l purpos
ingress of moisture.
– Place shrink element for hot air blower - VAS 1978/15A- on
nf
ercia
hot air blower - VAS 1978/14A- .
orm
m
atio
om
n in
Caution
or c
thi
te
sd
iva
Risk of damaging adjacent components.
o
r
rp
cu
o
m
f
♦ When shrink-fitting the hose, take care not to damage any
en
ng
t.
yi Co
other wiring, plastic parts or insulating material with the hot Cop py
nozzle of the hot air blower. ht. rig
rig ht
py by
o Vo
♦ Close attention to operating instructions for hot air blower
by c lksw
cted agen
is essential!
Prote AG.
– Position heat-shrink hose -1- centrally over butt connector

-2-.
• Dimension -a- must be approximately even on both sides.
– Heat up heat-shrink hose using hot air blower along a straight
and adhesive escapes from the ends.
• This is how the finished repair point should look -3-.
Note
♦ Ensure that, where several wires have to be repaired, the butt

great, position the butt connectors so they are offset slightly.
be wrapped again with yellow adhesive tape once the repair
motion.

2.4.9 Wiring open circuit with one repair posi‐

tion
Note

Repair position with single crimp connector

– Place the wire to be repaired to one side (about 20 cm either
side of repair position).
– If necessary, remove binding around wiring harness using
folding knife.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
– Cut out damaged section of wire using wire strippers - VAS

un
pt
an
d
1978/3- .
itte
y li
erm
ab
ility
ot p
wit
Note
is n
h re
ole,
spec
If, after the damaged wire has been cut out, both ends of the ve‐
hicle's own single wire are too short for a repair using single crimp
t to the co
connector, use a piece of repair wire of the appropriate length with
2 crimp connectors ⇒ page 142 .
rrectness o
cial p
f i
– Strip 6 - 7 mm of insulation from ends of wire.
nform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

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

single wire and crimp together using crimping pliers.
Note

After crimping, the crimp connector has to be shrink fitted using

the hot air blower in order to prevent any ingress of moisture.
– Place shrink element for hot air blower - VAS 1978/15- on hot
air blower - VAS 1978/14A- .
Caution
When shrink-fitting crimp connections, take care not to dam‐

age any other wiring, plastic gpartsAG.or
Volinsulating
kswagen AG material with
a en does
the hot nozzle of the hotVoair
lkswblower. not
y gu
db ar
Close attention to risoperating instructions for hot air blowerntis
e a
ee
essential! tho or
au a c
ss
ce
e
nl
pt
du
an
itte
– Heat up crimp connector using hot air blower along a straight y li

erm
ab
line, working from centre outwards, until it is sealed completely ility
ot p
and adhesive escapes from ends. 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
io
Note
n
c
in t
or
his
te
♦ If several wires need to be repaired, ensure that the crimp

a
do
riv

p
cum
or

f
en
ng
t.
yi
great, position the crimp connectors so they are offset slightly.
Co
Cop py
t. rig
gh
ht
pyri by
Vo
be wrapped again with yellow insulation tape once the repair
o
by c lksw
cted agen
has been carried out. Prote AG.

motion.

2.4.10 Wiring open circuit with two repair posi‐

tions
Note

AG. Volkswagen AG d
Repair position with interlinked wire. agen oes
olksw not
V gu
by ara
– Place wire to be repaired to side at 2 points (about 20 cm rto ised
nte
o
both sides of respective repair position). aut
h eo
ra
ss c
ce
e
nl
pt
folding knife.
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
– Place yellow repair wire next to damaged wiring harness and
cut repair wire to required length using wire strippers - VAS
rrectness of i
1978/3- .
l purpos
– Cut out damaged section from vehicle's own single wire.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
– Strip 6 - 7 mm of insulation from ends of wire. gh ht
pyri by
Vo
o
by c lksw
– Push crimp connector onto vehicle's own single wires on one Prote
cted AG.
agen
side and push it onto repair wire on other side.

– Crimp connector using crimping pliers to join both ends of wire.

– Repeat process at other end of repair wire.
Note

After crimping, the crimp connector has to be shrink fitted using

the hot air blower in order to prevent any ingress of moisture.
– Place shrink element for hot air blower - VAS 1978/15- on hot
air blower - VAS 1978/14A- .
Caution
When shrink-fitting crimp connections, take care not to dam‐

age any other wiring, plastic parts or insulating material with
the hot nozzle of the hot air blower.
Close attention to operating instructions for hot air blowerwaisgen AG. Volkswagen AG doe
essential! yV
olks s no
t gu
b ara
ed nte
oris e
th or
au ac
ss
– Heat up crimp connector using hot air blower along a straight
ce
le

un
pt
an
d
and adhesive escapes from ends.

itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
Note f inform
mer
atio
m

o
n
c

i
or
n thi
e

t
sd
va
great, position the crimp connectors so they are offset slightly.

i
o
pr
cum
r
fo

en
ng
t.
yi Co
be wrapped again with yellow insulation tape once the repair Cop py
t. rig
gh ht
pyri by
Vo
o
by c
lksw
cted agen
Prote AG.
motion.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b a
Amarok 2011 ➤ , Amarok o2017 e ➤ , Caddy 2004 ➤ , Caddy 2011 ➤ra,n Caddy 2 ...
ris tee
h
Electrical system - general
aut information - Edition 01.2019 or
ac
ss
ce
e
nl
2.5 Repairs to fibre optic cables
pt
du
an
itte
y li
erm
ab
⇒ “2.5.1 Notes on repairs to fibre optic cables”, page 144
ility
ot p
wit
⇒ “2.5.2 Preparing fibre optic cable”, page 144
, is n
h re
hole
⇒ “2.5.3 Detaching fibre optic cable from cable harness connec‐
spec
tor”, page 150
es, in part or in w
t to the co
2.5.1 Notes on repairs to fibre optic cables
It is very difficult to identify the exact location of the defect. Re‐
rrectness of i
place the damaged fibre optic cable by laying a new wire parallel
l purpos
to the defective fibre optic cable.
nform
ercia
Note
m
at
om
io
♦ Via the menu options of the vehicle diagnostic tester “Guided
n
c
in t
r
Fault Finding” or “Guided Functions”, it is possible to ascertain

o
his
te
the components between which the fibre optic cable has been
a
do
riv
damaged.
p
cum
for
en
g
♦ The colour “yellow” indicates a fibre optic cable that has al‐
n
t.
yi Co
op
ready been repaired. C py
t. rig
gh ht
pyri by
Vo
co
Procedure:
by lksw
cted agen
Prote AG.
– Select operating mode “Guided Fault Finding” or select “Gui‐
ded Functions” in Vehicle diagnostic tester .
♦ Body
♦ Electrical system
♦ 01 - Self-diagnosis compatible systems
♦ Ring break diagnosis
– Remove relevant components.
– Disengage connectors and pull them off components.
– Prepare fibre optic cable ⇒ page 144 .
Caution
Do not over-bend fibre optic cables. Minimum radius for bends

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


♦ Fibre optic cable repair kit - VAS 6223A-
♦ Cutting pliers - VAS 6228-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
♦ Vehicleoris diagnostic tester
e nte
h eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Caution
nform
ercia
Do not over-bend fibre optic cables. Minimum radius for bends

is 25 mm.
m
a
com
tio
Do not route fibre optic cables over sharp edges.

n in
r
te o
thi
Make sure that the ends of fibre optic cables are not dirty and
s
iva
do
do not touch them with your bare hands.

r
rp
cum
fo
en
Do not expose fibre optic cables to heat.

ng
t.
yi Co
op py
It is not permissible to twist 2 fibre optic cables together or one
t. C rig
gh ht
fibre optic cable with a copper wire.
pyri by
Vo
o
by c lksw
cted agen
Protect connectors and connecting cables against dust. Use
Prote AG.
protective caps from the case.

AG. Volkswagen AG d
agen oes
lksw not
Insert tool adapter into pliers for fibre-optic conductor - VAS byV
o gu
ara
6223/1- : rised
nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Press locking pins -arrows- out.
rrectness of i
– Fit tool adapter onto pliers -arrow- and press back locking pins.
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
Cutting fibre optic cable to size: co Vo
by lksw
cted agen
Prote
– Determine required length of fibre optic cable.
AG.
– Open fibre optic cable pliers and insert length of fibre optic
cable -1- to be cut -arrow-.
– To cut fibre optic cable to size, close fibre optic cable pliers
fully.
Stripping:
– Open fibre optic cable pliers.
– Push down the stripping lever -arrow-.
– Insert fibre optic cable into the stripping hole.
• The fibre optic cable must be flush with the rear of the cutting
pliers.

– Close fibre optic cable pliers as far possible and hold closed.
– Push the stripping lever upwards -arrow- and remove fibre op‐
tic cable.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
Cut precisely (making a clean optic surface at end of cable):
h re
hole
spec
– Insert fibre optic cable -1- into the cutting hole.
es, in part or in w
t to the co
• The insulation must be lying against stop of cutting station.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
e
– Close fibre optic cable pliers and remove cable.

at
do
priv
c
– Visually inspect cable -1- to make sure that it has been cut
um
for
correctly and that there are no burrs on the cross-cut surface

en
ng
t.
yi Co
at end of cable. t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
Note cted agen
Prote AG.
♦ Place the fibre optic cable only on surface or material that is

absolutely clean or keep it in your hand.
♦ Use protective caps if there is a danger that the cross-cut sur‐
face at the ends of the fibre optic cable will be soiled.
Crimp brass pin contact to fibre optic cable:

– Change tool adapter -arrow-.

– Move safety catch on fibre optic cable pliers -arrow- so that
the word “Pin” can be seen.
AG. Volkswagen AG d
agen oes
o lksw not
y V gu
d b ara
– Insert a brass pin contact -1- into the hole.
orise nte
eo
th
u ra
– Close locking lever on fibre optic cable
ss a pliers -arrow-. c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Push fibre optic cable into brass pin contact -arrow- as far as
spring-cushioned stop and close fibre optic cable pliers fully.
ss o
– Open fibre optic cable pliers and remove fibre optic cable to‐
cial p
f in
gether with brass pin contact.
form
mer
atio
om
Caution
n
c
i
or
n thi
te
sd
a
Do not kink or excessively bend fibre optic cables (min. bend‐

iv
o
pr
ing radius: 25 mm).

um
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted
– Check that the brass pin contact -2- is correctly attached to
agen
Prote AG.
fibre optic cable -1-.
• 4 crimping points must be visible on the brass connecting pin.
• Make sure that the brass pin contact cannot be pulled off fibre
optic cable by hand.
• The cross-cut end surface of the fibre optic cable is
0.01 … 0.1 mm behind the brass pin contact (visual inspec‐
tion).
Note
♦ There are push-on couplings that are used to connect fibre

optic cables ⇒ Electronic Parts Catalogue .
♦ Installation of the new fibre optic cable in the cable harness
connector ⇒ page 150 .

Inserting fibre optic cable into corrugated pipe:

– Cut corrugated tube to a suitable length.
• Use cutting pliers - VAS 6228- or a sharp knife for cutting.
• Do not cut the corrugated tube with a paper cutter.
• The corrugated tube must be cut at a crest -arrow- not in a
trough.
• When the corrugated tube is installed, it must engage audibly
in the housing of the fibre optic cable.
– Insert fibre optic cable into pliers for fitting the corrugated tube
- VAS 6223/10- as shown in the illustration.
– Position pliers in place on the groove of the corrugated tube.
– Push pliers in groove along the circumference of the corruga‐
ted tube. This causes the fibre optic cable to be inserted in the
corrugated tube.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
149
Prote AG.
2. Wiring harness and connector repairs
2.5.3 Detaching fibre optic cable from lksw

agecable
es n
harness connector Vo ot g
d by ua
ran
se
ri tee
ho
Removing aut or
ac
ss
– Disengage and pull fibre optic cable connector off relevant
ce
e
nl
pt
control unit.
du
an
itte
y li
erm
– Release locking element in fibre optic cable connector -1- by
ab
ility
pressing it.
ot p
wit
, is n
– Release secondary locking element -2-, using a small screw‐
h re
hole
driver.
spec
es, in part or in w
– Remove fibre optic cable.
t to the co
Caution
rrectness of i
♦ Use protective caps from the case in order to protect the
l purpos
fibre optic cable against dust and dirt.

♦ Use a new housing as the secondary locking element can
nf
ercia
o
be damaged when the fibre optic cable is removed.
rm
m
atio
m
♦ Take note of the arrows on the basic module for the as‐
o
n in
c
signment of “IN” and “OUT”.

or
thi
te
sd
iva
o
r
rp
cu
o
m
Installing
f
en
ng
t.
yi Co
op
Install in the reverse order of removal observing the following:
C py
t. rig
gh ht
yri by
– Install fibre optic cables in accordance with markings “IN” and
op Vo
by c lksw
“OUT”. cted agen
Prote AG.
Note
♦ Push corrugated pipe into connector housing until it engages

audibly.
♦ Seal the open connector -2- for fibre optic cable with the pro‐
tective cap for cable connector - VAS 6223/9- -item 1-.
♦ The protective cap prevents soiling and mechanical damage
at the cross-cut end of the fibre optic cable so that the trans‐
mission of light is not impaired.
2.6 Repair of aerial wires

⇒ “2.6.1 General information”, page 150
⇒ “2.6.2 Assembly overview - aerial wire”, page 151
⇒ “2.6.3 Installing a new aerial wire”, page 151
⇒ “2.6.4 Repair set, aerial cable VAS 6720 ”, page 152
2.6.1 General information

A new concept for repair work on aerial wires has been devel‐
oped. Now connecting wires in different lengths and various
adapter cables are available as replacement parts instead of a
complete aerial wire.

General description
♦ Aerial wires cannot be repaired. If repair is required, they must
be replaced only by connecting wires and adapter cables of‐
fered as genuine parts.
♦ The replacement parts can be found in the ⇒ electronic parts
catalogue “(ETKA)” . olks
wage es n
o V t gu
by a
♦ These genuine parts riare
se suitable for all aerial wires and wire rante
d
diameters which may
utho need to be replaced. eo
r a ac
ss
♦ The connector housings for aerial cables are only available as
ce
e
nl
replacement parts in one colour. However, they can be used
pt
du
an
for all colours of aerial connector.
itte
y li
erm
ab
♦ No provision has been made for replacement of individual
ility
ot p
aerial connectors in the event of repair.
wit
, is n
h re
♦ The wires can be used retroactively for all VW vehicles, with
hole
spec
all installed aerial wire diameters.
es, in part or in w
t to the co
♦ All adapter and connection wires are suitable for all transmitter
and receiver signals.
rrectness of i
♦ This repair method can also be used for testing or retrofitting.
l purpos
2.6.2 Assembly overview - aerial wire

Assembly overview - aerial wire
nf
ercia
orm
Example: aerial wire between radio - R- and aerial - R11- is de‐
m
atio
m
fective. The following wires are required for the repair:

o
n in
or c
1- Adapter cable for connection to radio - R- , length: approx.

thi
te
sd
a
30 cm
iv
o
r
rp
cu
o
2- Connecting wire available in different lengths.

f
en
ng
t.
yi Co
op
3- Adapter cable for connection to aerial - R11- , length: ap‐ C py
ht. rig
prox. 30 cm rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2.6.3 Installing a new aerial wire
Note that the total length of an aerial wire, depending on vehicle
equipment level, can be divided into sections by aerial selection
control unit - J515- , control unit for traffic information - J559- or
aerial amplifier - R24- . Only the defective section of aerial wire
must be replaced.
Procedure
– Disconnect connectors of defective aerial cable from devices.
– Ascertain routing of defective aerial lead in vehicle and meas‐
ure total length of aerial connection to be renewed in vehicle.

The total length of aerial connecting wire is the sum of the length
of adapter cables required -1- and -3- and the connecting wire
-2-.
– To determine the length of connecting wire required, subtract
60 cm from the measured total length of aerial connecting wire
-2-.
– Procure the required adapter cables -1- and -3- and connect‐
ing wire -2- at length calculated as genuine part from the ⇒
Electronic Parts Catalogue “ETKA” .
– Cut off connectors from defective aerial cable.
The remainder of the defective aerial wire remains in the vehicle.
– Connect adapter cables -1- and -3- to equipment in vehicle.
– Lay and secure connecting wire -2- in the direct vicinity of
where the wiring is laid in series-produced vehicles.
Note
Do not kink or excessively bend aerial wires! The bending radius

must not be below 50 mm.
– Connect connecting wire to adapter cables.

– Perform functional check.
2.6.4 Repair set, aerial cable - VAS 6720- n AG. Volkswagen AG

wage does
olks not
yV gu
Checking the aerial wire: ⇒ page 153 db ara
rise nte
tho eo
Changing tool adapter: ⇒ page 153 ss au ra
c
ce
le
Cutting aerial wire: ⇒ page 154

un
pt
an
d
itte
y li
Stripping shielding: ⇒ page 154
rm
ab
pe
ility
Stripping outer sleeve: ⇒ page 157
ot
wit
, is n
h re
Stripping inner insulation: ⇒ page 158
hole
Crimping inner conductor: ⇒ page 159 spec

es, in part or in w
t to the co
Crimping outer conductor: ⇒ page 161
rrectness of i
♦ Repair set, aerial cable - VAS 6720-

l purpos
♦ Wire stripping tool RTK-031 - VAS 6720/1-

♦ Crimping tool RTK-031 - VAS 6720/2-
nform
mercia
♦ Wire stripping tool RG 174 - VAS 6720/3-

a
com
tion in
♦ Crimping tool RG 174 - VAS 6720/4-

r
te o
thi
s
iva
The repair set, aerial cable - VAS 6720- allows for attaining opti‐
do
r
rp
mal repair quality when repairing the aerial wiring using the tools
um
fo
RG 174 (blue) and RKT 031 (black). The set includes the respec‐
en
ng
t.
yi
tive stripping tools and crimping tools for both aerial cables. In
Co
Cop py
addition, the case includes all the separate parts needed to con‐
t. rig
gh ht
yri
nect the Genuine plug in nearly production quality. In this case, p by
co Vo
lksw
only the 0-coded connector (green) is required. All other connect‐
by
cted agen
Prote
ing wires for the various infotainment systems can be found in
AG.
ETKA (EL-electrical connection elements) in plate 035-XX. These

various adapter aerial wires are specific to vehicle models and
must always be ordered separately. All the separate parts can be
found in the above-named plate for reordering. The compart‐
ments of the case are labelled with the part numbers of the

lkswage es n
o ot g
byV ua
ir se
d Amarok 2011 ➤ , Amarok 2017 ran ➤ , Caddy 2004 ➤
tee , Caddy 2011 ➤ , Caddy 2 ...
o
auth Electrical orsystem - general
ac information - Edition 01.2019
ss
ce
le
consumable materials. The repair set is based on the existing
un
pt
an
adapters and pliers system of the VAS 1978B.
d
itte
y li
erm
ab
ility
ot p
Note
wit
is n
h re
ole,
spec
For additional information refer to ⇒ Operating manual for repair
set, aerial cable - VAS 6720-
t to the co
Checking the aerial wire:
rrectne
Before beginning repairs, determine which aerial wire is affected
using the gauge.
ss
In both systems, the positioner of the adapters is colour-coded
o
cial p
f i
accordingly.
nform
mer
♦ -1- = system RG 174 = blue
atio
om
n
c
♦ -2- = system RTK 031 = grey
i
or
n thi
te
sd
Changing tool adapter:
iva
o
pr
cum
r
– Select appropriate adapter according to check of aerial wire

fo
en
ng
⇒ page 153 .
t.
yi Co
Cop py
t. rig
– Open handles of pliers completely.
opyri
gh by
Vo
ht
c by lksw
cted agen
– Release the two locking pins -arrows- from handles of pliers,
Prote AG.
and pull them out.
– Insert required tool adapter from above -arrow- into handles

of pliers.

Amarok 2011 ➤ , Amarok 2017e➤ , Caddy
. Volkswa2004
gen AG➤ , Caddy 2011 ➤ , Caddy 2 ...
g n AG does
Electrical system - general
Vo lkinformation
swa - Edition 01.2019
not
y gu
db ara
ise nte
– Lock adapter into handles
tho of pliers
r
by pressing in pins eo
-arrows-. s au ra
c
s
ce
le
Cutting aerial wire:
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
– Push aerial wire -2- into cutting mechanism -1-.
l purpos
– Close tool and open it again.
nform
ercia
– Pull aerial wire out of cutting mechanism.

m
a
Stripping shielding:
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.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Push locating pin -1- into rotary cutter to stop.

rrectne
– Push aerial wire -2- into rotary cutter to stop. The locating pin
-3- is again entirely visible.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

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
t to the co
– Push blade holder -1- against shaft of rotary cutter until it en‐
gages. The gap -2- beneath the blade holder is completely
closed.
rrectne
– Hold aerial wire securely so that it cannot turn.

s
– Turn rotary cutter -3- approximately 2 times in direction of ar‐

s o
cial p
row until it rotates easily.

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.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
– Pull release pin -1-. The blade holder is released and sepa‐ Prote
cted AG.
agen
rates from aerial wire.
– Push locating pin -2- into rotary cutter to stop. The aerial wire
is pressed out of rotary cutter.
– Remove shielding from aerial wire.
– Remove remnants of insulation from rotary cutter.
Stripping outer sleeve:

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Push aerial wire -2- through notch -3- into tool adapter to stop
ility
ot p
-1-.
wit
, is n
h re

hole
spec
– Pull out aerial wire -4-.

es, in part or in w
t to the co
Stripping inner insulation:

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
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
– Push aerial wire -2- through notch -1- into tool adapter
aut to stop. ra
ss c
– Close tool and open it again. ce
le
un
pt
an
d
itte
– Pull out aerial wire -3-. y li

rm
ab
pe
ility
Crimping inner conductor:
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
159
cted agen
Prote
2. Wiring harness and connector repairs
AG.
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
– Select appropriate adapter according to check of aerial wire

t to the co
⇒ page 153 ⇒ page 153 .

– Tilt back swinging positioner -2-.
rrectne
– Open positioning piece -3-. Positioning piece swings upwards.

– Push inner contact -1- into swinging positioner to stop and
ss
loosen positioning piece. The inner contact is fixed in place.

o
cial p
f inform
– Tip swinging positioner inwards. The inner contact -4- is posi‐

mer
tioned in the tool adapter.

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.

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.
– Push aerial wire -1- into inner contact -2- in tool adapter. Hold
swinging position in place while doing so.
– Close tool until it opens by itself.
– Open positioning piece -3- and pull out aerial wire.
Crimping outer conductor:

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Push sleeve -2- and outer contact -1- over inner conductor.
The knurled contact part must be pushed under shielding but
l purpos
over the aluminium foil.

nform
– Push on outer contact -3- completely. Ensure proper seating

ercia
of female connector and pin.

m
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.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
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
– Push on sleeve -3- to outer contact.

– Open tool and tilt out swinging positioner -1-.
nform
ercia
– Position mounted outer contact -2- in tool adapter in middle

m
notch on contact edge.

com
tion in
r

te o
thi
s
iva
do
– Pull out aerial wire.

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.

2.7 Repairing connector housings and con‐

nectors
⇒ “2.7.1 Notes on repairs to connector housings and connectors”,
page 164
⇒ “2.7.2 Repairing contacts in connector housings”, page 164
⇒ “2.7.3 Installing single wire seals”, page 165
⇒ “2.7.4 Repairing connector housings using cut and clamp meth‐
od”, page 167
2.7.1 Notes on repairs to connector housings

and connectors agen
AG. Volkswagen AG d
oes
olksw not
V gu
d by ara
ise nte
Note ut
hor eo
ra
s a c
s
ce
e
nl
pt
du
an
itte
y li
erm
♦ Allocation of the appropriate crimp contacts to the connector
ab
ility
housings is by way of the part number stamped on the con‐
ot p
wit
nector housing. Listed in illustration 198 (electrical connecting
, is n
h re
elements) in ⇒ Electronic Parts Catalogue (ETKA) are the part
hole
spec
numbers for the connector housings in conjunction with the
es, in part or in w
associated crimp contacts.
t to the co
♦ Damaged connector housings must always be replaced.
♦ New connector housings can be ordered from OTC Kassel.
rrectness of i
l purpos
2.7.2 Repairing contacts in connector hous‐

ings
nf
ercia
orm
– If necessary, first open or release secondary locking element
m
atio
m
of connector housing ⇒ page 168 .

o
n in
or c
thi
– Release contact (primary locking element) using suitable re‐
te
sd
a
lease tool ⇒ page 168 .

iv
o
r
rp
cu
o
m
– Pull out contact on single wire from connector housing.
f
en
ng
t.
yi Co
op
– Select yellow repair wire with correct contact from wiring har‐
C py
t. rig
gh
ness repair set.
ht
pyri by
Vo
o
by c lksw
– Free wire to be repaired from vehicle's own wiring harness
cted agen
Prote AG.
(about 20 cm either side of repair position).
folding knife.
– Insert new contact of repair wire into connector housing until

it is engages.
– Push single wire seal -A- onto repair wire.
Note
The small diameter of the single wire seal must face the connector
housing.
– Push single wire seal into connector housing using correct as‐
sembly tool -B- ⇒ page 165 .

– Trim repair wire and single wire of vehicle's own wiring harness
as required using wire strippers - VAS 1978/3- .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
– Strip 6 - 7 mm of insulation from end of repair wire and vehicle's
ility
ot p
own single wire using wire strippers.
wit
is n
h re
– Crimp stripped ends of repair wire and single wire of vehicle's
ole,
spec
own wiring harness using crimping pliers and a crimp connec‐
tor as described in chapter “Wiring open circuits with one
t to the co
repair position” ⇒ page 140 .
rrectness o
cial p
f inform
mer
atio
om
n
c
Note i
or
n thi
te
sd
iva
o
r

p
cum
r
fo

en
ng
t.
yi
Co
op py
great, position the crimp connectors so they are offset slightly. t. C rig
gh ht
pyri by
o Vo
by c lksw
cted
be wrapped again with yellow insulation tape once the repair
agen
Prote AG.
motion.
2.7.3 Installing single wire seals
Note
♦ Single wire seals prevent the ingress of moisture and dirt in

the connector housing. They are installed, for example, in the
engine compartment and must always be reinstalled following
repairs.
♦ As standard, the single wire seal is crimped together with the
contact on the wire; this is not the case with the repair wires.
Before crimping the repair line, the single wire seal must there‐
fore first be pushed onto the wire.
♦ It is essential that the single wire seals are of the correct size
to fit the cross section of the repair wire. The outer diameter
of the single wire seal is based on the socket diameter of the
connector housing. Only carry out installation using the ap‐
propriate assembly tool.

Installing single wire seal:

– Disengage contact locking element using appropriate release
tool -A- and pull wire with single wire seal backwards -arrow-
out of connector housing.
olkswagen AG
en AG. V
– Cut out old contact with single wire seal from vehicle's
olks
wagown does
not
wiring harness. ed
byV gu
ara
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Push repair wire with new contact into respective socket of
connector housing until it engages.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
– Push single wire seal -A- onto free end of repair wire. rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
The small diameter of the single wire seal must face the connector
housing.
– Push single wire seal -A- on repair wire up to connector hous‐

ing.

– Push single wire seal -A- to stop into connector housing using
respective assembly tool -B-.
– Trim repair wire and single wire of vehicle's own wiring harness
accordingly using wire strippers - VAS 1978/3- .
– Crimp stripped ends of repair wire and single wire of vehicle's
own wiring harness using crimping pliers and a crimp connec‐
tor as described in chapter “Wiring open circuits with one
repair position” ⇒ page 140 .
2.7.4 Repairing connector housings using cut

and clamp method
Note
♦ For technical reasons, the connector housings for thegecut and

n AG. Volkswagen AG
clamp method can only be supplied with the cut and
ksw clamp
a d oes
not
Vol
contacts inserted. ed by gu
ara
is nte
or
♦ These contacts can be removed just like
au in the case of any
th eo
ra
other connector housing if they are not
ss needed. c
ce
le
un
pt
♦ Repair wires can be supplied that already have the appropriate

an
d
itte
contacts crimped on ⇒ Electronics parts catalogue (ETKA) .

y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

2.8 Releasing and dismantling connector

housings
⇒ “2.8.1 Notes on releasing and dismantling connector housings”,
page 168
⇒ “2.8.2 Secondary locking element”, page 168
⇒ “2.8.3 Primary locking element”, page 169
⇒ “2.8.4 Round connector systems”, page 170
⇒ “2.8.5 Flat connector systems”, page 170
⇒ “2.8.6 Special connector systems”, page 172
2.8.1 Notes on releasing and dismantling con‐

nector housings n AG. Volkswagen A
age G do
ksw es n
y Vol ot g
ua
b
ed ran
Note horis tee
t or
au ac
ss
ce
le

un
pt
an
d
itte
y li
♦ Always use release tools specifically intended for releasing
erm
ab
purposes. Under no circumstances should the contacts be
ility
ot p
pulled out of the connector housings with force.

wit
is n
h re
ole,
♦ Damaged connector housings must always be replaced. New

connector housings can be ordered from OTC Kassel. spec
t to the co
♦ As an aid to disengage the secondary locking elements, a
small screwdriver can be used.
rrectne
♦ The socket/connector-pin assignment can be found stamped

on the secondary locking element or on the rear of the con‐
nector housing.
ss o
cial p
♦ For more detailed information about the locations of connec‐

inform
tors, see ⇒ Current flow diagrams, Electrical fault finding and

mer
Fitting locations.
atio
om
n
c
i
or
Allocation of the correct release tool to the respective locking

thi
te
mechanisms can be gleaned from the table in the ⇒ Operating

sd
iva
o
r
instructions of -VAS 1978/35- .

p
cum
r
fo
en
ng
2.8.2 Secondary locking element

t.
yi Co
Cop py
t. rig
gh
The secondary locking element is a housing catch (second line
ht
pyri by
Vo
o
locking element) that secures all the wires in one connector hous‐ by c lksw
cted agen
ing. If a secondary locking element is fitted to a connector hous‐ Prote AG.
ing, this must always be opened or removed using the appropriate

tool before releasing and pulling out individual crimp contacts.
The secondary locking element is different in colour from the rest
of the connector housing. This makes it easier to identify the sec‐
ondary locking element and clarifies its intended function.
The types of connector housing shown here are just a few exam‐
ples to show the different functions of secondary locking element.

Example 1:
The housing catch is disengaged by removing a “toothed ele‐
ment” -arrow-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
Example 2: thor eo
au ra
c
The housing catch is disengaged by opening a “flap” -arrow-. 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
Example 3:
l purpos
The housing catch can be disengaged by detaching a “slide”

-arrow-. 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
2.8.3 Primary locking element
AG.
The primary locking element is what fixes an individual crimp

contact in the connector housing.
If necessary, any housing catches in place (secondary locking
elements) must be released or removed prior to disengaging the
contacts using the prescribed tool ⇒ page 168 .
The types of primary locking elements shown as follows are just
a few examples to show the different functions of primary locking
element.
♦ Round connector systems ⇒ page 170
♦ Flat connector systems ⇒ page 170
♦ Special connector systems ⇒ page 172
Allocation of the correct release tool to the respective locking el‐
ement can be gleaned from the table in the ⇒ operating instruc‐
tions of -VAS 1978/35- .

2.8.4 Round connector systems
Note

contacts using the prescribed tool ⇒ page 168 . AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
e
– Insert corresponding connector housing release tool inhorelease
ris nte
eo
port of connector housing. aut ra
c
ss
– Hold contact on wire and push it into connector housing lightly
ce
le
un
pt
-arrow-.
an
d
itte
y li
rm
ab
pe
ility
Note
ot
wit
, is n
h re
hole
By pushing the contact in the direction of the connector housing,
spec
the locking tabs of the contact are lifted up by the housing edge
es, in part or in w
t to the co
and can be disengaged using the release tool.
– At the same time, push release tool in direction of connector
rrectness of i
housing -arrow- and pull released contact out of connector
housing.
l purpos
– The release tool can be pulled out of the connector housing
nform
ercia
again once the contact has been removed.

m
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.
2.8.5 Flat connector systems
Note

Flat connector with one locking tab:

– Insert corresponding connector housing release tool in release
port of connector housing.
-arrow-.
Note

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

Amarok
n AG. V2011
olkswa➤
gen, AAmarok
G do 2017 ➤ , Caddy 2004 ➤ , Caddy 2011 ➤ , Caddy 2 ...
wage es n
y Volks Electrical
ot g system - general information - Edition 01.2019
db ua
ran
ir se tee
– At the
ut same time, push release tool in direction of connector
ho or
housing
ss
a
and pull released contact out of connector housing ac
-arrow-.
ce
le
un
pt
an
d

itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
Flat connector with 2 locking tabs:
ss
o
cial p
f i
nform
mer
– Hold contact on wire and push it into connector housing
atio
m
-arrow- as far as it will go.

o
n
c
i
or
n thi
te
sd
iva
o
Note
pr
cum
r
fo
en
ng
t.
yi
Co
op py
t. C rig
gh ht
yri
p by
co Vo
by lksw
cted agen
Prote AG.

housing and pull released contact out of connector housing
-arrow-.
Asymmetrical:
-arrow-.
Note


olkswagen AG
wag 2017 ➤ , Caddy d2004 en AG. V
Amarok 2011 ➤ , VAmarok
olks
oes ➤ , Caddy 2011 ➤ , Caddy 2 ...
not
gu
Electrical system
sed - general information - Edition 01.2019
by ara
n
ri tee
ho
ut or
– At the same release tool in direction of time,
ss
a push connector ac
ce
e
nl
pt
-arrow-.
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
2.8.6 Special connector systems
nf
ercia
orm
m
Note
atio
om
n in
or c
thi
te
sd
iva
o
r

rp
cu
o
m
f
en
ng
t.
yi Co
op
FASTON contacts: C py
ht. rig
rig ht
– Insert corresponding connector housing release tool into re‐
py by
co Vo
by lksw
lease port of connector housing -arrow-. Prote
cted AG.
agen
– Hold contact on wire and push it into connector housing lightly.
Note


-arrow-.
GT 150/280 contacts:
– Insert corresponding connector housing release tool into con‐
nector housing by guiding it below locking tab.
– Push release tool to stop -arrow- into connector housing.

The contact is ejected from the connector housing.

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

olkswagen AG
– Insert corresponding connector housing release tool into con‐ agen
AG. V does
ksw
nector housing by guiding it below locking tab. by
Vol not
gu
d ara
se nte
– Push release tool onto stop, lifting slightly while doing
ho
ri so eo
-arrow-. aut ra
s s c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
The contact is ejected from the connector housing.
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 Cleaning contact surfaces

⇒ “3.1 General description - contact surface cleaning set VAS
6410 ”, page 174
⇒ “3.2 Repairing ring terminals”, page 174
n AG. Volkswagen A ge G do
swa es
⇒ “3.3 Repairing threaded
by
Vol electrical connections”, page
k not
gu 176
a d ran
se
⇒ “3.4 Cleaningthobattery
ri terminal clamp and battery terminal”,
tee
or
page 178 ss au ac
ce
e
⇒ “3.5 Preserving threaded electrical connections”, page 179

nl
pt
du
an
itte
y li
3.1 General description - contact surface
erm
ab
ility
cleaning set - VAS 6410-
ot p
wit
, is n
h re
The contact surface cleaning set - VAS 6410- allows optimal re‐
hole
spec
pair quality to be achieved in the area of vehicle electrics. The
es, in part or in w
tools allow performing repair work in the area of the sensor in
t to the co
wiring harnesses for threaded connections in the high-current cir‐
cuit (starting and charge current). The easy-to-use contact sur‐
face cleaning set - VAS 6410- has been designed to match the
rrectness of i
structural design of the vehicles and ensures that repairs are car‐
ried out correctly.
l purpos
nf
ercia
Note orm
m
atio
m
The illustrations shown here are just a few examples of repair

o
n in
c
work.
or
thi
te
sd
iva
o
r

rp
cu
o
m
f
en
ng
♦ Contact surface cleaning set - VAS 6410-

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


olkswagen AG Electrical system - general information - Edition 01.2019
en AG. V
ag does
ksw not
y Vol gu
b ara
ed
thoCaution
ris nte
eo
au ra
c
ss
Risk of damage!
ce
e
nl
pt
du
an
Penetrating fluid, contact spray or grease etc. may not be used
itte
y li
for threaded connections.
erm
ab
ility
ot p
Missing adhesion in the threads may cause a torque excess
wit
, is n
and, therefore, the break of the threaded connection.
h re
hole
spec
After cleaning, ensure that threaded connections are dry and
es, in part or in w
bolt them together without applying lubricants.
t to the co
rrectness of i
Note
l purpos
The grey sanding pads are suitable for light dirt and “soft surfa‐
nform
ercia
ces”. The red sanding pads are suitable for heavy dirt and “hard
surfaces”.
m
at
om
ion
c
in t
or
his
e
WARNING
at
do
priv
cum
or

f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐
lksw
cted agen
Prote
necting and reconnecting battery .
AG.
– Unscrew captivated nut and remove ring terminal from con‐

nection thread.
– Check ring terminal for corrosion, dirt, etc.
– Select matching adapter and sanding pad for ring terminal
from contact surface cleaning set - VAS 6410- .
Note
As an alternative, the sanding block may also be used.
Caution
Risk of corrosion!
If the tin coating of ring terminals is worn down to the copper
layer, a galvanic cell may be produced which destroys metal
and causes faulty repair.
The cleaning process of the ring terminals must be performed
step by step and a visual check is necessary between the
steps.
3. Cleaning contact surfaces 175

– Position adapter in ring terminal and remove corrosion AG. Volkswagen AG d

agen and dirt oes
ksw
with circular motion. by
Vol not
gu
a d ran
se
– Periodically check the progress of cleaning
ho
ri and clean further tee
ut or
if necessary. ss a ac
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
– If necessary, remove burring around hole of ring terminal using
deburring tool.
rrectness of i
– Fit ring terminal onto connection thread again, and tighten to
l purpos
specified torque ⇒ Current flow diagrams, Electrical fault find‐

ing and Fitting locations.
nf
ercia
orm
m
atio
Note
om
n in
or c
thi
Optimum contact is ensured when the bolted components are
te
sd
a
tightened to the specified torque after cleaning.

iv
o
r
rp
cu
o
m
f
en
ng
t.
– Apply appropriate anti-corrosion treatment to threaded con‐
yi Co
op
nection ⇒ page 179
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
WARNING
cted agen
Prote AG.

– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐

necting and connecting battery .
– Perform all given work steps such as window regulator setting,
clock setting and radio coding after connecting the battery.
3.3 Repairing threaded electrical connec‐

tions

AG. Volkswagen AG d
agen oes
olksw not
yV g
ed Amarok 2011 ➤ , Amarok 2017 ➤ u,aCaddy
b ran 2004 ➤ , Caddy 2011 ➤ , Caddy 2 ...
ris tee
tho Electrical system o - general information - Edition 01.2019
au ra
c
ss
ce
e
nl
pt
du
Caution
an
itte
y li
erm
ab
Risk of damage!
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
Note
orm
m
atio
m
The grey sanding pads are suitable for light dirt and “soft surfa‐
o
n in
c
ces”. The red sanding pads are suitable for heavy dirt and “hard
or
thi
e
surfaces”.
t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi
WARNING
Co
Cop py
ht. rig
rig ht
by
Danger of injury! Comply with the warning notices and safety copy Vo
by lksw
regulations ⇒ page 1 ! cted agen
Prote AG.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐

– Unscrew captivated nut and remove ring terminal from con‐
nection thread.
– Check ring terminal for corrosion, dirt, etc.
– Select matching adapter and sanding pad for threaded con‐
nection from contact surface cleaning set - VAS 6410- .
Caution
Risk of corrosion!
If the tin coating is worn down to the copper layer, a galvanic
cell may be produced which destroys metal and causes faulty
repair.
The cleaning process of the threaded connection must be per‐
formed step by step and a visual check is necessary between
the steps.

– Fit adapter onto threaded connection and remove corrosion

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

– Apply appropriate anti-corrosion treatment to threaded con‐

nection ⇒ page 179 AG. Volkswagen
agen AG do
ksw es n
y Vol ot g
ua
WARNING ris
ed
b ran
tee
tho
or
au ac
Danger of injury! Comply with the warning
ss notices and safety
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐
ility
ot p
necting and connecting battery .
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
3.4 Cleaning battery terminal clamp and
battery terminal
rrectness of i
l purpos

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Caution
Risk of damage!

WARNING
Danger of injury! Complywawith

gen Athe
G. Vowarning notices
lkswagen AG
does and safety
regulations ⇒ page y1Vo!lks not
gu
b ara
ed nte
oris e
th or
au a
– Disconnect
ss battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐
c
ce
e
nl
pt
du
an
itte
– Check battery terminal clamp and battery terminal for corro‐
y li
erm
ab
sion or dirt.
ility
ot p
– Insert wire brush of battery terminal cleaner into battery ter‐
wit
, is n
h re
minal clamp and clean it with circular movements.
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
– Connect bottom side of battery terminal cleaner to battery ter‐
or
his
e
minal and clean it with circular movements.

at
do
priv
cum
for
en
g
WARNING
n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
co Vo
by lksw
cted agen
Prote AG.
– Connect battery and tighten battery terminals to specified tor‐

que ⇒ Electrical system; Rep. gr. 27 ; Disconnecting and
connecting battery .
Note


3.5 Preserving threaded electrical connec‐

tions
Caution
Missing anti-corrosion treatment results in damage to the on-

board supply.

Note
♦ All threaded connections must be tightened to specified tor‐

que.
♦ Always use hose supplied with anti-corrosive agent tin.
♦ Use protection wax for cold area.
♦ Use cavity sealing agent for warm area.
♦ The sealing agent independently reaches the respective
points through capillary action.
– Hold nozzle under ring terminal and spray all around stud.
olksw
– Fit nozzle over ring terminal aand
gen Aspray
G. V all aaround
gen AG
stud
does n and ring
ksw
terminal. by Vol ot g
u ara
ed nte
oris e
th or
au ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
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.

Amarok 2011 ➤ , wAmarok
agen 2017
AG. V ➤ge,nCaddy
olkswa AG do 2004 ➤ , Caddy 2011 ➤ , Caddy 2 ...
es n
ks
by Vol Electrical system - general
ot g
u information - Edition 01.2019
ara
ed nte
oris e
th or
au
4 Renewing Lambda probe
ac
ss
ce
le
un
pt
⇒ “4.1 General notes - renewing Lambda probe”, page 181
an
d
itte
y li
rm
ab
⇒ “4.2 Types of protective tube on uniform Lambda probes”, page
pe
ility
181
ot
wit
, is n
h re
⇒ “4.3 Renewing LSF Lambda probe (4-pin)”, page 182
hole
spec
⇒ “4.4 Renewing LSU lambda probe (6-pin)”, page 183
es, in part or in w
t to the co
4.1 General notes - renewing Lambda
probe
rrectness of i
l purpos
Note
nform
ercia
♦ Do not repair Lambda probe wires, since this can result in

malfunctions.
m
a
com
tion in
♦ If necessary, replace attachment parts, cable ties or marking
r
te o
thi
rings to match the uniform probe to the defective probe as
s
iva
specified.
do
r
rp
cum
fo
♦ If necessary, identify the Lambda probe on basis of the pro‐
en
ng
t.
yi
tective tube ⇒ page 181 .
Co
Cop py
t. rig
gh ht
pyri by
4.2 Types of protective tube on uniform
o Vo
by c lksw
cted agen
Prote
Lambda probes
AG.
Note
In addition to identifying by way of the part number, the protective

tube can also be used as a means of identification.
Type D1:
6 openings with 3.5 mm each
Only used on 4-pin LSF Lambda probes.
Type D2:
6 openings with 2 mm each
Used on 4-pin LSF lambda probes and 6-pin LSU lambda probes.
4. Renewing Lambda probe 181

Type D4:
12 openings with 1.4 mm each
Used on 4-pin LSF lambda probes and 6-pin LSU lambda probes.
4.3 Renewing LSF Lambda probe (4-pin)
Note

specified.
♦ Do not repair Lambda probe wires, since this can result in
malfunctions.
– Remove defective Lambda probe ⇒ Power unit; Rep. gr. 26 ;

Exhaust system .
– Place both Lambda probes next to each other so that sensor
housings are at same height.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
Amarok 2011
aut ➤ , Amarok 2017 ➤ , Caddy 2004 ➤ , Caddy
ho e o 2011
ra ➤ , Caddy 2 ...
ss Electrical system - general information - Edition 01.2019
c
ce
le
un
pt
an
d
– Tie back any excess in uniform probe length (approx. 50 - 250
itte
y li
mm) to size of defective probe and secure with cable ties -1-.
erm
ab
ility
ot p
– Check that connector housing of Lambda probe is compatible
wit
is n
with onboard supply side.
h re
ole,
spec
– If necessary, replace onboard supply system connector with
Lambda probe connector housing supplied ⇒ page 164 .
t to the co
Note
rrectne
♦ The connector housing should only be replaced on older ve‐
ss
hicles. On new vehicles, the connector housing coding match‐
o
cial p
f
es.
inform
mer
♦ Observe correct connector pin assignment. For reasons of
atio
clarity, respective pins in new connector housing have a colour
om
n
marking.
c
i
or
n thi
te
♦ Further notes can be found in the leaflet of the new Lambda
sd
iva
o
r
probe.
p
cum
r
fo
en
ng
t.
yi Co
– Install new Lambda probe in vehicle ⇒ Power unit; Rep. gr. Cop py
t. rig
26 ; Exhaust system . opyri
gh by
Vo
ht
c by lksw
cted agen
4.4 Renewing LSU lambda probe (6-pin)
Prote AG.
Note

specified.
♦ The wires should not be crimped or cut as otherwise the func‐
tion of the Lambda probe will be impaired.
– Remove defective Lambda probe ⇒ Power unit; Rep. gr. 26 ;

Exhaust system .
– Place both Lambda probes next to each other so that sensor
housings are at same height.
4. Renewing Lambda probe 183

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

mm) to size of defective probe and secure with cable ties -1-.
– Install new Lambda probe in vehicle ⇒ Power unit; Rep. gr.
26 ; Exhaust system .
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
184
op Vo
by c lksw
Rep. gr.97 - Wiring Prote
cted AG.
agen
5 ESD workplace
agen
A-G.VAS
Volkswag6613-
en AG
do
w es n
olks ot g
byV ua
ed ran
ris tee
5.1 Use
s
of ESD workplace - VAS 6613-
au
tho or
ac
s
♦ ESD workplace -VAS 6613- serves to protect electronic com‐
ce
le
un
pt
ponents from damage through electrostatic discharge.
an
d
itte
y li
rm
ab
♦ Repairs to particularly sensitive electronic components and
pe
ility
exposed circuit boards can thereby be carried out.
ot
wit
, is n
h re
♦ Measures that require the use of ESD workplace -VAS 6613-
hole
are marked in the relevant chapter of the respective “Electrical
spec
system” workshop manual.
es, in part or in w
t to the co
– To set-up the ESD workplace, lay out the ESD table mat -3-
from -VAS 6613- on a dry, clean table.
rrectness of i
– Attach the ESD table mat to the earthing module -2- at one of
the press studs.
l purpos
– To do this, connect the plug adapter -1- of the earthing module

to the plug adapter of a socket with earthing contact or attach
nform
ercia
a crocodile clamp to an earth strap from the building or to a

m
water pipe.
a
com
tion in
– Attach the wrist strap -4- to one of the press studs of the mat.
r
te o
thi
s
iva
– Attach the wrist strap directly to the wrist - never to the sleeve
do
r
rp
of a shirt or jacket. cum

fo
en
ng
t.
yi Co
op py
Caution
. C rig
ht ht
rig by
copy Vo
by lksw
For repairs on particularly sensitive electronic components and cted agen
Prote AG.
exposed circuit boards, only use non-magnetic tools, such as
Torx screwdriver - T10072- .
5. ESD workplace VAS 6613 185

SM 13.c

Uploaded by

Copyright:

Available Formats

SM 13.c

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

SM 13.c

Uploaded by

Copyright:

Available Formats

Service

Amarok 2011 ➤ , Amarok 2017 ➤ , tho eo

Caddy 2004 ➤ , Caddy 2011 ➤ ,

TGE 2017 ➤ , Transporter 2004 ➤ ,

Service Department. Technical Information

All rights reserved.

Copyright © 2019 Volkswagen AG, Wolfsburg D4B8025555B

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

3.3 Battery charger VAS 5900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3.4 Battery charger VAS 5900 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

3.6 Battery charger VAS 5906 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

3.7 Battery charger VAS 5908 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

3.8 Midtronics INC 940 battery charger (USA/Canada only) . . . . . . . . . . . . . . . . . . . . . . . . . . spec 78

3.9 Battery charger Fronius Acctiva Professional 35A, MAN TGE . . . . . . . . . . . . . . . . . . . . . . 81

3.10 Solar charger module VAS 6102A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

4.1 Checking function of poly V-belt pulley with freewheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

5.1 General description - cruise control system (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

5.2 Activating and deactivating cruise control system (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . . 87

92 - Windscreen wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

1 Washer fluid line hose couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

1.1 Hose couplings - windscreen and rear window washer system . . . . . . . . . . . . . . . . . . . . . . 89

94 - Lights, bulbs, switches - exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

96 - Lights, bulbs, switches - interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

2.1 Removing and installing 12 V socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

2 Wiring harness and connector repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 – Starter, current supply, CCS

1.1 Fundamentals for batteries

Danger of injury! Comply with the warning notices and safety

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

to the complete electrical on-board supply of the vehicle.

For additional information, refer to ⇒ Self-study programme No.

234 ; Vehicle batteries .

1.2 Warning notices and safety regulations

⇒ “1.2.1 Dangers when handling vehicle batteries”, page 1

⇒ “1.2.2 Safety markings on battery”, page 2

1.2.1 Dangers when handling vehicle batter‐

Recognition and avoidance of dangers

Batteries can be dangerous. These dangers can be avoided when

the warnings on the battery, in the operating manual and in ELSA

♦ Untrained personnel e.g. apprentices and trainees, may

cutting operations and use naked lights in the vicinity of

♦ Only work on batteries in well ventilated and suitable

handling batteries. Avoid sparks as well as electrostatic discharge

Therefore never lay a tool on a battery.

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

3. - Keep children away from acid and batteries.

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

may only be disposed of through a suitable collection centre and

only in accordance with respective legislation.

7. - Always follow instructions given on battery in ELSA ⇒ Elec‐

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

1.3 Types of batteries

1.3.1 Battery with »standard« colour indicator

No stickers may be removed and do not replenish with distilled

1.3.2 Battery with »enhanced« colour indica‐

This is a maintenance-free battery with liquid electrolyte (wet bat‐

Observe the notes given in the chapters concerning battery

It is not permissible to test or charge batteries whose colour

The battery is used for particular requirements in certain vehicles