Audi Q7 2007 User Manual

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Service

Workshop Manual

Audi A1 2011 ➤ , Audi A2 2001 ➤ ,

Audi A3 2004 ➤ , Audi A4 2001 ➤ , Audi A4 2008 ➤ , Audi A4 Cabriolet 2003 ➤ , Audi A5 Cabriolet 2009 ➤ , Audi A5 Coupé 2008 ➤ , Audi A6 1998 ➤ , Audi A6 2005 ➤ , Audi A7 Sportback 2011 ➤ , Audi A8 2003 ➤ , Audi A8 2010 ➤ , Audi Q5 2008 ➤ , Audi Q7 2007 ➤ , Audi R8 2007 ➤ , Audi TT 1999 ➤ , Audi TT 2007 ➤

Electrical system; General information

Edition 10.2010

Service Department. Technical Information

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

Service

List of Workshop Manual Repair GroupsList of Workshop Manual Repair GroupsList of Workshop Manual Repair Groups

Re pa ir G ro up

27 - Starter, current supply, CCS

92 - Windscreen wash/wipe system

94 - Lights, bulbs, switches - exterior

96 - Lights, bulbs, switches - interior

97 - Wiring

Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

Audi A1 2011 ➤ , Audi A2 2001 ➤ , Audi A3 2004 ➤ , Audi A4 2001 ➤ , Au ...

Electrical system; General information - Edition 10.2010

Contents

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

1 Battery - general notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 Safety measures and procedures to be followed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2 Warnings and safety procedures when handling lead-acid batteries . . . . . . . . . . . . . . . . . . 1

2 Non maintenance-free batteries (without „magic eye“) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.1 Central gas venting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.2 Battery terminal screw connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.3 Checking non maintenance-free batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.4 Visual inspection of battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.5 Checking electrolyte level in battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.6 Measuring relative density of electrolyte in all battery cells . . . . . . . . . . . . . . . . . . . . . . . . 7

3 Maintenance-free batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.1 Battery with „magic eye“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.2 Checking battery with „magic eye“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.3 Valve-regulated lead acid (VRLA) or absorbent glass mat (AGM) battery without „magic eye“

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.4 Checking valve-regulated lead acid or AGM battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.5 Central gas venting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.6 Battery terminal screw connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.7 Visual inspection of battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.8 Checking colour indicator (electrolyte level in battery) - batteries with „magic eye“ . . . . . . 15

3.9 Checking electrolyte level in battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4 Checking battery - vehicles without battery monitor control unit J367 or energy management

control unit J644 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.1 Checking battery using battery tester with printer VAS 6161 . . . . . . . . . . . . . . . . . . . . . . 17

4.2 Checking battery using battery tester with printer VAS 5097A . . . . . . . . . . . . . . . . . . . . . . 21

4.3 Measuring no-load voltage - vehicles without battery monitor control unit J367 or energy

management control unit J644 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.4 Checking battery by measuring current draw - vehicles without battery monitor control unit

J367 or energy management control unit J644 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

5 Checking battery - vehicles with battery monitor control unit J367 or energy management

control unit J644 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5.1 Checking battery using vehicle diagnostic tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5.2 Checking battery by measuring current draw - vehicles with battery monitor control unit J367

or energy management control unit J644 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

5.3 Measuring no-load voltage - vehicles with battery monitor control unit J367 or energy

management control unit J644 „transport mode not active“ . . . . . . . . . . . . . . . . . . . . . . . . 32

5.4 Measuring no-load voltage - vehicles with battery monitor control unit J367 or energy

management control unit J644 „transport mode active“ . . . . . . . . . . . . . . . . . . . . . . . . . . 33

6 Charging battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

6.1 Charging battery with battery charger VAS 5095A , VAS 5900 , VAS 5903 , VAS 5904 or VAS

5906 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

6.2 Totally discharged battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

6.3 Rapid-charging battery - vehicles without battery monitor control unit J367 or energy

management control unit J644 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

6.4 Back-up power supply of battery via battery charger VAS 5095A , VAS 5900 , VAS 5903 ,

VAS 5904 or VAS 5906 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

6.5 Maintaining battery charge with solar panel VAS 6102 A . . . . . . . . . . . . . . . . . . . . . . . . . . 42

7 Checking and servicing alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

7.1 Checking alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

7.2 Bosch alternator up to 2000 - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

7.3 Bosch alternator from 2001 onwards - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

7.4 Removing and installing voltage regulator - Bosch alternator from 2001 onwards . . . . . . 46

7.5 Bosch alternator from 2007 onwards - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Contents i

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Audi A1 2011 ➤ , Audi A2 2001 ➤ , Audi A3 2004 ➤ , Audi A4 2001 ➤ , Au ... Electrical system; General information - Edition 10.2010

7.6 Removing and installing voltage regulator - Bosch alternator from 2007 onwards . . . . . . 48

7.7 Checking carbon brushes - all types of Bosch alternators from 2001 onwards . . . . . . . . . . 48

7.8 Valeo alternator up to 2000 - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

7.9 Valeo alternator from 2001 onwards - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

7.10 Removing and installing voltage regulator - Valeo alternator from 2001 onwards . . . . . . . . 51

7.11 Checking carbon brushes - Valeo alternator from 2001 onwards . . . . . . . . . . . . . . . . . . . . 51

7.12 Removing and installing voltage regulator - Valeo alternator from 2007 onwards . . . . . . . . 52

7.13 Checking carbon brushes - Valeo alternator from 2007 onwards . . . . . . . . . . . . . . . . . . . . 52

7.14 Removing and installing poly V-belt pulley without free-wheel . . . . . . . . . . . . . . . . . . . . . . 53

7.15 Removing and installing poly V-belt pulley with free-wheel . . . . . . . . . . . . . . . . . . . . . . . . 54

8 Cruise control system - vehicles with electronic throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

92 - Windscreen wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

1 Washer fluid hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

1.1 Disconnecting and connecting washer fluid hose connectors . . . . . . . . . . . . . . . . . . . . . . 57

1.2 Servicing a smooth washer fluid pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

1.3 Servicing a washer fluid hose with corrugated tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

94 - Lights, bulbs, switches - exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

1 Safety precautions when handling gas discharge bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . 61

96 - Lights, bulbs, switches - interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

1 Immobilizer for vehicles without entry and start authorisation switch E415 (mechanical

ignition lock) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

1.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

1.2 Defective transponder or loss of key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

1.3 Renewing reader coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

1.4 Procedure for renewing lock set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

2 Immobilizer for vehicles with entry and start authorisation switch E415 (electronic ignition

lock) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

3 Heated steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

4 Towing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

4.1 Removing and installing socket for towing bracket - version 1 . . . . . . . . . . . . . . . . . . . . . . 66

4.2 Removing and installing socket for towing bracket - version 2 . . . . . . . . . . . . . . . . . . . . . . 67

4.3 Removing and installing socket for towing bracket - version 3 . . . . . . . . . . . . . . . . . . . . . . 69

4.4 Pin assignment at socket for towing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

97 - Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

1 Repairing wiring harnesses and electrical connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

1.1 General information on repairs to the vehicle electrical system . . . . . . . . . . . . . . . . . . . . . . 72

1.2 ESD (electrostatic discharge) workplace VAS 6613 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

1.3 Notes on repairing wiring harnesses and electrical connectors . . . . . . . . . . . . . . . . . . . . . . 74

1.4 Repairing wiring for pyrotechnic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

1.5 Repairing CAN bus wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

1.6 Repairing FlexRay wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

1.7 Repairing an 0.25 mm2 wire with a single crimp connector . . . . . . . . . . . . . . . . . . . . . . . . 76

1.8 Repairing a wire of 0.35 mm2 section or thicker with a single crimp connector . . . . . . . . . . 78

1.9 Repairing an 0.25 mm2 wire by connecting in an additional wire . . . . . . . . . . . . . . . . . . . . 80

1.10 Repairing a wire of 0.35 mm2 section or thicker by connecting in an additional wire . . . . 83

2 Repairing connector housings and electrical connectors . . . . . . . . . . . . . . . . . . . . . . . . . . 86

2.1 Notes on repairing connector housings and electrical connectors . . . . . . . . . . . . . . . . . . . . 86

2.2 Repairing contacts in connector housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

2.3 Fitting seals for individual wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

2.4 Repairing connector housings with insulation displacement technology (IDC) . . . . . . . . . . 88

3 Releasing and dismantling connector housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

ii Contents

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Audi A1 2011 ➤ , Audi A2 2001 ➤ , Audi A3 2004 ➤ , Audi A4 2001 ➤ , Au ...

Electrical system; General information - Edition 10.2010

3.1 Notes on releasing and dismantling connector housings . . . . . . . . . . . . . . . . . . . . . . . . . . 89

3.2 Secondary locking device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

3.3 Primary locking device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

3.4 Primary locking device with round connector systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

3.5 Primary locking device with flat connector systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

3.6 Primary locking device with special connector systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

4 Cleaning contact surfaces with contact surface cleaning set VAS 6410 . . . . . . . . . . . . . . 96

4.1 Servicing wiring lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

4.2 Servicing screw connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

4.3 Cleaning battery terminal clamps and battery terminals . . . . . . . . . . . . . . . . . . . . . . . . . . 98

4.4 Corrosion protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

5 Repairing aerial wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

6 Fibre optic cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

6.1 Repairing fibre optic cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

6.2 Separating fibre optic cable from wiring harness connector . . . . . . . . . . . . . . . . . . . . . . . . 107

7 Vehicle diagnostic, testing and information systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

7.1 Notes on operation and safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

7.2 Connecting vehicle diagnostic tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Contents iii

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Audi A1 2011 ➤ , Audi A2 2001 ➤ , Audi A3 2004 ➤ , Audi A4 2001 ➤ , Au ... Electrical system; General information - Edition 10.2010

iv Contents

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

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Electrical system; General information - Edition 10.2010

27 – Starter, current supply, CCS

1 Battery - general notes

WARNING

Risk of injury.

♦ Observe warnings and safety regulations ⇒ page 1 .

Caution

Risk of damage to battery or vehicle.

♦ Vehicles with batteries that are not maintenance-free: Ob‐

serve notes

⇒ „2.4 Visual inspection of battery“, page 6 .

♦ Vehicles with maintenance-free batteries: Observe notes

⇒ „3.7 Visual inspection of battery“, page 13 .

♦ To ensure a long service life, the battery must be checked,

serviced and maintained according to the instructions in this Workshop Manual.

♦ Apart from starting the engine, the battery also acts as an

electrical buffer and supplies power to all parts of the vehicle's electrical system.

Note

Additional information ⇒ Self-study programme No. 234 ; Vehicle batteries

1.1 Safety measures and procedures to be followed

Before starting work, employees must be informed of the possible hazards involved with handling batteries.

Caution

Non-qualified personnel such as trainees and junior staff must only be allowed to perform work on vehicle batteries under the supervision of skilled workers such as qualified vehicle me‐ chanics or electricians.

1.2 Warnings and safety procedures when handling lead-acid batteries

Knowing and avoiding dangers

Handling batteries is dangerous. Such dangers can be avoided by paying attention to the warnings on the battery, in the Owner's Manual and in the Workshop Manual.

1. Battery - general notes 1

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Audi A1 2011 ➤ , Audi A2 2001 ➤ , Audi A3 2004 ➤ , Audi A4 2001 ➤ , Au ... Electrical system; General information - Edition 10.2010

Explanatory notes on battery symbols

1 - Fires, sparks, naked flames and smoking are prohibited

when handling batteries. Avoid sparks and static discharge when handling wires and electrical equipment. To avoid short circuits, never place tools on the battery.

2 - Wear eye protection when working on the battery.

3 - Keep children away from acid and batteries.

4 - Disposal: Old batteries are hazardous waste. They are only

to be disposed of at an official collection point; all legal re‐ quirements must be observed.

5 - Do not dispose of old batteries with household waste.

6 - There is a risk of explosion when handling batteries. A highly

explosive gas mixture is given off when batteries are under charge.

7 - Observe the instructions on the battery, in the Workshop

Manual „Electrical system; General information“ and in the Owner's Manual.

8 - Danger of acid burns: Electrolyte is highly corrosive; pro‐

tective gloves and eye protection should therefore always be worn when working on the battery. Do NOT tilt the battery as electrolyte can leak out of the gas vents.

WARNING

Risk of injury due to electrolyte.

♦ Can cause severe injury to the eyes, skin and mucous

membranes.

♦ Inhalation can damage the respiratory system.

♦ Swallowing is harmful to the digestive system.

♦ First aid: Rinse eyes and immediately consult first aid sta‐

tion or inform doctor.

♦ Never tilt battery. Acid can leak out of the gas vents.

♦ Soak up spilt electrolyte with binding agent and neutralise

any residual electrolyte. Use e.g. soap solution for neu‐ tralising.

♦ Never allow electrolyte to come into contact with hands.

♦ Avoid contact with skin.

♦ Never touch mouth, nose or eyes with soiled hands.

♦ Immediately change any clothing affected by electrolyte

and place in water if necessary.

♦ Do not eat, drink or store foodstuffs at workplace.

♦ Wash thoroughly before breaks and on completion of

work.

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

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Audi A1 2011 ➤ , Audi A2 2001 ➤ , Audi A3 2004 ➤ , Audi A4 2001 ➤ , Au ...

Electrical system; General information - Edition 10.2010

WARNING

Wear eye protection and protective clothing to reduce the risk of injury.

♦ Wear safety goggles and an acid-resistant apron or alter‐

natively electrolyte-proof overalls.

♦ Wear electrolyte-proof gloves.

WARNING

Risk of explosion due to gas produced when charging battery.

♦ The gas given off during charging and sometimes emitted

by the battery at rest even after charging is explosive. In the worst case, improper handling of the battery can lead to explosion caused by escaping gas.

♦ Smoking, naked flames and sparks (caused by grinding,

welding or cutting) are prohibited when working in the vi‐ cinity of the battery.

♦ Take care to avoid short circuits when handling wires and

electrical equipment. Never place tools on the battery.

♦ To avoid sparks as a result of electrostatic discharge, al‐

ways touch the vehicle body before handling the battery.

WARNING

Avoid explosion risks.

♦ If the display is colourless or light yellow on batteries with

„magic eye“, do not check or charge the battery. Do NOT boost start the vehicle. There is a risk of explosion when checking or charging the battery or boost starting the ve‐ hicle. The battery must be renewed.

♦ Old batteries (in use for 6 months or more) must be treated

with an anti-static spray (currently „Neostatic Antistatikum HB 155“) prior to handling.

♦ Sealing plugs of batteries which are not maintenance-free

must be firmly screwed in when charging.

♦ Charging of batteries removed from the vehicle is only

permitted in vented cubicles with extraction system.

♦ After charging, the battery must be left in the charging area

with extraction system for an appropriate length of time.

♦ Only work on batteries in suitable, well ventilated areas.

♦ Batteries must always be transported in conductive metal

containers.

♦ Do not use electrostatically chargeable materials for se‐

curing purposes.

1. Battery - general notes 3

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WARNING

Risk of damage to vehicle.

♦ Escaping electrolyte could cause acid corrosion and dam‐

age to safety-relevant vehicle components.

WARNING

Risk of environmental pollution.

♦ Old batteries are hazardous waste. They contain toxic

lead (Pb) and sulphuric acid.

♦ Observe disposal regulations. Old batteries should only

be disposed of in appropriate containers at an official col‐ lection point.

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

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2 Non maintenance-free batteries

(without „magic eye“)

Lead-acid batteries which are not maintenance-free are filled with liquid electrolyte (wet battery). They are fitted with sealing plugs.

WARNING

Risk of injury when handling electrolyte.

♦ Observe warnings and safety regulations ⇒ page 2 .

Risk of explosion due to gas produced when charging battery.

♦ Observe warnings and safety regulations ⇒ page 3 .

2.1 Central gas venting system

To prevent the gas produced when charging the battery from causing damage or becoming a health hazard, the gas is dis‐ charged through a central opening in the top of the battery cover.

– Make sure that the central gas venting system hose or pipe is

always attached to the battery.

– Make sure the central gas venting system hose or pipe is not

obstructed. Only then is the battery able to vent freely.

Note

More modern batteries are equipped with a fine-mesh flame trap at the central gas venting outlet. This circular glass-fibre mesh with a diameter of approx. 15 mm and a thickness of 2 mm oper‐ ates like a valve. It allows the gas given off during battery charging to escape and at the same time prevents ignition of the explosive gas in the battery.

2.2 Battery terminal screw connection

Observe the following to avoid damaging the battery terminals and battery housing:

♦ Battery terminal posts must not be greased.

♦ Only connect battery terminal clamps -arrows- by hand without

exerting force.

♦ Fit battery terminal clamps in such a way that the battery ter‐

minal post is flush with the terminal clamp or protrudes from it.

♦ Tightening torque for battery terminal clamps and additional

clamps ⇒ Electrical system; Rep. gr. 27 .

♦ Never re-tighten screw connections after tightening battery

terminal clamps to specified torque.

2. Non maintenance-free batteries (without „magic eye“) 5

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2.3 Checking non maintenance-free batter‐ ies

WARNING

Risk of injury and explosion.

♦ Observe warnings and safety regulations ⇒ page 1 .

Perform tests in the following order:

1. Visual inspection ⇒ page 6

2. Checking electrolyte level ⇒ page 7

3. Checking battery using battery tester with printer -

VAS 6161- ⇒ page 17 or using battery tester with printer

-VAS 5097A- ⇒ page 21 or measuring relative density of electrolyte ⇒ page 7 .

4. Further procedure depending on result of battery check us‐

ing battery tester.

2.4 Visual inspection of battery

– Visually inspect battery before performing comprehensive

measurements:

♦ External condition of battery

♦ Battery connections

♦ Secure fit of battery

Caution

Risk of explosion, poor crash safety, risk of corrosion, short‐ ened service life.

♦ If the retainer plate is loose, this may damage the battery

housing and allow electrolyte to escape.

♦ If not properly secured, the battery may be subject to vi‐

bration damage and the plates in the battery will be dam‐ aged.

♦ Tighten bolt for retainer plate; for tightening torque refer to

⇒ Electrical system; Rep. gr. 27 .

Risk of malfunctions in electrical system or cable fire.

♦ The wiring connections may not make proper contact if the

battery terminals are damaged or the battery terminal clamps are loose. Check condition of battery terminals; for tightening torques for battery terminal clamps and addi‐ tional clamps refer to ⇒ Electrical system; Rep. gr. 27 .

♦ Risk of corrosion due to escaping electrolyte.

♦ The battery openings must be fitted with the correct type

of genuine sealing plugs to ensure proper sealing of the battery cover (different types). Only use genuine sealing plugs of the same type when renewing missing or dam‐ aged sealing plugs.

♦ The plugs must be fitted with an O-ring.

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

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2.5 Checking electrolyte level in battery

Procedure

The correct electrolyte level is an important factor in ensuring long battery service life.

WARNING

Risk of injury when handling electrolyte.

♦ Observe safety instructions when handling battery elec‐

trolyte ⇒ page 2 .

♦ Wear eye protection and protective clothing ⇒ page 3 .

Risk of explosion due to naked flames, fires and smoking.

♦ Use only an electric hand torch to illuminate the inside of

the battery housing.

♦ Never illuminate the inside of the battery housing with a

naked flame.

♦ Never bring a naked flame or a burning cigarette into the

vicinity of the battery.

– If the „min“ and „max“ marks are visible on the outside of the

battery, only perform an external visual inspection.

• The electrolyte level must be above the „min“ mark, but may not exceed the „max“ mark.

– If it is difficult to detect the „min“ and „max“ marks on the out‐

side of the battery or they cannot be seen through the battery housing , unscrew the sealing plugs.

– Check the electrolyte level by making a visual inspection of the

inside of the battery.

• The electrolyte level must coincide with the internal level mark (plastic moulding). This corresponds to the „max“ marking on the outside.

Caution

Risk of corrosion due to escaping electrolyte.

♦ The battery openings must be fitted with the correct type

of genuine sealing plugs to ensure proper sealing of the battery cover (different types). Only use genuine sealing plugs of the same type when renewing missing or dam‐ aged sealing plugs.

♦ The plugs must be fitted with an O-ring.

♦ If the electrolyte level is too low, the battery must be re‐

newed. Do not top up with distilled water.

– Screw sealing plugs of battery cells back in again.

2.6 Measuring relative density of electrolyte

in all battery cells

Special tools and workshop equipment required

2. Non maintenance-free batteries (without „magic eye“) 7

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♦ Refractometer -T10007- or

♦ Hydrometer (commercially available)

Procedure

In conjunction with the battery check using the battery tester with printer -VAS 6161- ⇒ page 17 or using the battery tester with printer -VAS 5097A- ⇒ page 21 , the relative density test pro‐ vides information on the charge state of the battery.

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

WARNING

Risk of injury when handling electrolyte.

♦ Observe safety instructions when handling battery elec‐

trolyte ⇒ page 2 .

♦ Wear eye protection and protective clothing ⇒ page 3 .

Note

The relative density of the electrolyte can be checked immediately after charging the battery.

– Unscrew all battery cell sealing plugs.

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

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– Dip hydrometer into battery cell and draw in electrolyte until

the float is floating freely in the electrolyte.

♦ The greater the relative density of the electrolyte drawn in, the

higher the float will ride.

♦

The relative density in kg/dm3 (specific density of electrolyte) can be read off the hydrometer scale.

– Take reading on hydrometer and compare it to values given

in table:

Charge state

Relative density of electrolyte in kg/dm

In normal climatic

In tropical countries

3

zones

discharged 1.12 1.08 half charged 1.20 1.16 well charged 1.28 1.23

The relative density in normal climatic zones must be at least 1.24 kg/dm3. If relative density is too low in all battery cells:

– Charge battery and then repeat electrolyte relative density

test.

Example 1

Battery cell 1 2 3 4 5 6 Relative density per battery cell in

3

kg/dm

1)

•

Relative density in battery cell 4 is too low (difference greater than 0.03 kg/dm3).

Example 2

Battery cell 1 2 3 4 5 6 Relative density per battery cell in

3

kg/dm

1)

•

Relative density in battery cells 4 and 5 is too low (difference greater than 0.03 kg/dm3).

1.24 1.25 1.25

1.26 1.26 1.25

1.10

1.14

1)

1.24 1.25

1)

1.18

1.24

– Renew the battery if the specified values are not attained.

Note

The battery must be renewed if the relative density of the elec‐ trolyte measured in the individual battery cells varies by more than

0.03 kg/dm3.

2. Non maintenance-free batteries (without „magic eye“) 9

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Caution

Danger from escaping electrolyte.

♦ The battery openings must be fitted with the correct type

of genuine sealing plugs to ensure proper sealing of the battery cover (different types). Only use genuine sealing plugs of the same type when renewing missing or dam‐ aged sealing plugs.

♦ The plugs must be fitted with an O-ring.

– If specified values have been attained, screw sealing plugs of

battery cells back in.

Note

Observe disposal regulations if battery has to be renewed

⇒ page 4 .

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

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Electrical system; General information - Edition 10.2010

3 Maintenance-free batteries

Only install maintenance-free batteries with the specifications „TL82506“ (from December 1997 onwards) and „VW75073“ (from August 2001 onwards).

WARNING

Risk of injury when handling electrolyte.

♦ Observe warnings and safety regulations ⇒ page 2 .

Risk of explosion due to gas produced when charging battery.

♦ Observe warnings and safety regulations ⇒ page 3 .

3.1 Battery with „magic eye“

Lead-acid batteries with „magic eye“ are filled with liquid electro‐ lyte (wet battery). They are not fitted with sealing plugs for topping up with distilled water.

Note

♦

If batteries with „magic eye“ are fitted with sealing plugs for production reasons, these are covered with plastic foil.

♦

Do not remove plastic foil and do not top up with distilled water.

♦

Only perform visual inspections.

The „magic eye“ -arrow- provides information on the electrolyte level and battery charge via a colour indicator. Possible indicator colours ⇒ page 11 .

WARNING

Risk of explosion due to a discharged battery with „magic eye“.

♦ The battery must NOT be checked or charged if the indi‐

cator of the „magic eye“ is colourless or yellow. Do NOT boost start the vehicle. There is a risk of explosion when checking or charging the battery or boost starting the ve‐ hicle. The battery must be renewed.

3.2 Checking battery with „magic eye“

WARNING

Risk of injury and explosion.

♦ Observe warnings and safety regulations ⇒ page 1 .

Perform tests in the following order:

1. Visual inspection ⇒ page 6

2. Checking colour indicator of „magic eye“ ⇒ page 15

3. Checking electrolyte level ⇒ page 15

4. Checking battery

⇒ „4 Checking battery - vehicles without battery monitor

3. Maintenance-free batteries 11

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control unit J367 or energy management control unit J644 “, page 17 or ⇒ „5.2 Checking battery by measuring current draw - vehi‐ cles with battery monitor control unit J367 or energy man‐ agement control unit J644 “, page 30 .

5. Further procedure depending on result of battery check us‐ ing battery tester.

3.3 Valve-regulated lead acid (VRLA) or ab‐

sorbent glass mat (AGM) battery without „magic eye“

♦ VLRA or AGM batteries are deep-cycle resistant and leak-

proof.

♦ VRLA or AGM batteries are filled with electrolyte which is held

in place in an „A“bsorbent „G“lass „M“at. The battery is sealed and equipped with valves.

♦ As the electrolyte is absorbed in the mat, these batteries can‐

not have a „magic eye“. Absorbent glass mat batteries are marked with „AGM“ on the battery.

Note

♦

VLRA or AGM batteries cannot and must not be opened and must not be topped up with distilled water.

♦

Only perform visual inspections.

Caution

Fitting a wrong battery will result in poor crash safety.

♦ If a vehicle was originally equipped with a VRLA or AGM

battery, only replace the battery with another VRLA or AGM battery.

3.4 Checking valve-regulated lead acid or

AGM battery

WARNING

Risk of injury and explosion.

♦ Observe warnings and safety regulations ⇒ page 1 .

Perform tests in the following order:

1. Visual inspection ⇒ page 6

2. Checking battery

⇒ „4 Checking battery - vehicles without battery monitor control unit J367 or energy management control unit J644 “, page 17 or ⇒ „5.2 Checking battery by measuring current draw - vehi‐ cles with battery monitor control unit J367 or energy man‐ agement control unit J644 “, page 30 .

3. Further procedure depending on result of battery check us‐ ing battery tester.

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

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3.5 Central gas venting system

To prevent the gas produced when charging the battery from causing damage or becoming a health hazard in the engine or passenger compartment, the gas is discharged through a central opening in the top of the battery cover.

– Make sure that the central gas venting system hose or pipe is

always attached to the battery.

– Make sure the central gas venting system hose or pipe is not

obstructed. Only then is the battery able to vent freely.

Note

More modern batteries are equipped with a fine-mesh flame trap at the central gas venting outlet. This circular glass-fibre mesh with a diameter of approx. 15 mm and a thickness of 2 mm oper‐ ates like a valve. It allows the gas given off during battery charging to escape and at the same time prevents ignition of the explosive gas in the battery.

3.6 Battery terminal screw connection

Observe the following to avoid damaging the battery terminals and battery housing:

♦ Battery terminal posts must not be greased.

♦ Only connect battery terminal clamps -arrows- by hand without

exerting force.

♦ Fit battery terminal clamps in such a way that the battery ter‐

minal post is flush with the terminal clamp or protrudes from it.

♦ Tightening torque for battery terminal clamps and additional

clamps ⇒ Electrical system; Rep. gr. 27 .

♦ Never re-tighten screw connections after tightening battery

terminal clamps to specified torque.

3.7 Visual inspection of battery

– Visually inspect battery before performing comprehensive

measurements:

♦ External condition of battery

♦ Battery connections

♦ Secure fit of battery

3. Maintenance-free batteries 13

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Caution

Risk of explosion, poor crash safety, risk of corrosion, short‐ ened service life.

♦ If the retainer plate is loose, this may damage the battery

housing and allow electrolyte to escape.

♦ If not properly secured, the battery may be subject to vi‐

bration damage and the plates in the battery will be dam‐ aged.

♦ Tighten bolt for retainer plate; for tightening torque refer to

⇒ Electrical system; Rep. gr. 27 .

Risk of malfunctions in electrical system or cable fire.

♦ The wiring connections may not make proper contact if the

battery terminals are damaged or the battery terminal clamps are loose. Check condition of battery terminals; for tightening torques for battery terminal clamps and addi‐ tional clamps refer to ⇒ Electrical system; Rep. gr. 27 .

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

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3.8 Checking colour indicator (electrolyte level in battery) - batteries with „magic eye“

Procedure

Note

As the „magic eye“ is only located in one battery cell, the electro‐ lyte level is only checked for this battery cell.

– Prior to visual inspection, use a screwdriver handle to tap gen‐

tly and carefully on the magic eye -arrow-.

Note

When charging the battery and while driving, air bubbles may form under the „magic eye“ and falsify the colour indicator. Tap‐ ping on the „magic eye“ will disperse the air bubbles underneath.

– Read off electrolyte level in battery from colour indicator. Two

different displays are possible:

Colour indicator Battery charge state

Black or green • Electrolyte level in battery OK

Colourless or light

yellow

WARNING

• Electrolyte level in battery too low. Risk of explosion; do not check or charge bat‐ tery.

Risk of explosion due to a discharged battery with „magic eye“.

♦ The battery must NOT be checked or charged if the indi‐

cator of the „magic eye“ is colourless or yellow. Do NOT boost start the vehicle. There is a risk of explosion when checking or charging the battery or boost starting the ve‐ hicle. The battery must be renewed.

Note

Observe disposal regulations if battery has to be renewed

⇒ page 4 .

3.9 Checking electrolyte level in battery

Procedure

The correct electrolyte level is an important factor in ensuring long battery service life.

3. Maintenance-free batteries 15

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WARNING

Danger of injury when handling electrolyte.

♦ Observe safety instructions when handling battery elec‐

trolyte ⇒ page 2 .

♦ Wear eye protection and protective clothing ⇒ page 3 .

♦ If the electrolyte level is too low, the battery must be re‐

newed. Do not open battery and do not top up with distilled water.

Risk of explosion due to naked flames, fires and smoking.

♦ Never bring a naked flame or a burning cigarette into the

vicinity of the battery.

– If the „min“ and „max“ marks are visible on the outside of the

battery, perform an external visual inspection.

• The electrolyte level must be above the „min“ mark, but may not exceed the „max“ mark.

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

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4 Checking battery - vehicles without

battery monitor control unit -J367- or energy management control unit J644-

Do not open maintenance-free batteries; this would invalidate the warranty.

4.1 Checking battery using battery tester with printer -VAS 6161-

♦ When checking the battery using battery tester with printer -

VAS 6161- it is not necessary to disconnect the battery earth cable.

♦ The battery tester with printer -VAS 6161- no longer puts the

battery under load, but works by measuring the dynamic con‐ ductivity. For this reason it is possible to perform several measurements without re-charging the battery.

♦ No-load voltage measurement can be performed without de‐

lay.

♦ All types of battery are stored in the tester and they can be

updated.

♦ The battery bar code can be read off directly with the optionally

available 2D scanner.

♦ The integrated temperature sensor improves the quality of

measurements.

♦ Data can be stored on an SD card.

Note

For information on battery tester with printer, refer to ⇒ Instruction Manual for -VAS 6161- .

Special tools and workshop equipment required

♦ Battery tester with printer -VAS 6161-

Note

For information on how to use the battery tester, refer to ⇒ In‐ struction Manual for -VAS 6161- .

Procedure

• Battery temperature must be at least +10 °C.

4. Checking battery - vehicles without battery monitor control unit J367 or energy management control unit J644 17

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WARNING

Risk of injury due to electrolyte.

♦ Observe safety instructions when handling battery elec‐

trolyte ⇒ page 2 .

♦ Wear eye protection and protective clothing ⇒ page 3 .

♦ Sealing plugs of batteries which are not maintenance-free

must be firmly screwed in when measuring voltage under load.

Risk of explosion due to a discharged battery with „magic eye“.

♦ The battery must NOT be checked or charged if the indi‐

cator of the „magic eye“ is colourless or yellow. Do NOT boost start the vehicle. There is a risk of explosion when checking or charging the battery or boost starting the ve‐ hicle. The battery must be renewed.

– Switch off ignition and all electrical equipment.

– Check colour indicator of batteries with „magic eye“

⇒ page 15 .

– Switch on battery tester with printer -VAS 6161- .

– Connect red test clamp „+“ of battery tester to positive battery

terminal or jump start terminal in engine compartment.

– Connect black test clamp „–“ of battery tester to negative ter‐

minal of battery or jump start terminal in engine compartment.

Note

Make sure the test clamps make proper contact.

– Select one of the following functions:

♦ Maintenance test

♦ Service test

♦ Warranty test

Maintenance test

– Select „maintenance test“ from the menu.

– Connect scanner and scan in vehicle identification number.

– Select connection point: „at battery post“ or „at jump start

post“.

– Select vehicle model.

– Scan in battery bar code.

– Determine temperature by holding temperature sensor at a

distance of approx. 5 cm over battery or jump start post until a constant temperature is displayed.

– Start test.

– If required, print out test log.

Service test

– Select „service test“ from the menu.

– Select vehicle model.

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

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Electrical system; General information - Edition 10.2010

– Determine temperature by holding temperature sensor at a

distance of approx. 5 cm over battery until a constant temper‐ ature is displayed.

– Select type of battery: „regular“, „AGM“, „2*6V“ or „Gel“.

– Select rating units: „CCA“, „JIS“, „DIN“, „SAE“, „IEC“ or „EN“.

– Start test.

– If required, print out test log.

Warranty test

– Select „warranty test“ from the menu.

– Select fitting location: „in vehicle“ or „out of vehicle“.

– Select vehicle model.

– Determine temperature by holding temperature sensor at a

distance of approx. 5 cm over battery until a constant temper‐ ature is displayed.

– Select type of battery: „regular“, „AGM“, „2*6V“ or „Gel“.

– Select corresponding rating using arrow buttons.

– Start test.

– If required, print out test log.

Note

The test log is required for warranty processing.

– Switch off battery tester.

– Detach test clamps.

4. Checking battery - vehicles without battery monitor control unit J367 or energy management control unit J644 19

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Test result on printout:

1 - Test mode

2 - Test result

3 - Voltage measured

4 - Nominal value of battery measured

5 - Nominal value of battery as set on tester

6 - Temperature measured above battery

7 - Fitting location of battery

8 - Position of battery clamp as set on tester

9 - Type of battery set

Test result of maintenance test Measures

Good battery Battery OK Charge battery immediately Charge battery ⇒ page 35

and test again. Faults can occur if battery is not fully charged and tested again

Mark as defective Mark as „defective“ and remove

from vehicle

Check tester connection Disconnect battery and test

again. Poor contact of the ca‐ bles can be responsible for the result „Check tester connec‐ tion“

Check connection Cable must be connected di‐

rectly to battery and not to jump start post

Test result of service test and

Measures

warranty test

Good battery Battery OK Good battery - recharge Charge battery ⇒ page 35 ,

trace cause of fault responsible for discharging, if necessary

Perform current draw test Perform current draw test

⇒ page 26 . Charge battery ⇒ page 35 and test again

Replace battery Disconnect battery and test

again. Poor contact of the ca‐ bles can be responsible for the

result "Replace battery" Bad cell - replace Replace battery Frozen battery Thaw battery and test again Check connection Cable must be connected di‐

rectly to battery and not to jump

start post

Note

Observe disposal regulations if battery has to be renewed

⇒ page 4 .

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

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Electrical system; General information - Edition 10.2010

4.2 Checking battery using battery tester with printer -VAS 5097A-

♦ Measuring voltage under load simulates starting engine at low

temperatures. During the test, a high current flows through the battery, causing the voltage to drop. The amount of the voltage drop will depend on the state of charge of the battery. The voltage must not fall below the minimum value specified by the battery tester.

♦ After the test, the voltage will remain at a low level for a long

time, rising only slowly.

♦ If the battery is defective or only weakly charged, the battery

voltage will drop very rapidly below the specified minimum voltage level.

♦ The battery must be renewed if the voltage drops below the

specified minimum level.

♦ Only perform the test once. Repeating the test would falsify

the result.

♦ The battery tester must be allowed to cool down for approxi‐

mately 30 minutes before checking another battery.

The battery tester with printer -VAS 5097 A- can be used to check 12 V batteries with the following low temperature test currents:

Low temperature test current in A (Ampere)

1)

According to DIN

2)

According to EN /

3)

SAE

According to IEC

80 – 104 136 – 177 95 – 124 105 – 129 178 – 219 125 – 154 130 – 154 220 – 261 155 – 184 155 – 179 262 – 303 185 – 214 180 – 204 304 – 345 215 – 244 204 – 229 346 – 387 245 – 274 230 – 254 388 – 429 275 – 304 255 – 279 430 – 471 305 – 334 280 – 304 472 – 513 335 – 364

305 –329 514 – 555 365 – 394 330 – 354 556 – 597 395 – 424 355 – 379 598 – 639 425 – 454 380 – 389 640 – 657 455 – 464 390 – 399 658 – 675 465 – 474 400 – 409 676 – 693 475 – 484 410 – 419 694 – 711 485 – 494 420 – 429 712 – 729 495 – 504 430 – 439 730 – 747 505 – 514 440 – 449 748 – 765 515 – 524 450 – 459 766 – 783 525 – 534 460 – 469 784 – 801 535 – 544 470 – 479 802 – 819 545 – 554 480 – 489 820 – 837 555 – 564

490 – 499

4)

838 – 855 565 – 574

4)

4. Checking battery - vehicles without battery monitor control unit J367 or energy management control unit J644 21

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Low temperature test current in A (Ampere)

1)

According to DIN

2)

1)

•

DIN = Deutsche Industrie Norm (German industrial stand‐

According to EN /

3)

SAE

According to IEC

4)

ard).

2)

•

Batteries with a low temperature test current of 520 A ac‐ cording to DIN can be checked with the setting for 499 A according to DIN.

3)

•

EN / SAE = European standard / Society of Automotive Engineers.

4)

•

IEC = International Engineering Consortium.

Note

For information on battery tester with printer, refer to ⇒ Operating instructions for the -VAS 5097A- or sticker ⇒ Brief operating in‐ structions for battery tester with printer -VAS 5097 A- on unit.

Special tools and workshop equipment required

♦ Battery tester with printer -VAS 5097A-

Note

For information on how to use the battery tester, refer to ⇒ Op‐ erating instructions for -VAS 5097A- .

Procedure

• Battery temperature must be at least +10 °C.

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

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WARNING

Risk of injury due to electrolyte.

♦ Observe safety instructions when handling battery elec‐

trolyte ⇒ page 2 .

♦ Wear eye protection and protective clothing ⇒ page 3 .

♦ Sealing plugs of batteries which are not maintenance-free

must be firmly screwed in when measuring voltage under load.

Risk of explosion due to a discharged battery with „magic eye“.

♦ The battery must NOT be checked or charged if the indi‐

cator of the „magic eye“ is colourless or yellow. Do NOT boost start the vehicle. There is a risk of explosion when checking or charging the battery or boost starting the ve‐ hicle. The battery must be renewed.

– Switch off ignition before disconnecting earth wire at battery

⇒ Electrical system; Rep. gr. 27 .

– Check colour indicator of batteries with „magic eye“

⇒ page 15 .

– Determine the low temperature test current in amps (A) ac‐

cording to DIN from the data on the battery and use the table

⇒ page 21 to read off the setting range for the battery tester

with printer -VAS 5097 A- .

– Set the low temperature test current with the selector switch

-5-.

– Set the measuring range, 80 - 379 A or 380 - 499 A, with the

ON/OFF switch -6-.

Note

Batteries with a low temperature test current of 520 A according to DIN can be checked with the setting for 499 A according to DIN.

– Connect red test clamp „+“ of battery tester to positive battery

terminal.

– Connect black test clamp „–“ of battery tester to negative bat‐

tery terminal.

Note

♦

Make sure the test clamps make proper contact.

♦

Please note the TPI 2012182 on the battery tester with printer

-VAS 5097 A- .

4. Checking battery - vehicles without battery monitor control unit J367 or energy management control unit J644 23

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– Use the sliding switch -7- to select the connection point for the

test clamps.

1 - Direct connection to battery

2 - Connection to external test points in engine compartment

– Check whether the low temperature test current indicated on

the battery matches the value set on the battery tester.

– Press start button -4-.

• Green LED -1- lights up.

• The test program runs through automatically.

• The printer -9- will print out the test result after 20 seconds.

Note

♦

If battery tester does not start up (no LED lights, no printout), battery must be charged ⇒ page 35 .

♦

If red LED -2- lights up, battery tester has been connected with reverse polarity.

♦

If red LED -3- lights up, battery is not suitable for testing. Re‐ new battery.

– Switch off battery tester with ON/OFF switch -6-.

– Detach test clamps.

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

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Electrical system; General information - Edition 10.2010

Test result on printout:

1 - Measuring range set on battery tester

2 - Diagram (-arrow- indicates battery status)

3 - Test result

4 - Battery voltage during load test

5 - Vehicle data and date must be entered by mechanic

Battery tester printout Measures

Battery Very Good Battery OK Battery Good Battery OK Battery Sufficient Measure current draw

⇒ page 26

Battery Not Good Measure current draw

⇒ page 26

Battery Faulty Measure current draw

⇒ page 26

Cannot be tested Charge battery ⇒ page 35

and test again

Note

Observe disposal regulations if battery has to be renewed

⇒ page 4 .

4.3 Measuring no-load voltage - vehicles without battery monitor control unit J367- or energy management control unit -J644-

Note

By measuring no-load voltage, for example as part of the speci‐ fied care and maintenance work for vehicles not in use or in storage, it can be determined if the battery needs re-charging ⇒ Maintenance tables .

Special tools and workshop equipment required

♦ Hand-held multimeter -V.A.G 1526E-

Procedure

Observe the following points to ensure correct measurement.

4. Checking battery - vehicles without battery monitor control unit J367 or energy management control unit J644 25

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• Battery must NOT be subjected to electrical load within the next 2 hours prior to measurement.

• After the battery has been charged or the engine has been running, wait for 12 hours before performing measurements.

• Battery temperature must be at least –10 °C.

After a waiting time of at least 12 hours:

– Measure voltage between battery terminal clamps.

• Specification: 12.5 V or above = battery is OK

– If battery no-load voltage is below 12.5 V, battery must be re-

charged ⇒ page 35 .

– Current draw must be measured after a charging period of

5 minutes ⇒ page 26 .

– If battery no-load voltage is 11.6 V or less, battery is totally

discharged ⇒ page 38 .

4.4 Checking battery by measuring current

draw - vehicles without battery monitor control unit -J367- or energy manage‐ ment control unit -J644-

Checking the current draw capacity of a battery during charging allows you to assess quickly whether a partially or totally dis‐ charged battery ⇒ page 38 can be made serviceable again by re-charging or whether the battery has to be renewed.

Special tools and workshop equipment required

♦ Battery charger -VAS 5095A- and trigger clamp, 100A -VAS

5051B/7- or

♦ Battery charger -VAS 5900- or

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

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♦ Battery charger -VAS 5903-

♦ Battery charger -VAS 5904-

Electrical system; General information - Edition 10.2010

♦ Battery charger -VAS 5906-

Note

♦

When charging with battery charger -VAS 5095A- , the current draw of the battery must be measured using e.g. trigger clamp, 100A -VAS 5051B/7- . Battery chargers -VAS 5900- , -VAS 5903- , -VAS 5904- and -VAS 5906- indicate the current draw on the unit.

♦

Information on battery chargers ⇒ Operating instructions for appropriate battery charger.

Procedure

• Battery temperature must be at least +10 °C.

• The battery charger must be capable of supplying a charging current of at least 30 A, as is the case for example with the battery chargers -VAS 5095A- , -VAS 5900- , -VAS 5903- , VAS 5904- and -VAS 5906- .

• Battery charger connected and switched on

4. Checking battery - vehicles without battery monitor control unit J367 or energy management control unit J644 27

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– Measure battery charging current after a charging period of 5

minutes.

• Specification: Charging current must be greater than 10 % of rated capacity.

• Example: Charging current for a 60 Ah battery after 5 minute charging period: greater than 6 A.

– If reading matches specification, continue with charging proc‐

ess until battery is fully charged.

– Then check battery using the battery tester:

♦ Using battery tester with printer -VAS 6161- (no waiting time)

⇒ page 17 .

♦ Using battery tester with printer -VAS 5097A- (after charging,

wait for 12 hours) ⇒ page 21 .

– If reading is below specification, renew battery ⇒ Electrical

system; Rep. gr. 27 .

Note

Observe disposal regulations if battery has to be renewed

⇒ page 4 .

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

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Electrical system; General information - Edition 10.2010

5 Checking battery - vehicles with bat‐

tery monitor control unit -J367- or en‐ ergy management control unit -J644-

♦ On some models, the electrical system is monitored by the

energy management control unit -J644- or the battery monitor control unit -J367- in connection with the data bus diagnostic interface -J533- (allocation ⇒ Current flow diagrams, Electrical fault finding and Fitting locations). The battery test for these vehicles is performed via „Guided Fault Finding“.

♦ If is not possible to check the battery in the „Guided Fault

Finding“ because of a partially or totally discharged battery, the charge status of the battery can be assessed quickly via „Checking battery by measuring current draw“.

♦ Do not open maintenance-free batteries; this would invalidate

the warranty.

5.1 Checking battery using vehicle diagnos‐ tic tester

Special tools and workshop equipment required

♦ Vehicle diagnostic tester

Procedure

• Battery charger must not be connected during battery test and

engine must not be running.

• Battery temperature must be at least –10 °C.

• Temperature of diagnostic system must be between +5

and 45 °C.

– Connect vehicle diagnostic tester ⇒ page 110 .

Note

If a fault message appears on the display, refer to ⇒ Operating instructions for vehicle diagnostic tester .

– Select Guided Functions from menu.

5. Checking battery - vehicles with battery monitor control unit J367 or energy management control unit J644 29

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Display (example):

– Enter vehicle identification by touching the appropriate mes‐

sage line -1- in accordance with the selection prompt -A-.

– Select function or path:

Vehicle brand

Engine code

61 - Battery control or 19 - Data bus diagnostic interface or Service work

A - Battery, Testing (Repair group 27)

– Continue to follow the instructions on the display of the vehicle

diagnostic tester; the following messages can be displayed:

• Battery OK.

• Re-charge battery.

• Renew battery.

After performing battery test: – Press Go to button.

– Select „End“ function in list.

– Switch off ignition and separate diagnostic connection.

– If necessary, re-charge ⇒ page 35 or renew battery ⇒ Elec‐

trical system; Rep. gr. 27 .

Note

Observe disposal regulations if battery has to be renewed

⇒ page 4 .

5.2 Checking battery by measuring current draw - vehicles with battery monitor con‐ trol unit -J367- or energy management control unit -J644-

Checking the current draw capacity of a battery during charging allows you to assess quickly whether a partially or totally dis‐ charged battery ⇒ page 38 can be made serviceable again by re-charging or whether the battery has to be renewed.

Special tools and workshop equipment required

♦ Battery charger -VAS 5095A- and trigger clamp, 100A -VAS

5051B/7- or

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

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♦ Battery charger -VAS 5900- or

♦ Battery charger -VAS 5903-

Electrical system; General information - Edition 10.2010

♦ Battery charger -VAS 5904-

♦ Battery charger -VAS 5906-

5. Checking battery - vehicles with battery monitor control unit J367 or energy management control unit J644 31

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Note

♦

When charging with battery charger -VAS 5095A- , current draw of battery must be measured using e.g. trigger clamp, 100A -VAS 5051B/7- . Battery chargers -VAS 5900- , -VAS 5903- , -VAS 5904- and -VAS 5906- indicate the current draw on the unit.

♦

Information on battery chargers ⇒ Operating instructions for appropriate battery charger.

Procedure

• Battery temperature must be at least +10 °C.

• The battery charger must be capable of supplying a charging

current of at least 30 A, as is the case for example with the battery chargers -VAS 5095A- , -VAS 5900- , -VAS 5903- , VAS 5904- and -VAS 5906- .

• Battery charger connected and switched on

– Measure battery charging current after a charging period of 5

minutes.

• Specification: Charging current must be greater than 10 % of

rated capacity.

• Example: Charging current for a 60 Ah battery after 5 minute

charging period: greater than 6 A.

– If reading matches specification, continue with charging proc‐

ess until battery is fully charged.

– Then check battery using vehicle diagnostic tester

⇒ page 29 .

– If reading is below specification, renew battery ⇒ Electrical

system; Rep. gr. 27 .

Note

Observe disposal regulations if battery has to be renewed

⇒ page 4 .

5.3 Measuring no-load voltage - vehicles with battery monitor control unit -J367or energy management control unit J644- „transport mode not active“

Note

No-load voltage measurement for assessment of battery condi‐ tion is only advisable if it is not possible to test the battery with a vehicle diagnostic tester and if transport mode is not active in battery monitor control unit -J367- or energy management control unit -J644- .

Special tools and workshop equipment required

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

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♦ Hand-held multimeter -V.A.G 1526E-

Procedure

– Always observe the following; otherwise correct measurement

is not guaranteed.

• Leave battery in vehicle; do not disconnect earth cable.

• Open bonnet or rear lid and fix lock in „Locked“ position to stop luggage compartment light coming on.

• Use central locking system to lock vehicle.

• Battery must NOT be subjected to electrical load within the next 2 hours prior to measurement.

• Battery must NOT be charged in the 12 hours prior to meas‐ urement.

• Battery temperature must be at least –10 °C.

– Perform preparations for no-load voltage measurement ⇒

Electrical system; Rep. gr. 27 .

After a waiting time of at least 2 hours:

– Connect hand-held multimeter -V.A.G 1526E- between bat‐

tery terminal clamps or to remote positive terminal „+“ and to remote earth terminal „–“.

– Measure voltage between battery terminal clamps.

• Specification: 12.5 V or above = battery is OK

– If battery no-load voltage is below 12.5 V, battery must be re-

charged ⇒ page 35 .

– Current draw must be measured after a charging period of

5 minutes ⇒ page 30 .

– If battery no-load voltage is 11.6 V or less, battery is totally

discharged ⇒ page 38 .

5.4 Measuring no-load voltage - vehicles

with battery monitor control unit -J367or energy management control unit J644- „transport mode active“

Note

As part of the specified care and maintenance work for vehicles not in use or in storage, the state of charge in % (SOC) can be read off the trip recorder with the transport mode active. This shows whether the battery needs charging ⇒ Maintenance ta‐ bles .

5. Checking battery - vehicles with battery monitor control unit J367 or energy management control unit J644 33

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Procedure

The following test can only be performed if the transport mode is activated in the battery monitor control unit -J367- or the energy management control unit -J644- . If the transport mode is activa‐ ted later, for example when storing used vehicles, the SOC can only be determined after the systems have switched to „data bus rest mode“ once.

– Open driver's door.

– Switch on ignition.

– Read SOC in % off trip recorder.

Note

Depending on version, the value can be preceded by „TRA“.

• Specification: 50 % or above, charge state of battery is OK.

– If charge state of battery is below 50 %, battery must be charg‐

ed ⇒ page 35 .

– Current draw must be measured after a charging period of

5 minutes ⇒ page 30 .

– If charge state of battery is 0 %, battery is totally discharged

⇒ page 38 .

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

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Electrical system; General information - Edition 10.2010

6 Charging battery

6.1 Charging battery with battery charger -

VAS 5095A- , -VAS 5900- , -VAS 5903- ,

-VAS 5904- or -VAS 5906-

Special tools and workshop equipment required

♦ Battery charger -VAS 5095A- or

♦ Battery charger -VAS 5900- or

♦ Battery charger -VAS 5903-

6. Charging battery 35

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♦ Battery charger -VAS 5904-

♦ Battery charger -VAS 5906-

Note

♦

Battery chargers -VAS 5095A- , -VAS 5900- , -VAS 5903- , VAS 5904- and -VAS 5906- charge without current and volt‐ age peaks. Batteries can therefore also be charged when installed. Safety precautions must be observed when doing so. The chargers have a back-up function enabling them to supply power to on-board circuits.

♦

If electrical equipment has to be switched on periodically when performing work on the electrical system and for the „Guided Fault Finding“ mode, the battery must be charged using a charger with back-up function so as not to damage the battery

⇒ page 40 .

♦

Information on battery chargers ⇒ Operating instructions for appropriate battery charger.

Procedure

• Battery temperature must be at least +10 °C.

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

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Electrical system; General information - Edition 10.2010

WARNING

Risk of explosion due to naked flames, fires and smoking.

♦ Sealing plugs of batteries which are not maintenance-free

must be firmly screwed in.

♦ Ensure good ventilation.

♦ A highly inflammable gas is given off when batteries are

charged. Smoking and naked lights are consequently not allowed in rooms in which batteries are being charged.

♦ Observe safety regulations of manufacturers of battery

charger and battery.

♦ Rapid-charging of battery ⇒ page 39 .

Risk of explosion due to a discharged battery with „magic eye“.

♦ The battery must NOT be checked or charged if the indi‐

cator of the „magic eye“ is colourless or yellow. Do NOT boost start the vehicle. There is a risk of explosion when checking or charging the battery or boost starting the ve‐ hicle. The battery must be renewed.

Caution

Risk of damage to valve-regulated lead acid or AGM batteries.

♦ Valve-regulated lead acid or AGM batteries may only be

charged up to a limited voltage.

– Switch off ignition and take out ignition key.

– Switch off all electrical equipment.

– Perform preparations for charging battery ⇒ Electrical system;

Rep. gr. 27 .

Note

♦

On vehicles without battery monitor control unit -J367- or en‐ ergy management control unit -J644- , clamps of battery charger can be connected to battery terminals or remote pos‐ itive terminal and remote earth terminal in engine compart‐ ment.

♦

On vehicles with battery monitor control unit -J367- or energy management control unit -J644- , black clamp „–“ must not be connected to negative battery terminal, but to remote earth terminal in engine compartment or to earth stud of energy management control unit -J644- .

– After connecting charging clamps, plug in mains connector of

battery charger.

– Switch on battery charger.

– If necessary, set charging current at battery charger according

to battery capacity.

• The charging current should be around 10 % of the battery capacity (so for a 60 Ah battery around 6 A).

6. Charging battery 37

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– Once battery has been fully charged ⇒ Battery charger oper‐

ating instructions , disconnect charging clamps „+“ and „–“ of battery charger from battery.

– Unplug mains connector of battery charger.

6.2 Totally discharged battery

♦ Batteries that have not been used for an extended period of

time, e.g. in vehicles that have been stored, self-discharge.

♦ A battery is considered to be totally discharged if the no-load

voltage has dropped below 11.6 V. Initial battery damage can occur below 12.2 V (if vehicle has been stored for a longer period).

♦ On vehicles without battery monitor control unit -J367- or en‐

ergy management control unit -J644- , measure no-load volt‐ age ⇒ page 25 .

♦ On vehicles with battery monitor control unit -J367- or energy

management control unit -J644- , perform battery test using vehicle diagnostic tester ⇒ page 29 .

♦ In a totally discharged battery the electrolyte (sulphuric acid/

water mixture) is reduced to almost all water, as the sulphuric acid content is heavily reduced.

♦ Totally discharged batteries become sulphated, i.e. the entire

battery plate surfaces harden. The electrolyte has a slightly milky appearance (instead of being clear).

♦ If discharged batteries are charged directly after being dis‐

charged, the sulphation dissipates.

♦ If this is not done, the plates become even harder and the bat‐

tery's ability to absorb charge is impaired. This results in reduced power output.

Procedure

• Battery temperature must be at least +10 °C.

WARNING

Risk of explosion due to a discharged battery with „magic eye“.

♦ The battery must NOT be checked or charged if the indi‐

cator of the „magic eye“ is colourless or yellow. Do NOT boost start the vehicle. There is a risk of explosion when checking or charging the battery or boost starting the ve‐ hicle. The battery must be renewed.

Caution

Totally discharged batteries: Danger of freezing.

♦ Totally discharged batteries may freeze even at temper‐

atures only slightly below zero, causing the housing to burst.

♦ Never re-use frozen batteries.

Totally discharged batteries (that are also sulphated) must be charged as follows using a low charging current:

– Set charging current to approx. 5 % of battery capacity, i.e. for

a 60 Ah battery charging current is approx. 3 A.

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

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Note

♦

Battery voltage must be at least 0.6 V.

♦

Battery chargers -VAS 5095A- , -VAS 5900- , -VAS 5903- , VAS 5904- and -VAS 5906- detect totally discharged batteries automatically and start the charging process gently at a low charging current. Charging current is adapted automatically to battery charge.

Caution

Danger of damage to totally discharged batteries.

♦ Do NOT attempt to rapid-charge totally discharged bat‐

teries.

– Charge battery ⇒ page 35 .

• Charging voltage must not exceed 14.4 V.

Note

Observe disposal regulations if battery has to be renewed

⇒ page 4 .

6.3 Rapid-charging battery - vehicles with‐

out battery monitor control unit -J367- or energy management control unit -J644-

Procedure

• Battery temperature must be at least +10 °C.

WARNING

Risk of explosion due to naked flames, fires and smoking.

♦ Sealing plugs of batteries which are not maintenance-free

must be firmly screwed in.

♦ Ensure good ventilation.

♦ A highly inflammable gas is given off when batteries are

charged. Smoking and naked lights are consequently not allowed in rooms in which batteries are being charged.

♦ Observe safety regulations of manufacturers of battery

charger and battery.

Risk of explosion due to a discharged battery with „magic eye“.

♦ The battery must NOT be checked or charged if the indi‐

cator of the „magic eye“ is colourless or yellow. Do NOT boost start the vehicle. There is a risk of explosion when checking or charging the battery or boost starting the ve‐ hicle. The battery must be renewed.

6. Charging battery 39

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Caution

Risk of damage to battery and electronic vehicle components.

♦ Valve-regulated lead acid or AGM batteries must NOT be

rapid-charged.

♦ Do not rapid-charge batteries in vehicles with battery mon‐

itor control unit -J367- or energy management control unit

-J644- .

♦ Do NOT attempt to rapid-charge totally discharged bat‐

teries.

♦ Rapid-charging of batteries should only be performed in

exceptional circumstances (e.g. if necessary to start the engine) as rapid-charging may cause damage.

♦ Battery must not be connected to vehicle electrical system

when performing rapid-charging. Disconnect earth cable and positive wires ⇒ Electrical system; Rep. gr. 27 .

♦ Charging voltage must not exceed 14.8 V.

Note

Observe disposal regulations if battery has to be renewed

⇒ page 4 .

6.4 Back-up power supply of battery via bat‐ tery charger -VAS 5095A- , -VAS 5900- ,

-VAS 5903- , -VAS 5904- or -VAS 5906-

Back-up power supply of battery is required for example at the workshop for Fault Finding or when renewing battery.

Special tools and workshop equipment required

♦ Battery charger -VAS 5095A- or

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

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♦ Battery charger -VAS 5900- or

♦ Battery charger -VAS 5903-

Electrical system; General information - Edition 10.2010

♦ Battery charger -VAS 5904-

♦ Battery charger -VAS 5906-

6. Charging battery 41

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Procedure

Note

♦

Information on battery chargers ⇒ Operating instructions for appropriate battery charger.

♦

The following instructions describe the back-up power supply mode with battery charger -VAS 5900- .

– Switch off ignition and take out ignition key.

– Switch off all electrical equipment.

– Plug in mains connector of battery charger -VAS 5900- .

• The display shows the last mode selected.

– Press and hold Start/Stop button for approx. 5 seconds.

• Menu option „charging totally discharged batteries/back-up

supply“ is activated.

– Press button ↑ or ↓ to select vehicle voltage.

Note

The battery charger -VAS 5900- returns to the main menu if no button is pressed within 5 seconds.

– Press Start/Stop button to confirm selected battery voltage.

– Perform preparation for back-up power supply of battery ⇒

Electrical system; Rep. gr. 27 .

• Battery charger will check correct polarity of clamps.

Caution

Risk of damage to battery charger -VAS 5900- and electronic vehicle components.

♦

Start/Stop

button must not be pressed if the battery ter‐

minal clamps are not connected correctly.

– Press Start/Stop button to confirm correct connection of

clamps.

• Battery charger -VAS 5900- will start back-up power supply.

– Press Start/Stop button to end back-up power supply.

– Unplug mains connector of battery charger.

6.5 Maintaining battery charge with solar panel -VAS 6102 A-

♦ The solar panel -VAS 6102 A- supports the vehicle's electrical

system and prevents self-discharge of the battery.

♦ All rechargeable batteries may be charged with the solar pan‐

el.

♦ The solar panel must be connected to the diagnostic connec‐

tion in the vehicle. Battery chargers must not be connected to the diagnostic connection.

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

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Special tools and workshop equipment required

♦ Solar panel -VAS 6102 A-

Procedure

Note

For information on solar panel -VAS 6102 A- ⇒ Operating in‐ structions for -VAS 6102 A- .

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

– Place underside of solar panel on dash panel -2-.

Note

Do not allow the complete solar panel -VAS 6102 A- to make contact with the dash panel; only place down the lower edge to provide support. Placing down the whole panel can result in col‐ our change of the dash panel.

– Pull securing cable together until solar panel is close to wind‐

screen.

– Connect solar panel -arrow- to diagnostic connection of vehi‐

cle.

• The green LED in the solar panel frame indicates the function: the brighter this LED lights up, the higher is the charging cur‐ rent; however, the integrated electronics prevent overcharging the battery.

6. Charging battery 43

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7 Checking and servicing alternator

7.1 Checking alternator

– The alternator is checked in „Guided Fault Finding“ function

under „Body/electrical system / 27 - Starter, current supply/ electrical components / C- Alternator, checking“ ⇒ Vehicle di‐ agnostic, testing and information system VAS 5051.

7.2 Bosch alternator up to 2000 - exploded view

1 - Bolts

❑ 1 Nm

2 - Cover

❑ With three retaining tabs

3 - Bolts

❑ 2 Nm

4 - Voltage regulator

❑ Removing:

– Unscrew bolts -item 1-

and detach protective cap -item 2-

– Unscrew bolts -item 3-

and detach voltage reg‐ ulator

❑ Carbon brush wear limit:

5 mm

5 - Alternator

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

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7.3 Bosch alternator from 2001 onwards - exploded view

Note

The alternators were introduced gradually.

1 - Alternator

2 - Voltage regulator

❑ Removing and installing

⇒ page 46

❑ Checking carbon brush‐

es ⇒ page 48

3 - Bolt

❑ 2.5 Nm

4 - Cover

5 - Nut

❑ 12 Nm

6 - Nut

❑ 30 Nm

7 - Bolt

❑ 3 Nm

8 - Bolt

❑ 1.5 Nm

7. Checking and servicing alternator 45

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7.4 Removing and installing voltage regula‐ tor - Bosch alternator from 2001 on‐ wards

Removing

– Remove alternator ⇒ Electrical system; Rep. gr. 27 .

– Unscrew bolt -1- and nuts -3- and -4-.

– Detach cover -2- from rear of alternator.

– Unscrew bolts -arrows-.

– Remove voltage regulator.

Installing

– When positioning voltage regulator, ensure carbon brushes

are positioned correctly on contact surfaces.

Further installation is carried out in the reverse order; note the following:

– Install alternator ⇒ Electrical system; Rep. gr. 27 .

• Tightening torque ⇒ page 45

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

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7.5 Bosch alternator from 2007 onwards - exploded view

Note

The new alternators were introduced gradually.

1 - Nut

❑ 65 Nm

2 - Poly V-belt pulley

3 - Alternator

4 - Voltage regulator

❑ Removing and installing

⇒ page 48

❑ Checking carbon brush‐

es ⇒ page 48

5 - Bolt

❑ 1.5 Nm

6 - Cover

7 - Bolt

❑ 3 Nm

8 - Bolt

❑ 2.5 Nm

7. Checking and servicing alternator 47

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7.6 Removing and installing voltage regula‐ tor - Bosch alternator from 2007 on‐ wards

Removing

– Remove alternator ⇒ Electrical system; Rep. gr. 27 .

– Unscrew bolts -arrows-.

– Detach cover -1- from rear of alternator.

– Unscrew bolts -arrows-.

– Detach voltage regulator -1-.

Installing

– When positioning voltage regulator, ensure carbon brushes

are positioned correctly on contact surfaces.

Further installation is carried out in the reverse order; note the following:

– Install alternator ⇒ Electrical system; Rep. gr. 27 .

• Tightening torque ⇒ page 45

7.7 Checking carbon brushes - all types of Bosch alternators from 2001 onwards

Procedure

– Remove voltage regulator: Up to 2007 ⇒ page 46 ; from 2007

onwards ⇒ page 48 .

– Check length -a- of carbon brushes.

• Wear limit: -a- = 5 mm.

– Install voltage regulator: Up to 2007 ⇒ page 46 ; from 2007

onwards ⇒ page 48 .

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

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7.8 Valeo alternator up to 2000 - exploded view

1 - Alternator

2 - Voltage regulator

❑ Removing:

– Remove nuts -item 5-

and detach cover

-item 4-

– Unscrew bolt -item 6-

and nuts -item 7- and detach voltage regulator

❑ Carbon brush wear limit:

5 mm

3 - Protective cap

4 - Cover

5 - Nut

❑ 2 Nm

6 - Bolt

❑ 2 Nm

7 - Nut

❑ 2x ❑ 3.5 Nm

7. Checking and servicing alternator 49

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7.9 Valeo alternator from 2001 onwards - exploded view

Note

The alternators were introduced gradually.

1 - Alternator

2 - Voltage regulator

❑ Removing and instal‐

ling: Up to 2007

⇒ page 51 ; from 2007

onwards ⇒ page 52

❑ Checking carbon brush‐

es: Up to 2007

⇒ page 51 ; from 2007

onwards ⇒ page 52

3 - Bolt

❑ 2 Nm

4 - Cover

5 - Protective cap

6 - Bolt

❑ 2 Nm

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

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7.10 Removing and installing voltage regula‐ tor - Valeo alternator from 2001 onwards

Removing

– Remove alternator ⇒ Electrical system; Rep. gr. 27 .

– Press cover on rear of alternator off studs -arrows-.

– Unscrew bolts -1- and centre hex stud -2-.

– Remove voltage regulator.

Installing

– Press protective cap -2- off voltage regulator -1- in direction of

-arrow-.

– When positioning voltage regulator, ensure carbon brushes

are positioned correctly on contact surfaces.

– Refit protective cap when voltage regulator has been installed.

Further installation is carried out in the reverse order; note the following:

– Install alternator ⇒ Electrical system; Rep. gr. 27 .

• Tightening torque ⇒ page 50

7.11 Checking carbon brushes - Valeo alter‐ nator from 2001 onwards

Procedure

– Remove voltage regulator ⇒ page 51 .

– Check length -a- of carbon brushes.

• Wear limit: -a- = 5 mm.

– Install voltage regulator ⇒ page 51 .

7. Checking and servicing alternator 51

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7.12 Removing and installing voltage regula‐ tor - Valeo alternator from 2007 onwards

Special tools and workshop equipment required

♦ Feeler gauge, 0.3 mm

Removing

– Remove alternator ⇒ Electrical system; Rep. gr. 27 .

– Press cover on rear of alternator off studs -arrows-.

– Unscrew bolts -1- and centre hex stud -2-.

– Remove voltage regulator.

Installing

– Insert 0.3 mm feeler gauge -item 4- between protective cap

-2- and carbon brushes -3-.

– Pull protective cap off only as far as point where projection on

protective cap keeps carbon brushes pressed down.

– After installing voltage regulator, press protective cap on as

far as stop.

Further installation is carried out in the reverse order; note the following:

– Install alternator ⇒ Electrical system; Rep. gr. 27 .

• Tightening torque ⇒ page 50

7.13 Checking carbon brushes - Valeo alter‐ nator from 2007 onwards

Special tools and workshop equipment required

♦ Feeler gauge, 0.3 mm

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

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Procedure

– Remove voltage regulator ⇒ page 52 .

– Insert 0.3 mm feeler gauge -item 3- between protective cap

-2- and carbon brushes.

– Pull protective cover off voltage regulator -1- -arrow-.

– Check length -a- of carbon brushes.

• Wear limit: -a- = 5 mm.

– With protective cap -2- in position, press down carbon brushes

-3- with feeler gauge -4-.

– Slide protective cap on in direction of -arrow- until projection

on protective cap keeps carbon brushes pressed down.

– Install voltage regulator ⇒ page 52 .

7.14 Removing and installing poly V-belt pul‐ ley without free-wheel

Special tools and workshop equipment required

7. Checking and servicing alternator 53

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♦ Socket -3310-

♦ 8 mm hexagon socket or TORX T50 socket

Removing

– Remove alternator ⇒ Electrical system; Rep. gr. 27 .

– If fitted, press off protective cap on alternator pulley.

– Counterhold on securing nut using socket -3310- and turn al‐

ternator shaft clockwise to loosen.

– Detach poly V-belt pulley.

Installing

Installation is carried out in the reverse order; note the following:

– Turn alternator shaft anti-clockwise to tighten.

– Clip protective cap onto alternator pulley.

Tightening torque

Component Nm

Poly V-belt pulley to alternator 65

7.15 Removing and installing poly V-belt pul‐ ley with free-wheel

Special tools and workshop equipment required

♦ Adapter -3400-

♦ 8 mm hexagon socket or TORX T50 socket

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

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Removing

– Remove alternator ⇒ Electrical system; Rep. gr. 27 .

– If fitted, press off protective cap on alternator pulley.

– Counterhold on belt pulley using adapter -3400- and turn al‐

ternator shaft clockwise to loosen.

Installing

Installation is carried out in the reverse order; note the following:

– Turn alternator shaft anti-clockwise to tighten.

– Clip protective cap onto alternator pulley.

Tightening torque

Component Nm

Poly V-belt pulley with free-wheel to alternator 80

7. Checking and servicing alternator 55

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8 Cruise control system - vehicles with

electronic throttle

♦ On vehicles with electronic throttle, the cruise control system

functions are controlled by the engine control unit.

♦ Faults in the cruise control system are output via the engine

control unit.

– Use a vehicle diagnostic tester in „Guided Fault Finding“ mode

to identify faults.

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

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Electrical system; General information - Edition 10.2010

92 – Windscreen wash/wipe system

1 Washer fluid hoses

1.1 Disconnecting and connecting washer fluid hose connectors

Different types of hose couplings are used to connect hoses to washer fluid pumps and washer jets or as disconnection points.

Non-secured hose coupling

– Pull the two coupling elements apart to separate connection.

– To connect, press the two coupling elements firmly together

until they engage audibly and palpably.

Secured hose coupling with retaining ring

– To separate connection, turn retaining ring -1- 90° -arrow- and

detach hose connection.

– To connect, push on hose connection and turn retaining ring

-1- -arrow- until it engages.

Secured hose coupling with retaining clip version 1

– To separate connection, lift retaining clip -1- by approx. 1 mm

-arrow- and detach hose connection.

– To connect, push on hose connection and press in retaining

clip until it engages.

1. Washer fluid hoses 57

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Secured hose coupling with retaining clip version 2

– To separate connection, lift retaining clip -1- -arrow- and de‐

tach hose connection.

– To connect, push on hose connection and press in retaining

clip until it engages.

Hose coupling for headlight washer system with retaining clip

– To separate connection, press retaining clip -1- -arrow- and

detach hose connection.

– To connect, press and hold retaining clip -arrow- and push on

hose connection.

– Check whether connection is properly engaged by pulling on

hose without pressing retaining clip.

Hose coupling for headlight washer system with O-type clip

– To separate connection, use side-cutting pliers to sever O-

type clip -1- and detach hose connection.

– To connect, slip a new O-type clip onto hose, attach hose

connection and secure O-type clip using hose clip pliers V.A.G 1275- .

Hose coupling for headlight washer system with spring clip

– To separate connection, open spring clip -1- using hose clip

pliers -V.A.G 1921- and detach hose connection.

– To connect, open spring clip using hose clip pliers -V.A.G

1921- and attach hose connection.

1.2 Servicing a smooth washer fluid pipe

Note

Smooth pipes with a diameter of 5x1 mm or 6x1 mm can be serv‐ iced using an EPDM hose (Ethylene Propylene Diene Monomer) ⇒ Electronic parts catalogue .

58 Rep. gr.92 - Windscreen wash/wipe system

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– Cut the damaged section out of the smooth pipe to be repaired,

making the cuts at right-angles to the pipe.

– Choose an appropriate EPDM hose -2- and cable tie ⇒ Elec‐

tronic parts catalogue .

– Cut the EPDM hose -2- to length such that the ends of the

smooth pipe -1- and -3- can both be slipped roughly 10 mm into the EPDM hose -2-.

– Secure the repair joint with cable ties -1-.

– Check operation and test for leaks.

1.3 Servicing a washer fluid hose with cor‐ rugated tube

Note

Corrugated tubes can be serviced using a shrink hose ⇒ Elec‐ tronic parts catalogue .

Special tools and workshop equipment required

♦ Hot air blower -VAS 1978/14A- from wiring harness repair set

-VAS 1978 B-

1. Washer fluid hoses 59

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♦ Cutting pliers -VAS 6228-

♦ Connection piece -1J0 955 875 R-

♦ Connection piece -1J0 955 875-

Procedure

– Cut washer fluid hose at point of damage using cutting pliers

-VAS 6228- .

– Join the severed ends -1 and 4- of the washer fluid hose using

connection pieces -2 and 3-.

– Push shrink hose -5- over one end of washer fluid hose and

fit connection pieces together.

– Push shrink hose over connection pieces on washer fluid

hose.

– After pushing on the shrink hose, shrink-fit it using hot air

blower -VAS 1978/14A- .

• The shrink hose must be heated starting from the centre and working outwards until it is sealed tight.

• Set hot air blower to appropriate temperature as indicated in operating instructions.

• When shrink-fitting, ensure no other wires, plastic components or insulating materials are damaged by the hot nozzle.

– Check operation and test for leaks.

60 Rep. gr.92 - Windscreen wash/wipe system

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94 – Lights, bulbs, switches - exterior

1 Safety precautions when handling

gas discharge bulbs

Never renew bulbs if you are not familiar with the necessary pro‐ cedure, safety precautions and tools required.

WARNING

High voltage! Danger to life!

♦ Always disconnect the battery earth cable before working

on parts of the gas discharge headlights marked with yel‐ low high-voltage warning symbols.

♦ Then switch dipped beam on and off again to dissipate any

remaining voltage.

♦ Switch off ignition and all electrical equipment and remove

ignition key.

♦ Never operate the gas discharge bulb control unit without

a gas discharge bulb.

♦ The gas discharge bulb may only be operated in the head‐

light housing because of the high voltages (above 28,000 V when the gas discharge bulb is ignited).

WARNING

Risk of injury from burns, UV radiation, dazzling and explosion.

♦ The gas discharge bulb may only be operated in the head‐

light housing because of the high temperatures, the ab‐ sorption of UV radiation and to avoid dazzling.

♦ Never look into the light beam as this could disturb the eye

sight for an extended period of time.

♦ Gas discharge bulbs are pressurised and can burst when

they are renewed.

♦ Always wear safety goggles and gloves when removing

and installing gas discharge bulbs.

WARNING

Observe environmental requirements.

♦ Gas discharge bulbs are hazardous waste. They contain

metallic mercury (Hg) and traces of thallium.

♦ Never break off gas discharge bulbs and do not touch

broken glass part of bulb.

♦ Observe disposal regulations. Gas discharge bulbs

should only be disposed of in the appropriate containers at an official collection point.

1. Safety precautions when handling gas discharge bulbs 61

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Caution

♦ Do not touch the glass part of the gas discharge bulb with

bare hands. The remaining fingerprint would be evapora‐ ted by the heat of the bulb when it is switched on, become deposited on the reflector and thus impair the brightness of the headlight. Wear clean fabric gloves when fitting the gas discharge bulb.

♦ Only replace defective gas discharge bulbs with gas dis‐

charge bulbs of the same type. The type can be found on the base of the bulb or on the glass part of the bulb.

♦ When installing, make sure connectors engage properly

and are securely attached.

62 Rep. gr.94 - Lights, bulbs, switches - exterior

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96 – Lights, bulbs, switches - interior

1 Immobilizer for vehicles without entry

and start authorisation switch -E415(mechanical ignition lock)

1.1 General notes

The immobilizer control unit is integrated into the instrument clus‐ ter, i.e. the immobilizer control unit can only be renewed together with instrument cluster ⇒ Electrical system; Rep. gr. 90 .

– If the control unit is renewed, select „Replacement“ for the ap‐

propriate control unit in the „Guided Functions“ mode ⇒ Vehi‐ cle diagnostic, testing and information system VAS 5051.

1.2 Defective transponder or loss of key

♦ The transponder is integrated into the ignition key and cannot

be renewed separately.

♦ The complete ignition key must be replaced if the transponder

is defective.

– Order a new replacement key with vehicle-specific lock num‐

ber from your importer (or distribution centre), quoting vehicle identification number.

– Match all ignition keys in the „Guided Functions“ mode ⇒ Ve‐

hicle diagnostic, testing and information system VAS 5051.

1.3 Renewing reader coil

♦ The reader coil is integrated into the lock cylinder and cannot

be renewed separately.

♦ The complete lock cylinder must be renewed if the reader coil

is defective.

– Order a new lock cylinder with vehicle-specific lock number

from your importer (or distribution centre), quoting vehicle identification number.

1.4 Procedure for renewing lock set

The ignition keys can only be matched in the „Guided Functions“ mode ⇒ Vehicle diagnostic, testing and information system VAS 5051.

1. Immobilizer for vehicles without entry and start authorisation switch E415 (mechanical ignition lock) 63

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2 Immobilizer for vehicles with entry

and start authorisation switch -E415(electronic ignition lock)

The immobilizer control system is either located in the conven‐ ience system central control unit -J393- or in the entry and start authorisation control unit -J518- . Fitting location: ⇒ Current flow diagrams, Electrical fault finding and Fitting locations.

The following components also form part of the immobilizer:

♦ Ignition key with built-in transponder.

♦ Reader coil in entry and start authorisation switch -E415-

(electronic ignition lock).

♦ Engine control unit.

♦ Gearbox control unit.

When renewing control unit, select appropriate control unit in „Guided Functions“ ⇒ Vehicle diagnostic, testing and information system VAS 5051.

64 Rep. gr.96 - Lights, bulbs, switches - interior

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3 Heated steering wheel

– For fault finding, remove airbag unit ⇒ Rep. gr. 69 .

– Remove steering wheel ⇒ Rep. gr. 48 .

– Check wiring ⇒ Current flow diagrams, Electrical fault finding

and Fitting locations.

Note

The steering wheel must be renewed if the heated steering wheel is defective.

3. Heated steering wheel 65

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4 Towing bracket

4.1 Removing and installing socket for tow‐

ing bracket - version 1

Removing

– Switch off ignition and take out ignition key.

– Unscrew bolts -arrows-.

– Detach socket from retaining plate.

Socket with rear fog light cut-out contact switch -F216- :

– Unplug connector -2- for rear fog light cut-out contact switch -

F216- and press connector -1- out of trailer socket -U10- .

Socket without rear fog light cut-out contact switch -F216- :

– Press multi-pin connector -1- out of socket -2- in direction of

-arrow-.

Version 1:

– Release retaining tabs -arrows- and then release the clips

-1- and -3 ... 5-.

– Remove frame from connectors -2-.

66 Rep. gr.96 - Lights, bulbs, switches - interior

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Version 2:

– Release retaining tabs -arrows- and then release clips

-1, 2, 3, 4, 6, 7-.

– Remove frame from multi-pin connector -5-.

Installing

Installation is carried out in the reverse order; note the following:

Note

Make sure that seals -1- and -3- are not damaged.

– Insert connectors -4- into frame -2- until they audibly engage.

4.2 Removing and installing socket for tow‐ ing bracket - version 2

Removing

Refit cable ties at the same locations when reinstalling.

– Switch off ignition and take out ignition key.

– Open out towing bracket and engage.

– Cut open cable tie -1- and remove bolts -2- and -4-.

– Press socket out of towing bracket -3- in direction of -arrow-.

Note

4. Towing bracket 67

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– Turn cover cap -1- anti-clockwise -arrow- and detach from

socket -3-.

– Detach rubber cover -2-.

– Release clips -arrows- and press multi-pin connector -2- out

of socket -1-.

– Release clips -arrows- and detach frame -1- from multi-pin

connector -3-.

Note

Pull frame off carefully so that contacts -2- of multi-pin connector are not separated from wiring harness.

68 Rep. gr.96 - Lights, bulbs, switches - interior

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Installing

Installation is carried out in the reverse order; note the following:

– Frame -1- can only be fitted onto multi-pin connector -3- in one

position.

• Guide pins -4- can be inserted in frame in one position only

(the contacts -2- must be in the frame).

– Slide frame into multi-pin connector until it engages audibly.

4.3 Removing and installing socket for tow‐ ing bracket - version 3

Removing

– Open out towing bracket with electric control and engage in

position ⇒ Owner's Manual for the specific vehicle.

– Switch off ignition and remove ignition key.

– Remove bolts -arrows-.

– Detach socket from retaining plate.

– Detach rubber cover from socket.

– Release retaining clips -arrows- and press multi-pin connector

-2- out of socket -1-.

4. Towing bracket 69

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– Release clips -arrows- and detach frame -2- from multi-pin

connector -3-.

Note

Pull frame off carefully so that contacts -2- of multi-pin connector are not separated from wiring harness.

Installing

Installation is carried out in the reverse order; note the following:

– Frame -1- can only be fitted onto multi-pin connector -3- in one

position.

• Guide pins -4- can be inserted in frame in one position only (the contacts -2- must be in the frame).

– Slide frame into multi-pin connector until it engages audibly.

70 Rep. gr.96 - Lights, bulbs, switches - interior

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4.4 Pin assignment at socket for towing bracket

Socket for towing bracket, 13-pin (country-specific version)

1 - Terminal BL - turn signal (left-side)

2 - Terminal NSL - rear fog light

3 - Terminal 31 - earth

4 - Terminal BR - turn signal (right-side)

5 - Terminal 58 R - tail light (right-side)

6 - Terminal 54 - brake light

7 - Terminal 58 L - tail light (left-side)

8 - Terminal RF - reversing light

9 - ⇒ Current flow diagrams, Electrical fault finding and Fitting

locations

10 - ⇒ Current flow diagrams, Electrical fault finding and Fitting

locations

11 - ⇒ Current flow diagrams, Electrical fault finding and Fitting

locations

12 - ⇒ Current flow diagrams, Electrical fault finding and Fitting

locations

13 - ⇒ Current flow diagrams, Electrical fault finding and Fitting

locations

Socket with rear fog light cut-out contact switch -F216- :

Pin assignment at rear fog light cut-out contact switch -F216⇒ Current flow diagrams, Electrical fault finding and Fitting loca‐ tions

4. Towing bracket 71

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97 – Wiring

1 Repairing wiring harnesses and elec‐

trical connectors

Special tools and workshop equipment required

♦ Wiring harness repair set -VAS 1978 B-

Caution

♦ Wiring harness and connector repairs are only to be per‐

formed using wiring harness repair set -VAS 1978 B- .

♦ Pay attention to the relevant regulations in the individual

countries.

Note

♦

Information on how to use the wiring harness repair set -VAS 1978 B- is given in the enclosed instructions.

♦

Examples are also given showing how to repair open circuits in wiring and defective connectors.

1.1 General information on repairs to the ve‐ hicle electrical system

WARNING

Risk of injury.

♦ Pay attention to stickers on vehicle pointing out compo‐

nents with high voltage. Remaining voltage must be dis‐ sipated before commencing repair work.

♦ Certain tools are equipped with a guard. This is placed

over the end of the tool after use to prevent injury to em‐ ployees and to protect the tip of the tool against damage.

72 Rep. gr.97 - Wiring

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Caution

♦ Pay attention to the relevant regulations in the individual

countries.

♦ Disconnecting the battery earth cable prevents accidents

when working on the vehicle electrical system. Switch off ignition before disconnecting earth wire at battery ⇒ Elec‐ trical system; Rep. gr. 27 .

♦ Before commencing repair work, always eliminate cause

of damage, e.g. sharp body edges, defective electrical components, corrosion etc.

Note

♦

Do not loosen earth straps on body if this can be avoided (danger of corrosion).

♦

Further information, for example about removal and installa‐ tion of individual components, can be found in the appropriate Workshop Manual.

1.2 ESD (electrostatic discharge) workplace

-VAS 6613-

♦ The ESD (electrostatic discharge) workplace -VAS 6613- is

designed for preventing damage to electronic components due to static discharge.

♦ Therefore it is possible to perform repairs on extremely sen‐

sitive electronic components and open printed circuit boards.

♦ Details on repairs which must be performed on the ESD (elec‐

trostatic discharge) workplace -VAS 6613- can be found in the relevant chapter of the appropriate Workshop Manual "Elec‐ trical system".

– For setting up the ESD (electrostatic discharge) workplace,

place the ESD table mat -3- from -VAS 6613- on a dry and clean table.

– Connect earthing module -2- to one of the snap fasteners on

ESD table mat.

– Then proceed by plugging in connector adapter -1- of earthing

module with adapting connector to an electrical mains socket equipped with earthing contact or attach crocodile clip to build‐ ing earth strap or water pipe.

– Connect wrist strap -4- to one of the snap fasteners on mat.

– Put on wrist strap directly on wrist – never on sleeve of shirt or

jacket.

Caution

For repairs on extremely sensitive electronic components and open printed circuit boards always use nonmagnetic tools, e.g. socket wrench -T10072- .

1. Repairing wiring harnesses and electrical connectors 73

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1.3 Notes on repairing wiring harnesses and electrical connectors

Note

♦

Observe general information on repairs to the vehicle electri‐ cal system ⇒ page 72 .

♦

Not all wiring cross sections found in the vehicle are contained in the wiring harness repair set -VAS 1978 B- . If the wiring cross section required is not contained, use the next largest cross section.

♦

Soldering is not permitted when repairing the vehicle electrical system.

♦

Never repair crimp connectors. Route a new wire along the defective wire if necessary.

♦

After crimping, hot air blower must be used to shrink-fit crimp connectors to prevent moisture from ingressing.

♦

Screened wires, e.g. on speed senders and knock sensors, must NOT be repaired. These wires must be renewed com‐ pletely if damaged.

♦

Only use yellow wires for repairs to wiring.

♦

Repaired wiring harnesses must not to be re-incorporated into the wrapping of the original vehicle wiring harness.

♦

Mark location of repair with yellow insulating tape.

♦

Yellow wiring and locations with yellow insulating tape on wir‐ ing harness designate a previous repair.

Always check operation after completing repair work. It may be necessary to interrogate and erase the event memories and/or reset the systems to basic setting.

1.4 Repairing wiring for pyrotechnic compo‐ nents

Note

♦

Observe general information on repairs to the vehicle electri‐ cal system ⇒ page 72 .

♦

Observe notes on repairing wiring harnesses and connectors

⇒ page 74 including marking repair locations.

74 Rep. gr.97 - Wiring

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WARNING

Carrying out repair work to wiring for pyrotechnic components incorrectly (for example on airbags, belt tensioners) will cause a malfunction in passenger protection systems.

♦ To maintain the repair standards required by the Audi fac‐

tory, repairs to wiring for pyrotechnic components may only be performed on the in-vehicle wiring using wiring harness repair set -VAS 1978 B- and genuine replace‐ ment parts (connector housings, contacts, wiring).

♦ Wires on the individual airbag units must NOT be repaired.

♦ If wires or connectors on airbag units are damaged, the

corresponding airbag units must be renewed for safety reasons.

♦ Do not repair wiring for pyrotechnic components at more than

two repair locations. Repair locations increase the resistance in wiring and can be the cause of faults in the system's selfdiagnosis.

♦ Repairs in the area around pyrotechnic components should

not be performed more than 30 cm from the nearest connector housing. This procedure and the marking with the yellow ad‐ hesive tape ensure that previous repairs can be easily identi‐ fied.

♦ The two wires going to the airbag igniters have a twist length

specification of 20 ± 5 mm. This twist length must always be observed when repairing twisted wires.

♦ When performing repair work, both wires to the airbag igniters

must be of the same length. When twisting the wires

-1 and 2-, the twist length specification -A- = 20 mm must be met.

♦ When making repairs, there must be no untwisted section of

wire which is longer than -B- = 100 mm, e.g. in the vicinity of crimp connectors -arrow-.

♦ Repair operations must be recorded in the Audi Service

Schedule under „Workshop entries“ with a brief outline of the repair work completed, company stamp and signature.

♦ Any warranty claims made under the AUDI AG factory war‐

ranty are invalid if airbag wiring harness repairs have not been performed using genuine replacement parts and wiring har‐ ness repair set -VAS 1978 B- .

1.5 Repairing CAN bus wiring

Note

♦

Observe general information on repairs to the vehicle electri‐ cal system ⇒ page 72 .

♦

Observe notes on repairing wiring harnesses and connectors

⇒ page 74 including marking repair locations.

1. Repairing wiring harnesses and electrical connectors 75

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Use an unscreened two-wire line -1 and 2- (cross-section 0.35 mm2 or 0.5 mm2) as CAN bus wire.

♦ The CAN bus wires are colour-coded as follows:

CAN bus wire High (powertrain) Orange/black CAN bus wire High (convenience) Orange/green CAN bus wire High (infotainment) Orange/purple CAN bus wire Low (all) Orange/brown

♦ Both CAN bus wires must be of the same length when repair‐

ing.

♦ When twisting the wires -1 and 2-, the twist length specification

-A- = 20 mm must be met.

♦ When making repairs, there must be no untwisted section of

wire which is longer than -B- = 50 mm, e.g. in the vicinity of crimp connectors -arrow-.

1.6 Repairing FlexRay wiring

Note

♦

Observe general information on repairs to the vehicle electri‐ cal system ⇒ page 72 .

♦

Observe notes on repairing wiring harnesses and connectors

⇒ page 74 including marking repair locations.

FlexRay wiring consists of a sheathed pair of wires -1 and 2- with a cross-section of 0.35 mm2.

♦ Both wires must be of exactly the same length when repairing.

♦ When twisting the wires -1 and 2-, the twist length specification

♦ When making repairs, there must be no untwisted section of

♦ Maximum stripped length of wire = 100 mm.

♦ Protect repair location against environmental effects with suit‐

-A- = 30 mm must be met.

wire which is longer than -B- = 30 mm, e.g. in the vicinity of crimp connectors -arrow-.

able measures. This requires a crimp connector with shrink hose, internal bonding material over untwisted repair joint and water-tight insulating tape around stripped wire.

1.7 Repairing an 0.25 mm2 wire with a single crimp connector

Procedure

– Release a length of approx. 20 cm of the defective wire on both

sides of the repair joint.

Caution

Risk of damage to electrical wiring.

♦ Take care when releasing wiring from wrapped wiring har‐

nesses.

76 Rep. gr.97 - Wiring

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– If necessary, use a knife to remove wrapping of wiring har‐

ness.

– Use wire stripper -VAS 1978/3- to cut out damaged section of

wiring.

Note

If cutting out the damaged section of wiring makes the two ends of the original vehicle wire too short for repair with a single crimp connector, insert a corresponding length of repair wire with two crimp connectors ⇒ page 80 .

– Set adjustable stop in jaws of wire stripper -VAS 1978/3- to

12 ... 14 mm (length to be stripped).

– Working from the front, insert end of wire into jaws of wire

stripper as far as it will go press stripper together completely.

– Open wire stripper again and take out stripped end of wire.

– Fold back half of the stripped wire ends.

–

To repair an 0.25 mm2 wire, take a small yellow crimp con‐ nector out of the wiring harness repair set -VAS 1978 B- .

– To fit crimp connector, use crimping pliers (base tool) -VAS

1978/1-2- with head adapter 0.35 mm² - 2.5 mm² -VAS 1978/1-1- .

– Slide small yellow crimp connector over two stripped and fol‐

ded back ends of original vehicle wire and fasten with crimping pliers.

Note

Take care not to crimp insulation of wire.

1. Repairing wiring harnesses and electrical connectors 77

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After crimping, hot air blower must be used to shrink-fit crimp connector to prevent moisture from ingressing.

– Attach shrink element for hot air blower -VAS 1978/15A- to hot

air blower, 220 V/ 50 Hz -VAS 1978/14A- .

Caution

Risk of damage to surrounding components.

♦ When shrinking crimp connectors, take care not to dam‐

age any other pipes/wires, plastic parts or insulating ma‐ terial with hot nozzle of the hot air blower.

♦ Always observe operating instructions for hot air blower.

– Working from centre outwards, use hot air blower to heat crimp

connector in longitudinal direction until it is completely sealed and adhesive emerges at ends.

• A wire repaired using a single crimp connector must look as

shown in illustration.

Note

♦

If several wires have to be repaired, make sure crimp connec‐ tors are not directly adjacent to one another. Offset the crimp connectors slightly to restrict the size of the wiring harness.

♦

If the repair location was previously wrapped, yellow adhesive tape must be wrapped around this location again on comple‐ tion of repair.

♦

If necessary, secure the repaired wiring harness with a cable tie to prevent rattling noises when the vehicle is driven.

1.8 Repairing a wire of 0.35 mm2 section or thicker with a single crimp connector

Procedure

– Release a length of approx. 20 cm of the defective wire on both

sides of the repair joint.

Caution

Risk of damage to electrical wiring.

♦ Take care when releasing wiring from wrapped wiring har‐

nesses.

– If necessary, use a knife to remove wrapping of wiring har‐

ness.

78 Rep. gr.97 - Wiring

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– Use wire stripper -VAS 1978/3- to cut out damaged section of

wiring.

Note

If cutting out the damaged section of wiring makes the two ends of the original vehicle wire too short for repair with a single crimp connector, insert a corresponding length of repair wire with two crimp connectors ⇒ page 83 .

– Set adjustable stop in jaws of wire stripper -VAS 1978/3- to

6 ... 7 mm (length to be stripped).

– Working from the front, insert end of wire into jaws of wire

stripper as far as it will go press stripper together completely.

– Open wire stripper again and take out stripped end of wire.

– For repair, take a suitable crimp connector out of the wiring

harness repair set -VAS 1978 B- .

– Use crimping pliers (base tool) -VAS 1978/1-2- for fitting crimp

connectors.

The following head adapters are available for the crimping pliers (base tool) -VAS 1978/1-2- :

♦ Head adapter 0.35 mm² - 2.5 mm² -VAS 1978/1-1-

♦ Head adapter 4.0 - 6.0 mm² -VAS 1978/2 A-

– Slide crimp connector over two stripped ends of original vehi‐

cle wire and fasten with crimping pliers.

Note

Take care not to crimp insulation of wire.

1. Repairing wiring harnesses and electrical connectors 79

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After crimping, hot air blower must be used to shrink-fit crimp connector to prevent moisture from ingressing.

– Attach shrink element for hot air blower -VAS 1978/15A- to hot

air blower, 220 V/ 50 Hz -VAS 1978/14A- .

Caution

Risk of damage to surrounding components.

♦ When shrinking crimp connectors, take care not to dam‐

age any other pipes/wires, plastic parts or insulating ma‐ terial with hot nozzle of the hot air blower.

♦ Always observe operating instructions for hot air blower.

– Working from centre outwards, use hot air blower to heat crimp

connector in longitudinal direction until it is completely sealed and adhesive emerges at ends.

• A wire repaired using a single crimp connector must look as

shown in illustration.

Note

♦

If several wires have to be repaired, make sure crimp connec‐ tors are not directly adjacent to one another. Offset the crimp connectors slightly to restrict the size of the wiring harness.

♦

If the repair location was previously wrapped, yellow adhesive tape must be wrapped around this location again on comple‐ tion of repair.

♦

If necessary, secure the repaired wiring harness with a cable tie to prevent rattling noises when the vehicle is driven.

1.9 Repairing an 0.25 mm2 wire by connect‐ ing in an additional wire

Note

For repairing an 0.25 mm2 wire only 0.5 mm2 repair wires are available.

Procedure

– Release a length of approx. 20 cm of the defective wire at two

points on both sides of the repair joint.

80 Rep. gr.97 - Wiring

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Electrical system; General information - Edition 10.2010

Caution

Risk of damage to electrical wiring.

♦ Take care when releasing wiring from wrapped wiring har‐

nesses.

– If necessary, use a knife to remove wrapping of wiring har‐

ness.

– Lay yellow repair wire next to damaged wiring harness and

use wire stripper -VAS 1978/3- to cut repair wire to required length.

– Cut damaged section out of original vehicle wire.

– Set adjustable stop in jaws of wire stripper -VAS 1978/3- to

12 ... 14 mm (length to be stripped).

– Working from the front, insert end of original vehicle wire into

jaws of wire stripper as far as it will go and press wire stripper together completely.

– Open wire stripper again and take out stripped end of wire.

– Fold back half of the stripped wire ends.

– Repeat procedure at other end of original vehicle wire.

– Set adjustable stop in jaws of wire stripper -VAS 1978/3- to

6 ... 7 mm (length to be stripped).

– Working from the front, insert end of the yellow repair wire into

jaws of wire stripper as far as it will go and press wire stripper together completely.

– Open wire stripper again and take out stripped end of wire.

– Repeat procedure at other end of repair wire.

–

To repair an 0.25 mm2 wire, take a small yellow crimp con‐ nector out of the wiring harness repair set -VAS 1978 B- .

1. Repairing wiring harnesses and electrical connectors 81

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– To fit crimp connectors from wiring harness repair set -VAS

1978 B- , use crimping pliers (base tool) -VAS 1978/1-2- with head adapter 0.35 mm² - 2.5 mm² -VAS 1978/1-1- .

– Slide small yellow crimp connector over original vehicle wire

on one side and over repair wire on the other.

– Use crimping pliers to fasten crimp connector to both wire

ends.

– Repeat procedure at other end of repair wire.

Note

Take care not to crimp insulation of wire.

After crimping, hot air blower must be used to shrink-fit crimp connector to prevent moisture from ingressing.

– Attach shrink element for hot air blower -VAS 1978/15A- to hot

air blower, 220 V/ 50 Hz -VAS 1978/14A- .

Caution

Risk of damage to surrounding components.

♦ When shrinking crimp connectors, take care not to dam‐

age any other pipes/wires, plastic parts or insulating ma‐ terial with hot nozzle of the hot air blower.

♦ Always observe operating instructions for hot air blower.

– Working from centre outwards, use hot air blower to heat crimp

connector in longitudinal direction until it is completely sealed and adhesive emerges at ends.

• A wire repaired using inserted repair wire and two crimp con‐

nectors must look as shown in illustration.

82 Rep. gr.97 - Wiring

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Note

♦

If several wires have to be repaired, make sure crimp connec‐ tors are not directly adjacent to one another. Offset the crimp connectors slightly to restrict the size of the wiring harness.

♦

If the repair location was previously wrapped, yellow adhesive tape must be wrapped around this location again on comple‐ tion of repair.

♦

If necessary, secure the repaired wiring harness with a cable tie to prevent rattling noises when the vehicle is driven.

1.10 Repairing a wire of 0.35 mm2 section or thicker by connecting in an additional wire

Note

For repairing an 0.35 mm2 wire only 0.5 mm2 repair wires are available.

Procedure

– Release a length of approx. 20 cm of the defective wire at two

points on both sides of the repair joint.

Caution

Risk of damage to electrical wiring.

♦ Take care when releasing wiring from wrapped wiring har‐

nesses.

– If necessary, use a knife to remove wrapping of wiring har‐

ness.

– Lay yellow repair wire next to damaged wiring harness and

use wire stripper -VAS 1978/3- to cut repair wire to required length.

– Cut damaged section out of original vehicle wire.

1. Repairing wiring harnesses and electrical connectors 83

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– Set adjustable stop in jaws of wire stripper -VAS 1978/3- to

6 ... 7 mm (length to be stripped).

– Working from the front, insert end of original vehicle wire into

jaws of wire stripper as far as it will go and press wire stripper together completely.

– Open wire stripper again and take out stripped end of wire.

– Repeat procedure at other end of original vehicle wire.

– For repair, take two suitable crimp connectors out of wiring

harness repair set -VAS 1978 B- .

– Use crimping pliers (base tool) -VAS 1978/1-2- for fitting crimp

connectors.

The following head adapters are available for the crimping pliers (base tool) -VAS 1978/1-2- :

♦ Head adapter 0.35 mm² - 2.5 mm² -VAS 1978/1-1-

♦ Head adapter 4.0 - 6.0 mm² -VAS 1978/2 A-

– Slide crimp connector over original vehicle wire on one side

and over repair wire on the other.

– Use crimping pliers to fasten crimp connector to both wire

ends.

– Repeat procedure at other wire ends.

Note

Take care not to crimp insulation of wire.

After crimping, hot air blower must be used to shrink-fit crimp connector to prevent moisture from ingressing.

– Attach shrink element for hot air blower -VAS 1978/15A- to hot

air blower, 220 V/ 50 Hz -VAS 1978/14A- .

Caution

Risk of damage to surrounding components.

♦ When shrinking crimp connectors, take care not to dam‐

age any other pipes/wires, plastic parts or insulating ma‐ terial with hot nozzle of the hot air blower.

♦ Always observe operating instructions for hot air blower.

84 Rep. gr.97 - Wiring

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Electrical system; General information - Edition 10.2010

– Working from centre outwards, use hot air blower to heat crimp

connector in longitudinal direction until it is completely sealed and adhesive emerges at ends.

• A wire repaired using inserted repair wire and two crimp con‐

nectors must look as shown in illustration.

Note

♦

If several wires have to be repaired, make sure crimp connec‐ tors are not directly adjacent to one another. Offset the crimp connectors slightly to restrict the size of the wiring harness.

♦

If the repair location was previously wrapped, yellow adhesive tape must be wrapped around this location again on comple‐ tion of repair.

♦

If necessary, secure the repaired wiring harness with a cable tie to prevent rattling noises when the vehicle is driven.

1. Repairing wiring harnesses and electrical connectors 85

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Audi A1 2011 ➤ , Audi A2 2001 ➤ , Audi A3 2004 ➤ , Audi A4 2001 ➤ , Au ... Electrical system; General information - Edition 10.2010

2 Repairing connector housings and

electrical connectors

2.1 Notes on repairing connector housings and electrical connectors

Note

♦

Observe general information on repairs to vehicle electrical system ⇒ page 72 .

♦

The appropriate crimp contacts are assigned to the connector housings on the basis of the part number stamped on the con‐ nector housing. For part numbers of connector housings in conjunction with appropriate crimp contacts, refer to ⇒ Elec‐ tronic parts catalogue; Special catalogue „Electrical connect‐ ing elements“; Electrical equipment; Sub-group 70 from chart 970-00 onwards .

♦

Always renew damaged connector housings.

2.2 Repairing contacts in connector hous‐ ings

Procedure

– If applicable, start by opening or releasing secondary locking

device on connector housing ⇒ page 89 .

– Use appropriate release tool -A- to release connector (primary

locking device) ⇒ page 89 .

– Take hold of wire and pull connector towards rear and out of

connector housing (if applicable with wire seal) -arrow-.

– Cut old connector off original vehicle wiring harness (if appli‐

cable with wire seal).

– Take yellow repair wire with correct connector out of wiring

harness repair set -VAS 1978 B- .

– Release a length of approx. 20 cm of the defective wire on both

sides of the repair joint.

Caution

Risk of damage to electrical wiring.

♦ Take care when releasing wiring from wrapped wiring har‐

nesses.

– If necessary, use a knife to remove wrapping of wiring har‐

ness.

86 Rep. gr.97 - Wiring

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Electrical system; General information - Edition 10.2010

– Slide connector of new repair wire into corresponding con‐

nector housing slot until it engages.

– If applicable, attach wire seal to repair wire ⇒ page 87 .

– Use wire stripper -VAS 1978/3- to shorten repair wire and wire

of original vehicle wiring harness as required.

– Strip ends of repair wire and original vehicle wire and crimp

stripped ends of repair wire and wire of original vehicle wiring harness using crimping pliers and a crimp connector

⇒ „1.7 Repairing an 0.25 mm2 wire with a single crimp con‐ nector“, page 76 or ⇒ „1.10 Repairing a wire of 0.35 mm2 section or thicker by connecting in an additional wire“, page 83 .

2.3 Fitting seals for individual wires

Procedure

Note

♦

Wire seals prevent water and dirt from ingressing into the con‐ nector housing. They are fitted e.g. in the engine compartment and must always be re-installed after completing a repair.

♦

As a standard, wire seal is crimped to wire together with con‐ nector. This is not the case with repair wires. Wire seal must be slipped onto wire before crimping repair wire.

♦

Wire seals must always match the wire cross section of the repair wire used. The outer diameter of the wire seal depends on the diameter of the connector housing slot. Always use the appropriate assembly tool when fitting.

– Attach wire seal -A- to free end of repair wire.

• The small diameter of the wire seal must face the connector housing.

2. Repairing connector housings and electrical connectors 87

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Audi A1 2011 ➤ , Audi A2 2001 ➤ , Audi A3 2004 ➤ , Audi A4 2001 ➤ , Au ... Electrical system; General information - Edition 10.2010

– Slide wire seal -A- over repair wire as far as connector housing

and then as far as it will go into connector housing using an appropriate fitting tool -B-.

2.4 Repairing connector housings with insu‐ lation displacement technology (IDC)

Note

♦

For technical reasons, connector housings with insulation dis‐ placement technology can only be supplied with the connec‐ tors inserted.

♦

If these connectors are not required, they can be removed in the same manner as for any other connector housing.

♦

Repair wires which are already fitted with the corresponding crimped-on connectors are available ⇒ Electronic parts cata‐ logue .

88 Rep. gr.97 - Wiring

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Electrical system; General information - Edition 10.2010

3 Releasing and dismantling connector

housings

3.1 Notes on releasing and dismantling con‐ nector housings

WARNING

Risk of injury.

♦ Certain tools are equipped with a guard. This is placed

over the end of the tool after use to prevent injury to em‐ ployees and to protect the tip of the tool against damage.

Note

♦

Observe general information on repairs to vehicle electrical system ⇒ page 72 .

♦

Always use the release tools intended for this purpose. Never force connectors out of connector housings.

♦

Always renew damaged connector housings.

♦

Small screwdrivers can be used to help release secondary locking devices.

♦

The pin assignment may be stamped on the secondary locking device or on the back of the connector housing.

♦

For further information on fitting locations of connectors, refer to ⇒ Current flow diagrams, Electrical fault finding and Fitting locations.

♦

For correct release tools for corresponding locking devices, refer to ⇒ Operating instructions for -VAS 1978/35- .

3.2 Secondary locking device

♦ The secondary locking device is a securing element designed

to secure all the wires in a connector housing. If a connector housing is fitted with a secondary locking device, this must always be opened or removed using the specified tool before releasing and extracting individual crimp connectors.

♦ The secondary locking device is of a different colour to the rest

of the connector housing to aid identification and show how it works.

♦ The types of connector housing shown here are only a selec‐

tion designed to illustrate examples of the various operating principles of the secondary locking devices.

3. Releasing and dismantling connector housings 89

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Example 1:

– Release the housing securing element by removing the

„comb“ -arrow-.

Example 2:

– Release the housing securing element by opening the „flap“

-arrow-.

Example 3:

– Release the housing securing element by disengaging a

„slide“ -arrow-.

3.3 Primary locking device

♦ The primary locking device engages an individual crimp con‐

nector in the connector housing.

♦ If housing securing elements (secondary locking devices) are

fitted, they must be released or removed using the specified tool before releasing the contacts ⇒ page 89 .

♦ The types of primary locking device shown here are only a

selection designed to illustrate examples of the various oper‐ ating principles of the primary locking devices.

♦ For correct release tool for corresponding locking device, refer

to ⇒ Operating instructions for -VAS 1978/35- .

90 Rep. gr.97 - Wiring

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Electrical system; General information - Edition 10.2010

3.4 Primary locking device with round con‐ nector systems

Procedure

Note

If housing securing elements (secondary locking devices) are fit‐ ted, they must be released or removed using the specified tool before releasing the contacts ⇒ page 89 .

– Insert appropriate release tool for connector housing in re‐

lease slot at connector housing.

– Take hold of connector at wire and press it slightly into con‐

nector housing -left arrow-.

Note

Pressing connector towards connector housing causes retaining tabs of connector to be lifted off housing shoulder, enabling them to be released with release tool.

– At the same time, press release tool towards connector hous‐

ing -right arrow- and pull released connector out of connector housing.

– After removing connector, pull release tool out of connector

housing.

3.5 Primary locking device with flat connec‐ tor systems

Procedure

Note

If housing securing elements (secondary locking devices) are fit‐ ted, they must be released or removed using the specified tool before releasing the contacts ⇒ page 89 .

3. Releasing and dismantling connector housings 91

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Flat connector system with one retaining tab:

– Insert appropriate release tool for connector housing in re‐

lease slot at connector housing.

– Take hold of connector at wire and press it slightly into con‐

nector housing -arrow-.

Note

Pressing connector towards connector housing causes retaining tab of connector to be lifted off housing shoulder, enabling it to be released with release tool.

– At the same time, press release tool towards connector hous‐

ing and pull released connector out of connector housing

-arrow-.

– After removing connector, pull release tool out of connector

housing.

Flat connector system with two retaining tabs:

– Insert appropriate release tool for connector housing in re‐

lease slot at connector housing.

– Take hold of connector at wire and press it into connector

housing -arrow- as far as stop.

Note

Pressing connector towards connector housing causes retaining tabs of connector to be lifted off housing shoulder, enabling them to be released with release tool.

– At the same time, press release tool towards connector hous‐

ing and pull released connector out of connector housing

-arrow-.

– After removing connector, pull release tool out of connector

housing.

92 Rep. gr.97 - Wiring

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Electrical system; General information - Edition 10.2010

Asymmetrical:

– Insert appropriate release tool for connector housing in re‐

lease slot at connector housing.

– Take hold of connector at wire and press it slightly into con‐

nector housing -arrow-.

Note

Pressing connector towards connector housing causes retaining tabs of connector to be lifted off housing shoulder, enabling them to be released with release tool.

– At the same time, press release tool towards connector hous‐

ing and pull released connector out of connector housing

-arrow-.

– After removing connector, pull release tool out of connector

housing.

3.6 Primary locking device with special con‐ nector systems

Procedure

Note

If housing securing elements (secondary locking devices) are fit‐ ted, they must be released or removed using the specified tool before releasing the contacts ⇒ page 89 .

Fast-on contacts:

– Insert appropriate release tool for connector housing in re‐

lease slot at connector housing -arrow-.

– Take hold of connector at wire and press it slightly into con‐

nector housing.

Note

Pressing connector towards connector housing causes retaining tabs of connector to be lifted off housing shoulder, enabling them to be released with release tool.

3. Releasing and dismantling connector housings 93

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– At the same time, press release tool towards connector hous‐

ing and pull released connector out of connector housing

-arrow-.

– After removing connector, pull release tool out of connector

housing.

GT 150/280 connectors:

– Insert appropriate release tool for connector housing beneath

retaining tab into connector housing.

– Press tool -arrow- in connector housing as far as it will go.

• Connector is ejected from connector housing.

– After connector has been ejected, pull release tool out of con‐

nector housing.

Contacts without retaining tabs:

– Insert release tool beneath retaining tab on connector hous‐

ing.

– Lifting it slightly -arrow-, press release tool as far as stop.

94 Rep. gr.97 - Wiring

Audi Q7 2007 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

27 – Starter, current supply, CCS

1 Battery - general notes

1.1 Safety measures and procedures to be followed

1.2 Warnings and safety procedures when handling lead-acid batteries

2.1 Central gas venting system

2.2 Battery terminal screw connection

2. Non maintenance-free batteries (without „magic eye“) 5

2.4 Visual inspection of battery

2.5 Checking electrolyte level in battery

3 Maintenance-free batteries

3.1 Battery with „magic eye“

3.2 Checking battery with „magic eye“

3.5 Central gas venting system

3.6 Battery terminal screw connection

3.7 Visual inspection of battery

3.8 Checking colour indicator (electrolyte level in battery) - batteries with „magic eye“

3.9 Checking electrolyte level in battery

4.1 Checking battery using battery tester with printer -VAS 6161-

4.2 Checking battery using battery tester with printer -VAS 5097A-

6 Charging battery

6.2 Totally discharged battery

6.5 Maintaining battery charge with solar panel -VAS 6102 A-

7 Checking and servicing alternator

7.1 Checking alternator

7.2 Bosch alternator up to 2000 - exploded view

7.3 Bosch alternator from 2001 onwards - exploded view

7.5 Bosch alternator from 2007 onwards - exploded view

7.7 Checking carbon brushes - all types of Bosch alternators from 2001 onwards

7.8 Valeo alternator up to 2000 - exploded view

7.9 Valeo alternator from 2001 onwards - exploded view

92 – Windscreen wash/wipe system

1 Washer fluid hoses

1.1 Disconnecting and connecting washer fluid hose connectors

1.2 Servicing a smooth washer fluid pipe

94 – Lights, bulbs, switches - exterior

1. Safety precautions when handling gas discharge bulbs 61

96 – Lights, bulbs, switches - interior

1.1 General notes

1.2 Defective transponder or loss of key

1.3 Renewing reader coil

1.4 Procedure for renewing lock set

3 Heated steering wheel

4 Towing bracket

4.4 Pin assignment at socket for towing bracket

97 – Wiring

1.3 Notes on repairing wiring harnesses and electrical connectors

1.5 Repairing CAN bus wiring

1.6 Repairing FlexRay wiring

1.7 Repairing an 0.25 mm2 wire with a single crimp connector

1.8 Repairing a wire of 0.35 mm2 section or thicker with a single crimp connector

1.10 Repairing a wire of 0.35 mm2 section or thicker by connecting in an additional wire

2.1 Notes on repairing connector housings and electrical connectors

2.3 Fitting seals for individual wires

3.2 Secondary locking device

3. Releasing and dismantling connector housings 89

3.3 Primary locking device