SKODA Citigo 2012, Fabia 2000, Fabia II 2007, Fabia II 2009, Fabia II 2011 Workshop Manual

Service

Workshop Manual

Citigo 2012 ➤ , Fabia 2000 ➤ ,

F
Fabia II 2011 ➤ , Fabia III 2015 ➤ ,
Octavia 1997 ➤ , Octavia II 2004 ➤ ,
Octavia II 2010 ➤ , Octavia III 2013 ➤ ,
Octavia III 2014 ➤ , Rapid 2011 ➤ ,

abia II 2007 ➤ , Fabia II 2009 ➤ ,

Rapid NH 2013 ➤ , Rapid NH 2014 ➤ ,
Roomster 2006 ➤ , Superb 2002 ➤ ,
Superb II 2008 ➤ , Yeti 2010 ➤ ,
Yeti 2011 ➤

Electrical System - general notes

Edition 12.2014

Service Department. Technical Information

Service

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

R

ep ai r Gr ou p

27 - Starter, current supply, CCS
92 - Windscreen wash/wipe system
94 - Lights, bulbs, switches - exterior
96 - Lights, bulbs, switches - interior
97 - Wiring

Citigo 2012 ➤ , Fabia 2000 ➤ , Fabia II 2007 ➤ , Fabia II 2009 ➤ , Fab ...

Electrical System - general notes - Edition 12.2014

Contents

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

1 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 Basics about batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2 Battery types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.3 Warning instructions and safety precautions when working on the battery . . . . . . . . . . . . 4

1.4 Screwed connections of battery poles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.5 No-load voltage measurement - Demonstration vehicles and stock vehicles . . . . . . . . . . 6

2 Checking the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.1 Visual inspection of the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.2 Check battery with a magic eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.3 Checking fleece battery (AGM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.4 Checking battery with battery tester with printer VAS 6161 or with battery tester with printer

VAS 5097 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.5 Check current drain when charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3 Charge battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.1 Charging battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.2 Severely discharged batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4 Cruise control system (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.2 Activate/deactivate cruise control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

92 - Windscreen wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1 Repairing washer fluid level pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1.1 Repair solution for plain ended pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1.2 Repair solution for corrugated pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2 Washer fluid lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.1 Connections of washer fluid level pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

94 - Lights, bulbs, switches - exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1 Gas discharge lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1.1 Use and safety instructions for gas discharge lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

96 - Lights, bulbs, switches - interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1 12V power sockets, cigarette lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1.1 Removing and installing the 12 V power socket/cigarette lighter in the centre console . . . . 27

97 - Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1 Vehicle diagnosis, measurement and information systems . . . . . . . . . . . . . . . . . . . . . . . . 29

1.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1.2 Connect vehicle diagnosis, measurement and information system VAS 505x . . . . . . . . . . 29

2 Wiring loom repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

2.1 General instructions for the repair on the vehicle electrics . . . . . . . . . . . . . . . . . . . . . . . . . . 31

2.2 General instructions for wiring loom and plug repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

2.3 Tool descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

2.4 Repair of airbag and belt tensioner cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

2.5 Repair of CAN bus lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

2.6 Repairing wires with a cross-section of up to 0.35 mm2 . . . . . . . . . . . . . . . . . . . . . . . . . . 39

2.7 Line break with single repair point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

2.8 Line break with two repair points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

3 Repairing socket housings and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

3.1 Notes on repairing socket housings and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

3.2 Repairing contacts in socket housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Contents i

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Electrical System - general notes - Edition 12.2014

3.3 Assembly of single cable seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

4 Unlocking and disassembling socket housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

4.1 Notes on unlocking and disassembling socket housings . . . . . . . . . . . . . . . . . . . . . . . . . . 49

4.2 Secondary lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

4.3 Primary lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

5 Repairing optical fibres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

5.1 General points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

5.2 Preparing optical fibres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

5.3 Removing and installing optical fibre in the housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

6 Contact surface cleaning set VAS 6410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

6.1 Use contact surface cleaning set VAS 6410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

6.2 Repairing the cable eyes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

6.3 Repairing screwed connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

6.4 Cleaning the battery pole terminals and battery poles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

6.5 Preserving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

7 Replace the lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

7.1 Replace the LSF lambda probe (4-pole) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

7.2 Replace the LSU lambda probe (6-pole) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

7.3 Protective pipe variants of the unit lambda probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

ii Contents

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Electrical System - general notes - Edition 12.2014

27 – Starter, current supply, CCS

1 Battery

(SRL000768; Edition 12.2014)

⇒ “1.1 Basics about batteries”, page 1
⇒ “1.2 Battery types”, page 1
⇒ “1.3 Warning instructions and safety precautions when working

on the battery”, page 4
⇒ “1.4 Screwed connections of battery poles”, page 5
⇒ “1.5 No-load voltage measurement - Demonstration vehicles

and stock vehicles”, page 6

1.1 Basics about batteries

In order to ensure a long use, the battery must be inspected,
serviced and cared for according to the versions in this workshop
manual.

In addition to the function as energy supplier for the start opera‐
tion, the battery has further tasks as buffer and supplier of elec‐
trical energy for the complete electrical on-board power supply in
the vehicle.

1.2 Battery types

⇒ “1.2.1 Batteries with a magic eye”, page 1
⇒ “1.2.2 Fleece batteries (AGM batteries)”, page 2

1.2.1 Batteries with a magic eye

WARNING

Danger of injury! Observe the warning instructions and safety
precautions when working on the battery

⇒ “1.3 Warning instructions and safety precautions when work‐
ing on the battery”, page 4 .

Caution

When the battery is being replaced, the correct battery type
must always be selected.

The correct battery type must be assigned according to vehicle
type, engine type and equipment using the ⇒ Electronic Cata‐
logue of Original Parts .

The batteries described in the following are maintenance-free.
The labels must not be released and or covers for cell plugs
must not be removed or no distilled water must be topped up.

Battery with a magic eye »Standard«
In all vehicle types with the battery in the engine compartment

(except vehicles with the start-stop system and vehicles with the
auxiliary heating and additional heating), maintenance-free bat‐
teries with liquid battery acid and magical eye are mounted.

1. Battery 1

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Electrical System - general notes - Edition 12.2014

Battery with a magic eye »Enhanced«
A battery with a magic eye with EFB technology (Enhanced Floo‐

ded Battery) is fitted in vehicles with petrol engines with start-stop
system and small engine displacement. It is fitted with thicker
plates and separators with special polyester scrim. Thereby the
cycle durability as well as the loading capacity are considerably
increased in order to recover the energy more quickly while driv‐
ing.

Note

♦

This battery type is visible at the lettering “EFB” on the top of
its housing.

♦

An “EFB” battery must only be replaced with an “EFB” battery
or an AGM fleece battery.

The magic eye on the battery lid gives information via a colour
indicator about:

♦ The electrolyte level - the battery indicator of the magic eye

can show two colours

⇒ “2.2.1 Checking the two-coloured indicator of the magic
eye”, page 9

♦ The electrolyte level and the charge state of the battery - the

battery indicator of the magic eye can show three colours

⇒ “2.2.2 Checking the three-coloured indicator of the magic
eye”, page 10 (not valid for “EFB” batteries).

Note

The variant with three colour displays of the magical eye is no
longer installed- this can arise on old batteries.

WARNING

♦ Battery with colourless or bright yellow magic eye must not

be subjected to any test or charge. No starting aid must
be performed!

♦ There is a risk of explosion when testing or performing a

starting aid.

♦ These batteries must be replaced.

Note

We recommend to replace batteries which are older than 5 years
of age.

1.2.2 Fleece batteries (AGM batteries)

♦ Maintenance-free lead acid batteries on which the electrolyte

is defined in a microglass fibre fleece (AGM). The battery is
closed and fitted with valves.

♦ The fleece batteries are marked with the abbreviation AGM

(AGM is the English abbreviation for Absorbed Glass Matt).

♦ Due to defining the electrolyte, these batteries cannot have a

magic eye.

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Electrical System - general notes - Edition 12.2014

Caution

The fleece batteries cannot and may not be opened.
If the vehicle was fitted with a fleece battery (AGM battery) for

first equipment, a new fleece battery must absolutely be in‐
stalled when replacing the fleece battery.

The maintenance-free fleece battery (AGM battery) is installed:
♦ in vehicles with the battery in the luggage compartment (Su‐

perb II, 3.6 l engine)
♦ in some vehicles with the “start/stop” system
♦ in some vehicles with the auxiliary heating and additional heat‐

ing

Caution

If the vehicle was fitted with a fleece battery (AGM battery) for
first equipment, a new fleece battery must absolutely be in‐
stalled when replacing the fleece battery.

The correct battery type must be assigned according to vehicle
type, engine type and equipment using the ⇒ Electronic Cata‐
logue of Original Parts .

1. Battery 3

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Electrical System - general notes - Edition 12.2014

1.3 Warning instructions and safety precau‐
tions when working on the battery

WARNING

♦ Persons under supervision e.g. apprentices or trainees

must work with vehicle batteries only under the supervi‐
sion of skilled labourers e.g. mechanics/teachers or elec‐
tricians/teachers.

♦ Battery acid is highly caustic. There is a risk that in case

of incorrect work on the battery, the personnel can be ex‐
posed to the harmful effect of the battery acid. Therefore
suitable agents against acid causticization should be
made available. A suitable agent is, for example, deter‐
gent.

♦ If battery acid flows out this could lead to causticization of

the skin, acid seizure and vehicle corrosion. Under some
circumstances, components which are important for the
safety of the vehicle could be damaged.

♦ The detonating gas which results during the charging and

also partially when the battery is at rest, is explosive when
degassing after the charge. In an extreme case, the bat‐
tery can explode due to escaping gases as a result of
incorrect work on the battery.

♦ Battery with colourless or bright yellow magic eye must be

replaced. It must not be subjected to any test or charge
and no starting aid must be performed. There is a risk of
explosion when testing, charging or performing a starting
aid.

♦ It is prohibited to create sparks through grinding, welding,

cutting work and to use open fire, e.g. smoking in the
proximity of the battery. Avoid spark formation through
electrostatic discharging. Before touching the battery, it is
therefore necessary to touch the vehicle body.

♦ Work on the batteries must only be carried out in suitable

well-ventilated areas.
♦ Do not expose batteries to direct sunlight.
♦ Discharged batteries may freeze.

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Electrical System - general notes - Edition 12.2014

Warning instructions and safety precautions for lead acid batter‐
ies

1 - Observe the instructions on the battery, in the Workshop Man‐
ual Electrical System and in the Owner's Manual.

2 - Risk of acid burns:
♦ Battery acid is highly caustic, for this reason always wear pro‐

tective gloves and eye protection.

♦ Do not tilt battery as otherwise acid may flow out of the vent

openings.
3 - No fire, sparks, naked lights or smoking:
♦ Avoid creating sparks when handling cables and electrical

equipment.
♦ Avoid short circuits.
4 - Wear eye protection.
5 - Keep acid and batteries away from children.
6 - Disposal:
♦ Old batteries must be disposed of in compliance with the

country specific regulations.
7 - Never dispose of old batteries as domestic waste!
8 - Risk of explosion:
♦ A highly explosive gas mixture is produced when charging

batteries.

1.4 Screwed connections of battery poles

WARNING

When working on the battery - risk of accident. Observe the
warning instructions and safety precautions

⇒ “1.3 Warning instructions and safety precautions when work‐
ing on the battery”, page 4 .

1. Battery 5

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Electrical System - general notes - Edition 12.2014

Caution

In order to prevent damage to the battery pole terminals as well
as the battery poles, pay attention to the following:

♦ Neither grease nor oil the battery terminals.
♦ The battery pole terminals must only be fitted by hand

without using any force in order to avoid damaging the
battery housing.

♦ Install the battery pole terminals in such a way that the

battery poles with the terminals are on the same level or
protrude.

♦ After tightening the battery pole terminals to the specified

tightening torque, the screws must not be tightened again.

♦ If both terminals are disconnected, only then disconnect

the battery positive pole terminal (+).

If the battery terminals are not correctly connected and tight‐
ened, the cable can ignite. This can result in extensive function
problems of the electrical system. A safe vehicle operation is
no longer guaranteed.

1.5 No-load voltage measurement - Dem‐
onstration vehicles and stock vehicles

Special tools and workshop equipment required
♦ Hand multimeter (e.g. -V.A.G 1526A - )

Note

♦

No-load voltage measurement on demonstration and stock
vehicles must only be carried out within the prescribed main‐
tenance procedures as a criterion for evaluating the battery
state.

♦

The no-load voltage measurement serves to determine wheth‐
er the batteries of demonstration and stock vehicles should be
charged.

♦

The battery must not be drained by any electrical equipment
for at least 2 hours before the measurement is taken.

♦

If the battery tester with printer - VAS 6161- is used for the
measurement, the result from this tester is the determining
factor for assessment of the battery state.

Follow the procedure described below for measuring the battery
voltage in the no-load state:

– Use the handheld multimeter to measure the battery voltage.
The battery no-load voltage must not fall below 12.5 V.
If the handheld multimeter indicates 12.5 V or more, the battery

voltage is O.K.
If the handheld multimeter a battery voltage of less than 12.5 V:
– Charge battery ⇒ “3.1 Charging battery”, page 15 .
After charging wait at least 2 hours during which the battery with

electrical components must not be subjected to any load or
charge:

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Electrical System - general notes - Edition 12.2014

– Use the handheld multimeter to measure the battery voltage.
The battery no-load voltage must not fall below 12.5 V.

1. Battery 7

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Electrical System - general notes - Edition 12.2014

2 Checking the battery

Test is carried out in the following order.

⇒ “2.1 Visual inspection of the battery”, page 8
⇒ “2.2 Check battery with a magic eye”, page 9 or

⇒ “2.3 Checking fleece battery (AGM)”, page 11
⇒ “2.4 Checking battery with battery tester with printer VAS 6161

or with battery tester with printer VAS 5097 A ”, page 12
⇒ “2.5 Check current drain when charging”, page 13

2.1 Visual inspection of the battery

WARNING

♦ When working on the battery - risk of accident. Observe

the warning instructions and safety precautions

⇒ “1.3 Warning instructions and safety precautions when
working on the battery”, page 4 .

A visual inspection of the outer state of the battery and of the fixed
battery connections must be carried out before comprehensive
measurements.

During the visual inspection determine:
♦ If the battery housing is not damaged. In the event of damage

to the battery housing e.g. the excess acid can lead to severe
vehicle damage (not valid for fleece batteries). In the event of
excess acid, the contamined components must be immedi‐
ately treated with neutralizing agent or with a detergent. Paint
damage must be repaired by a specialist.

♦ If the battery terminals (connections of the battery cable) are

not damaged and if the fixed connection of the terminals is not
destroyed in the event of damage to the battery terminals.

Caution

When connecting the battery terminals, observe the work pro‐
cedure in the prescribed workshop manual

⇒ “1.4 Screwed connections of battery poles”, page 5 .

♦ To see whether the battery is seated properly in the vehicle,

see the assembly workflow of the battery in the associated
vehicle.

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Electrical System - general notes - Edition 12.2014

2.2 Check battery with a magic eye

⇒ “2.2.1 Checking the two-coloured indicator of the magic eye”,
page 9

⇒ “2.2.2 Checking the three-coloured indicator of the magic eye”,
page 10

2.2.1 “Checking the two-coloured” indicator of the magic eye

WARNING

When working on the battery - risk of accident. Observe the
warning instructions and safety precautions

⇒ “1.3 Warning instructions and safety precautions when work‐
ing on the battery”, page 4 .

Difference between the batteries with a magic eye, “two-coloured”
indicator.

• Batteries with the two-coloured indicator which are factory-in‐

stalled are marked with a code which always begins with
“5K0”. Then the exact identification is for example 5K0 915
105 D

• The replacement batteries with the three-coloured indicator,

which have been purchased from the Škoda Original Acces‐
sories, are marked with “000 915 105 Dx”, whereby “x” is a
variable. Then the exact identification is for example 000 915
105 DB.

Check the colour indicator of the magic eye

Note

When recharging the battery via a charger or during operation, air
locks can form under the magic eye, which can distort the indi‐
cator regarding the battery state. For this reason before an in‐
spection of the battery, tap lightly and carefully on the magic eye
(for example by using the handle of a screwdriver). The air bub‐
bles disperse in this way and the colour indicator becomes more
accurate.

The colour indicator of the magic eye no longer gives information
about the charge state of the battery, yet only about the electrolyte
level. An exact assessment of the charge state of the battery is
only possible using a battery tester

⇒ “2.4 Checking battery with battery tester with printer VAS 6161
or with battery tester with printer VAS 5097 A ”, page 12 .

The battery indicator can show two different colours:
♦ Black - Electrolyte level O.K.
♦ Colourless or bright yellow - Electrolyte level too low. Replace

battery.

2. Checking the battery 9

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WARNING

♦ Battery with colourless or bright yellow magic eye must not

be subjected to any test or charge under load. No starting
aid must be performed!

♦ There is a risk of explosion when testing or performing a

starting aid.

♦ These batteries must be replaced.

Note

In accordance with the guarantee, the load-dependent battery
tester with printer - VAS 5097A- is no longer used for testing these
batteries, but has instead been replaced with the stress-free bat‐
tery tester with printer - VAS 6161- .

2.2.2 “Checking the three-coloured” indicator of the magic eye

WARNING

When working on the battery - risk of accident. Observe the
warning instructions and safety precautions

⇒ “1.3 Warning instructions and safety precautions when work‐
ing on the battery”, page 4 .

Note

Not valid for “EFB” batteries.

Difference between the batteries with a magic eye, “three-col‐
oured” indicator.

• Batteries with the three-coloured indicator which are factory-

installed are marked with a code which always begins with
“1J0, 7N0 or 3B0”. Then the exact identification is for example
1J0 915 105 AC

• The replacement batteries with the three-coloured indicator,

which have been purchased from the Škoda Original Acces‐
sories, are marked with “000 915 105 Ax”, whereby “x” is a
variable. Then the exact identification is for example 000 915
105 AB.

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

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Check the colour indicator of the magic eye

Note

♦

When recharging the battery via a charger or during operation,
air locks can form under the magic eye, which can distort the
indicator regarding the battery state. For this reason before an
inspection of the battery, tap lightly and carefully on the magic
eye (for example by using the handle of a screwdriver). The
air bubbles disperse in this way and the colour indicator be‐
comes more accurate.

♦

The fact that the magic eye is only located in one battery cell
means that the reading is only relevant for that one battery cell.
An exact assessment of the charge state of the battery is only
possible by means of a battery load test

⇒ “2.4 Checking battery with battery tester with printer VAS
6161 or with battery tester with printer VAS 5097 A ”,
page 12 .

The colour indicator of the magic eye on these batteries gives
information about the electrolyte level and the charge state of the
battery.

The battery indicator can show three different colours:
♦ Green - Battery adequately charged and electrolyte level O.K.
♦ Black - Battery discharged or charged inadequately. Charge

battery ⇒ “3.1 Charging battery”, page 15 .

♦ Colourless or bright yellow - Electrolyte level too low. Replace

battery.

WARNING

♦ Battery with colourless or bright yellow magic eye must not

be subjected to any test or charge under load. No starting
aid must be performed!

♦ There is a risk of explosion when testing or performing a

starting aid.

♦ These batteries must be replaced.

Note

In accordance with the guarantee, the load-dependent battery
tester with printer - VAS 5097A- is no longer used for testing these
batteries, but has instead been replaced with the stress-free bat‐
tery tester with printer - VAS 6161- .

2.3 Checking fleece battery (AGM)

WARNING

When working on the battery - risk of accident. Observe the
warning instructions and safety precautions

⇒ “1.3 Warning instructions and safety precautions when work‐
ing on the battery”, page 4 .

2. Checking the battery 11

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Check battery in the following sequence:
1 - Visual inspection

⇒ “2.1 Visual inspection of the battery”, page 8 .

2 - Check battery with stress-free battery tester with printer -

VAS 6161- or with load-dependent battery tester with printer

- VAS 5097A- .

3 - Depending on the last test result, check the current drain

when charging

⇒ “2.5 Check current drain when charging”, page 13 .

2.4 Checking battery with battery tester with printer - VAS 6161- or with battery tester with printer - VAS 5097 A-

Special tools and workshop equipment required
♦ Stress-free battery tester with printer - VAS 6161­♦ Load-dependent battery tester with printer - VAS 5097 A-

WARNING

♦ When working on the battery - risk of accident. Observe

the warning instructions and safety precautions

⇒ “1.3 Warning instructions and safety precautions when
working on the battery”, page 4 .

♦ Battery with colourless or bright yellow magic eye must not

be subjected to any test or charge. These batteries must
be replaced.

♦ Carefully read through the operating instructions and ob‐

serve during the measurement before using the battery
tester.

Note

♦

The battery temperature must be at least 10 °C.

♦

On vehicles with the “start-stop” system and with the battery
monitoring control unit - J367- installed, the “-” terminal of the
tester must be connected to the body mass. If it is connected
to the negative terminal of the battery, this can lead to the fail‐
ure of the “start-stop” system after the measurement.

Depending on the test result (see operating instructions of the
tester):

– Connect battery to charger

⇒ “3.1 Charging battery”, page 15 and when charging starts,

check the current drain

⇒ “2.5 Check current drain when charging”, page 13 .

Explanations regarding battery test with stress-free battery tester
with printer - VAS 6161-

When using the battery tester with printer - VAS 6161- , the battery
must not be disconnected or removed.

The battery tester with printer - VAS 6161- does not stress the
battery. It operates on the principle of dynamic conductivity de‐
tection.

All types of batteries are stored in the tester, the data can be stor‐
ed on the SD card.

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

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The integrated temperature sender improves the measurement
quality.

Explanations regarding battery test with load-dependent battery
tester with printer - VAS 5097 A- :

The load current of the battery tester with printer - VAS 5097 A­and the minimum voltage differ according to the capacity of the
battery and are indicated on the sticker of the tester.

The battery voltage drops during this test as a result of the high
load on the battery (a high current flows).

If the battery is O.K., the voltage drops only as far as the minimum
voltage.

If the battery is faulty or only has a weak charge, the battery volt‐
age will drop very rapidly below the specified minimum voltage.

After completion of the test in case of discharged or poorly dis‐
charged batteries, this low voltage is retained for a lengthy period,
the voltage rises only slowly again.

2.5 Check current drain when charging

Information about the state of the discharged battery can be re‐
ceived as fast as possible when charging starts by determining
according to the current drain of the battery, if the battery has to
be replaced or can be fully charged.

WARNING

♦ When working on the battery - risk of accident. Observe

the warning instructions and safety precautions

⇒ “1.3 Warning instructions and safety precautions when
working on the battery”, page 4 .

♦ Battery with colourless or bright yellow magic eye must not

be subjected to any test or charge. These batteries must
be replaced.

Check the current drain according to the test result with the bat‐
tery tester:

Battery tester with printer - VAS 5097 A- :
1 - Starting power output adequate
2 - Starting power output weak
3 - Starting power output very weak
4 - not testable (the device does not switch on, LED does not

light up, does not print)
Battery tester with printer - VAS 6161- :
1 - Carry out current drain test
Test requirements
♦ The battery temperature when charging must be at least 10 °

C.

♦ Use battery chargers recommended by the manufacturer, with

a capability of at least 30 A charge current (e.g. - VAS 5900

- , -VAS 5903- , -VAS 5095A- ). - VAS 5900 - , -VAS 5903- , ­VAS 5095A- ).

♦ If the battery charger does not display directly the power of the

charge current (e.g. VAS 5095 A), the charge current must be
measured with current probe e.g. - VAS 5051B/7- .

2. Checking the battery 13

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Test sequence
– Connect the battery to the charger and start charging

⇒ “3.1 Charging battery”, page 15 .

– After five minutes, read off battery charge current at battery

charger or measure with current probe.
Test result
Five minutes after the beginning of the charging process, the

charge current must be more than 10 % rated capacity.
If five minutes after the beginning of the charging process, the

charge current is less than 10 % rated capacity, replace the bat‐
tery. In the case of warranty and goodwill, the protocol regarding
the battery test must be completed and stored together with the
battery.

Example
For a 60 Ah battery, 5 minutes after the beginning of the charging

process, the charge current should be more than 6 A. If this con‐
dition is fulfilled, continue the charging and two hours after ending
the charging, when the battery is not subjected to any load due
to an electrical component, measure the voltage again with the
battery tester

⇒ “2.4 Checking battery with battery tester with printer VAS 6161
or with battery tester with printer VAS 5097 A ”, page 12 .

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

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3 Charge battery

⇒ “3.1 Charging battery”, page 15
⇒ “3.2 Severely discharged batteries”, page 16

3.1 Charging battery

WARNING

♦ Battery with colourless or bright yellow magic eye must not

be subjected to any test or charge. These batteries must
be replaced.

♦ The cell plugs must always be securely tightened when

charging the battery, measuring the voltage and conduct‐
ing a test under load to ensure they are really sealed.

♦ Do not smoke or use a naked light in rooms in which bat‐

teries are being charged. The reason is that a gas is
formed by the charging process in the battery and this gas
can easily ignite.

♦ Frozen batteries must be replaced.

Special tools and workshop equipment required
♦ Battery charger e.g. - VAS 5900A- , -VAS 5903- , -VAS 5095A-

or -VAS 5901A- .

Note

♦

Batteries must only be charged with battery chargers recom‐
mended by the manufacturer.

♦

Carefully read through the operating instructions and observe
during the charging before using the battery charger.

♦

The battery must be at a temperature of at least 10 °C.

Charging a battery
Battery charger switched off
– Switch off all electrical components and take out the ignition

key.
Vehicles with the battery located in the engine compartment
– Open the battery cover.
– Connect the positive cable of the battery charger to the posi‐

tive terminal of the battery.
– Connect the negative cable of the battery charger to the neg‐

ative terminal of the battery.

3. Charge battery 15

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Caution

On vehicles with the “start-stop” system and with the battery
monitoring control unit - J367- installed, the “-” terminal (black)
of the charger must be connected to the body mass. If it is
connected directly to the negative terminal of the battery, this
can lead to the failure of the “start-stop” system after charging.

On severely discharged batteries, it can happen that on the
battery charger the charging voltage can switch over to the
nominal value of 6 V (the battery charger automatically evalu‐
ates if it is a 6V battery). In this case, the battery charger must
be switched over manually to charge a 12 V battery, see ⇒
Operating instructions of the battery charger .

– Switch on battery charger see ⇒ Operating instructions of the

battery charger .
– Leave the front flap open while charging the battery.
Vehicles with the battery located in the luggage compartment
– Release the cover -3- of the additional positive terminal of the

battery in the engine compartment -arrow- and open.
– Connect the positive cable of the battery charger -1- at the

additional positive terminal of the battery -2-.
– Connect the negative cable of the battery charger -4- to an

earth point in the engine compartment (e. g. -5- or lifting eye

of the engine).
– Switch on battery charger see ⇒ Operating instructions of the

battery charger .

3.2 Severely discharged batteries

Explanations regarding severely discharged batteries:
Batteries which have not been operational for a long time, e.g. in

stock vehicles, discharge themselves.
A battery is severely discharged if the no-load voltage has drop‐

ped below 11.6 V.
If a battery is severely discharged, the battery electrolyte (sul‐

phuric acid/water mixture) consists practically only of water as the
sulphuric acid portion is greatly reduced.

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Note

♦

Battery acid in severely discharged batteries can already
freeze at low frost-point temperature.

♦

Frozen batteries must no longer be used.

♦

On severely discharged batteries, it can happen that on the
battery charger the charging voltage can switch over to the
nominal value of 6 V (the battery charger automatically eval‐
uates if it is a 6V battery). In this case, the battery charger can
be switched over manually to charge a 12 V battery.

Severely discharged batteries sulphate, i.e. the entire surface of
the plates of the battery harden. The battery acid is not clear but
has a weak white colouring.

If a severely discharged battery is re-charged immediately after
losing its charge, the sulphate deposit forms again.

If such batteries are not re-charged, the plates continue to harden
and this restricts the battery's ability to accept a charge. This re‐
sults in a loss of battery power.

3. Charge battery 17

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4 Cruise control system (CCS)

⇒ “4.1 General description”, page 18
⇒ “4.2 Activate/deactivate cruise control system”, page 18

4.1 General description

The Cruise control system is controlled by the engine control unit.
– Activate/deactivate cruise control system

⇒ “4.2 Activate/deactivate cruise control system”, page 18 .

Fault recognition and fault display
Faults from the Cruise control system are transmitted via the en‐

gine control unit.
For fault finding, use the ⇒ Vehicle diagnostic tester in the mode

“Targeted fault finding”.

4.2 Activate/deactivate cruise control sys‐

tem

– Connect ⇒ Vehicle diagnostic tester.
– Select the operating mode “Targeted fault-finding” in the ⇒ Ve‐

hicle diagnostic tester.
– Select the “Selected Functions/Components” and subse‐

quently the following menu points using the button “Skip”:
♦ Drivetrain
♦ 01 – Self-diagnosable systems
♦ 01 - Engine control unit/Direct fuel injection and preheating

system
♦ 01 - Functions
♦ Activate/deactivate cruise control system

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

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92 – Windscreen wash/wipe system

1 Repairing washer fluid level pipes

⇒ “1.1 Repair solution for plain ended pipe”, page 19
⇒ “1.2 Repair solution for corrugated pipe”, page 20

1.1 Repair solution for plain ended pipe

Note

♦

Spare parts can be found in ⇒ Electronic Catalogue of Original
Parts .

♦

Plain ended pipes with diameter 5 x 1 mm or 6 x 1 mm can be
repaired with EPDM hose.

Method:
– Cut the damaged point straight out of the plain ended pipe to

be repaired.

– Select the suitable EPDM hose -2- and cable strap according

to the ⇒ Electronic Catalogue of Original Parts .

– Lengthen off the EDPM hose in such a way that both plain

ended pipe ends -1- and -3- can be inserted each 10 to 15 mm
into the EDPM hose.

– Secure the repair point with cable straps -1-.
– Perform a functional and tightness test.

1. Repairing washer fluid level pipes 19

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1.2 Repair solution for corrugated pipe

⇒ “1.2.1 Repairing corrugated washer fluid level pipes - vehicles
up to 12.2010”, page 20

⇒ “1.2.2 Repairing corrugated washer fluid level pipes - vehicles
as of 01.2011”, page 21

1.2.1 Repairing corrugated washer fluid level

pipes - vehicles up to 12.2010

Note

♦

When changing the material of the corrugated pipe, the fol‐

lowing procedure cannot be applied to vehicles manufactured

as of 01.2011 (this would result in a leaky connection point).

♦

The other described procedure

( ⇒ “1.2.2 Repairing corrugated washer fluid level pipes - ve‐

hicles as of 01.2011”, page 21 ) can also be applied to

vehicles manufactured up to 01.2011.

♦

Spare parts can be found in ⇒ Electronic Catalogue of Original

Parts .

Summary of components of connecting piece
1 - Catch clamp
2 - Connecting piece
3 - Tensioning ring
4 - O-ring
5 - O-ring
6 - Corrugated pipe
Method:

– Cut the damaged point straight out of the corrugated pipe to

be repaired so that the distance between the pipe ends is

maximum 20 mm.

Note

♦

If the damaged point is longer than 20 mm, insert new corru‐

gated pipe and then perform the described work sequence

twice.

♦

The repair point must not be exposed to tension or flexion.

– Push tensioning rings -2- onto the ends of the pipes -1- in such

a way that two shafts of the pipe protude.
– Then push O-rings -3- onto the ends of the pipe. One shaft of

the pipe protrudes.
– Fit pipes with tensioning rings onto the connecting pieces -4-

and -5- -arrows A-.

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– Compress connecting pieces -4- and -5- -arrows B-.
– Perform a functional and tightness test.

1.2.2 Repairing corrugated washer fluid level pipes - vehicles as of 01.2011

Note

♦

The following repair procedure of corrugated washer fluid level
pipes can also be applied to vehicles manufactured up to

01.2011.

♦

The repair point must not be exposed to tension or flexion.

♦

If the damaged point is longer than 15 mm, insert new corru‐
gated pipe and then perform the described work sequence
twice.

♦

Spare parts can be found in ⇒ Electronic Catalogue of Original
Parts .

Special tools and workshop equipment required
♦ Hot-air blower
Procedure
– Cut the damaged point straight out of the corrugated pipe to

be repaired so that the distance between the pipe ends is
maximum 15 mm.

– Select the suitable connecting pieces -2-, -3- as well as the

suitable shrink hose according to the ⇒ Electronic Catalogue
of Original Parts .

– Warm up the end of the corrugated pipe -1- slightly using a

hot-air blower.

– Press the connecting piece -2- into the corrugated pipe

-arrow A-.

– Warm up the end of the corrugated pipe -4- slightly using a

hot-air blower.

– Press the connecting piece -3- into the corrugated pipe

-arrow B-.

1. Repairing washer fluid level pipes 21

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– Lengthen off the shrink hose so that the corrugated pipe on

both sides can be covered by the shrink hose at least 20 mm

-dimension X-.

– Slide the shrink hose -5- over the corrugated pipe and connect

up the connecting pieces -2- and -3-.

– Secure the repair point with the shrink hose.

Note

♦

The shrink hose must be heated from the middle outwards until
it is completely sealed.

♦

During shrinking make sure the hot nozzle does not damage
any other cables, plastic parts or insulating materials.

– Perform a functional and tightness test.

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

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2 Washer fluid lines

⇒ “2.1 Connections of washer fluid level pipes”, page 23

2.1 Connections of washer fluid level pipes

In order to connect the hoses to the washer fluid pumps and the
spray nozzles, the following hose couplings are used for example
as separating points.

Unsecured hose coupling
– Pull apart both coupling parts in order to separate the con‐

nection.

– In order to connect, firmly press together both coupling parts

until they lock audibly. Check for secure locking by pulling at
the connection.

Secured hose coupling with circlip

– Turn the circlip -1- by approx. 90° -arrow- in order to separate

the connection and pull off the hose connection. After pulling
off the circlip -1-, turn back again.

– In order to connect, press together the connections until they

lock audibly. Check for secure locking by pulling at the con‐
nection.

Secured hose coupling with securing clip, version 1

– Pull up the securing clip -1- by approx. 1 mm -arrow- in order

to separate the connection and pull off the hose connection.

– In order to connect, press together the connections until they

lock audibly. Check for secure locking by pulling at the con‐
nection.

Secured hose coupling with securing clip, version 2

2. Washer fluid lines 23

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– Pull up the securing clip -1- -arrow- in order to separate the

connection and pull off the hose connection.

– In order to connect, press together the connections until they

lock audibly. Check for secure locking by pulling at the con‐
nection.

Hose coupling for headlight cleaning system with securing clip

– Press the securing clip -1- -arrow- in order to separate the

connection and pull off the hose connection.

– In order to connect, press together the connections until they

lock audibly. Check for secure locking by pulling at the con‐
nection.

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

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94 – Lights, bulbs, switches - exterior

1 Gas discharge lamps

⇒ “1.1 Use and safety instructions for gas discharge lamps”, page
25

1.1 Use and safety instructions for gas dis‐
charge lamps

WARNING

Never change lamps, if one is not familiar with the relevant
handling and safety instructions.

If installation is performed on the headlight with gas discharge
lamps, pay attention to the following points:

♦ Notes for dangerous high voltage / current ⇒ page 25
♦ Notes for pressure, temperature and radiation/arc

⇒ page 26

♦ Mounting instructions for gas discharge lamps ⇒ page 26
♦ Disposal instructions for gas discharge lamps ⇒ page 26
Special tools and workshop equipment required
♦ Protective goggles
♦ Gloves
Notes for dangerous high voltage / current

WARNING

♦ Mortal high voltage flows through the control units for light

system, plugs or parts of lamp base.

♦ The control unit for gas discharge lamp must never be op‐

erated without gas discharge lamp.

♦ The battery earth strap must be disconnected before

working on the parts of the gas discharge headlight
marked with the yellow high voltage symbols (this does
not apply if the gas discharge lamp is removed from an
already disassembled headlight, e.g. on Octavia ll).

♦ Then switch the low beam light on and off again. Thus

remaining voltage is discharged.

Note

Pay attention to the correct sequence when disconnecting and
connecting the battery ⇒ Electrical System; Rep. gr. 27 .

1. Gas discharge lamps 25

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Notes for pressure, temperature and radiation/ blinding

WARNING

♦ The gas discharge lamp must only be operated in the

headlight housing due to the high voltage (over 28000 V

when igniting the gas discharge lamp).
♦ Glass and bulbs can be very hot - risk of burning!
♦ Do not look directly into the ray of light because the inten‐

sity of the UV ray of the gas discharge lamp is approx. 2.5

times greater than that of the usual halogen light. The vis‐

ual power can be impaired for a long period.
♦ Avoid contact with exploded glass.
♦ Halogen bulbs and gas discharge lamps (Xenon/bi-xe‐

non) are pressurized and can burst when changing the

bulb - risk of injury!
♦ Always wear protective goggles and gloves for removing

and installing halogen bulbs and gas discharge lamps.

Mounting instructions for gas discharge lamps

Caution

♦ Do not touch the glass bulb with bare fingers when chang‐

ing the gas discharge lamps, use clean material gloves.

The remaining finger print would evaporate through the

heat of the switched on bulb and condense on the reflec‐

tor, which impairs the luminosity of the headlight.
♦ Replace defective gas discharge lamp with a gas dis‐

charge lamp of the same version. The designation is on

the lamp base or on the glass bulb.
♦ Lock plug connections correctly in place when installing

and pay attention to correct fitting of the connection.

Disposal instructions for gas discharge lamps

WARNING

♦ Gas discharge lamps must be disposed of as hazardous

waste, they do not belong to the usual household waste.
♦ Gas discharge lamps contain metallic mercury (Hg) and

traces of thallium.
♦ Do not destroy gas discharge lamps, avoid contact with

exploded glass.
♦ Observe the disposal instructions, dispose of gas dis‐

charge lamps only in the provided reservoirs at a proper

collection point.

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96 – Lights, bulbs, switches - interior

1 12V power sockets, cigarette lighter

⇒ “1.1 Removing and installing the 12 V power socket/cigarette
lighter in the centre console”, page 27

1.1 Removing and installing the 12 V power socket/cigarette lighter in the centre console

Special tools and workshop equipment required
♦ Extractor - T40148­Removing

Note

For purposes of clearer presentation, the socket is shown as
partly removed in the figure.

– Switch off the ignition and all electrical components.
– Insert the extractor -T40148- in such a way that the catch pegs

lock into the recesses in the socket housing -arrow- at the ex‐
tractor -2-.

– After locking the catch pegs, position the clamp -2- and turn

with the knurled nut -1- -arrow-, until the socket -3- is com‐
pletely pulled out of the centre console -4-.

Note

Pay attention to the wiring length when pulling out the socket.

– Disconnect plug.

1. 12V power sockets, cigarette lighter 27

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– Unscrew the knurled nut and push out the support bracket

-1-.

– The catch pegs -2- are unlocked by pressing on the spindle of

the extractor and by turning -arrow- the knurled wheel -4-.

– Push the extractor out of the socket housing -3-.

Note

The retaining springs of the socket are pressed apart by inserting
the extractor and the holding torque of the cigarette lighter is re‐
duced.

– Carefully press together again the retaining springs of the

socket -arrow-, in order to increase the holding torque.

– Slacken the tensioning sleeve of the socket -1- out of the catch

peg -2-, tilt out the tensioning sleeve -arrow- and remove it.

Install

Note

When installing, ensure that neither a cigarette lighter nor a plug
is in the power socket.

– Insert the tensioning sleeve of the socket into the centre con‐

sole until it clicks audibly into place.
– Place the connector onto the socket.
– Insert the socket into the tensioning sleeve up to the stop.

Caution

Vehicles with a cigar lighter - check that the cigar lighter works
correctly.

After the preheating process, this remains in the removal po‐
sition, and after the preheating process it remains in the re‐
moval position and is not hurled into the vehicle interior.

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97 – Wiring

1 Vehicle diagnosis, measurement and

information systems

⇒ “1.1 Safety instructions”, page 29
⇒ “1.2 Connect vehicle diagnosis, measurement and information

system VAS 505x”, page 29

1.1 Safety instructions

WARNING

♦ During test or drives with the vehicle diagnosis, measuring

and information system there is a risk of difficult or fatal
injuries!

♦ If the vehicle diagnosis, measurement and information

system is operated during a test or measuring drive in the
range of influence of the airbag, there is a risk of severe
or fatal injuries when activating the airbag!

♦ A second mechanic should assist during test or measuring

drive, who sits at the rear and operates the vehicle diag‐
nosis, measurement and information system.

Note

♦

Observe the current operating instructions for ⇒ Vehicle diag‐
nostic tester, which is displayed after selecting the buttons
“Administration” and “Operating manual”.

♦

All described work instructions such as adaptations, codings
etc. are not performed using the ⇒ Vehicle diagnostic tester

♦

All work instructions are performed in the operating modes
“Targeted fault-finding” and “Targeted functions”.

1.2 Connect vehicle diagnosis, measure‐
ment and information system VAS 505x

Note

Observe the current operating instructions for ⇒ Vehicle diagnos‐
tic tester, which is displayed after selecting the buttons “Admin‐
istration” and “Operating manual”.

Special tools and workshop equipment required
♦ ⇒ Vehicle diagnostic tester
♦ corresponding diagnostic cable
Connect ⇒ Vehicle diagnostic tester
– Apply handbrake.
– On vehicles with manual gearbox, shift the gearshift lever into

neutral position.

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– On vehicles with automatic gearbox, shift selector lever in “P”

or “N” position.

– When the ignition is switched off, connect the ⇒ Vehicle diag‐

nostic tester with the corresponding diagnostic cable at vehicle

diagnostic connection.
– Switch on ignition.
– Switch off all electrical components.

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2 Wiring loom repair

⇒ “2.1 General instructions for the repair on the vehicle electrics”,
page 31

⇒ “2.2 General instructions for wiring loom and plug repair ”, page
32

⇒ “2.4 Repair of airbag and belt tensioner cables”, page 36
⇒ “2.5 Repair of CAN bus lines”, page 38
⇒ “2.6 Repairing wires with a cross-section of up to 0.35 mm2 ”,

page 39
⇒ “2.7 Line break with single repair point”, page 41
⇒ “2.8 Line break with two repair points”, page 43

2.1 General instructions for the repair on the vehicle electrics

WARNING

♦ Pay attention to the stickers affixed to the vehicle which

indicate components with high voltage. The remaining
voltage must be discharged when undertaking repair work
(e.g. switch the electrical component on and off again after
disconnecting the battery).

♦ Some tools have a tool locking element which must be

pushed over the tip of the tool after use, in order to protect
the employee from injury and the tool tip from damage.

Caution

♦ When disconnecting and connecting the battery, respect

the specified procedure ⇒ Electrical System; Rep. gr. 27 .

♦ Before starting a repair, it is absolutely necessary to elim‐

inate the cause of the damage (e.g. sharp-edged body
parts, defective electrical components, corrosion etc.).

♦ When carrying out repairs, observe the current instructions in

the relevant Workshop Manuals.

♦ If possible, do not loosen any earth straps from the body (risk

of corrosion).

♦ When carrying out repairs, observe the current instructions in

the relevant Workshop Manuals.

♦ Country-specific regulations must be observed.

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2.2 General instructions for wiring loom and plug repair

Caution

Observe the general instructions for the repair on the vehicle
electrics

⇒ “2.1 General instructions for the repair on the vehicle elec‐
trics”, page 31 .

Do not solder when carrying out repairs on the vehicle electrics.
After crimping, the crimp connector must be shrunk with the

hot-air blower in order to prevent moisture from penetrating.
Shielded cables, such as wheel speed sensor and knock sen‐

sor cables, must not be repaired. They must be replaced
completely in case of damage.

If the required cable cross-section is not present in the wiring
loom repair kit, the larger cross-section must be used.

Mark the repair points with yellow adhesive tape.
The points in the wiring loom marked with the yellow adhesive

tape indicate a previous repair.
A functional test must be carried out after each repair. If nec‐

essary, the event memories must be interrogated with the
⇒ Vehicle diagnostic tester, erased and/or the systems must
be put into the basic setting.

Special tools and workshop equipment required
♦ Release tool set - S506815V­♦ Release tool set - S506825V­♦ Auxiliary measuring set - S504500V- or:
♦ Auxiliary measuring set - VAS 1978B­The car tool kit includes necessary tools (except the release tool

set) as well as consumables.
The car tool kit ensures optimal repair quality of the vehicle elec‐

trics. Repairs of plug connections and line interruptions can be
carried out with the tools.

For this purpose, complete repair cables with pre-crimped con‐
tacts are used and connected to the vehicle's own wiring loom by
means of crimp connectors.

The repair cables can be ordered ⇒ Electronic Catalogue of
Original Parts .

A stop plier with three different crimp recesses and a hot-air blow‐
er for shrinking the crimp connectors ensure a proper electrical
connection.

In case of re-ordering, only use the order number of the spare
part, which is given on the checklist enclosed with the operating
instructions.

The release tool set is used to release different primary and sec‐
ondary locks at the contact plugs.

For example, round plug connector systems, flat contacts with
one or two catches as well as single cable seals can be profes‐
sionally released or mounted using the release tool set.

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Note

♦

Further information and how to use the set ⇒ Operating in‐
structions of the car tool kit .

♦

Refer to the table in the ⇒ Operating instructions of the release
tool set in order to allocate the correct release tools.

2.3 Tool descriptions

⇒ “2.3.1 Stop plier with insert”, page 33
⇒ “2.3.2 Release tools for contacts”, page 34
⇒ “2.3.3 Assembly tools for single cable seals”, page 34
⇒ “2.3.4 Wire stripper VAS 1978/3 ”, page 34
⇒ “2.3.5 Hot-air blower, 220 V, 50 Hz VAS 1978/14 ”,

page 35
⇒ “2.3.6 Crimping pliers VAS 1978/1A ”, page 35

2.3.1 Stop plier with insert

The stop plier without insert - VAS 1978/1- with the insert for stop
plier - VAS 1978/2- is part of the wiring loom repair set - VAS
1978- .

Crimp con‐
nector colour

yellow yellow
red red
blue blue
yellow yellow

Note

♦

Alternatively, the crimping pliers (base body) - VAS1978/1-2--

Crimping
recess col‐
our

Cable cross-section

0.35 mm

0.5 mm2 - 1.0 mm

1.5 mm2 - 2.5 mm

4.0 mm2 - 6.0 mm

2

2

2

2

with the head adapters - VAS 1978/1-1- or -VAS 1978/2A- can
be used to crimp the connectors.

⇒ “2.3.6 Crimping pliers VAS 1978/1A ”, page 35 .

♦

You must ensure that the correct crimping recess is used for
the crimp connector.

♦

The insulation of the cable must not be crimped at the same
time.

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2.3.2 Release tools for contacts

The various release tools are used to remove the various contacts
from the socket housings non-destructively.

A selection of release tools is part of the wiring loom repair set ­VAS 1978 B- and previous sets.

WARNING

♦ Some tools have a tool locking element which must be

pushed over the tip of the tool after use, in order to protect
the employee from injury and the tool tip from damage.

Unlocking and disassembling socket housings

⇒ “4 Unlocking and disassembling socket housings”, page 49 .

2.3.3 Assembly tools for single cable seals

The assembly tools are used to slide the single cable seals into
the socket housing up to the stop without damage so that a com‐
plete seal is achieved between single cable and socket housing.

Four assembly tools for single cable seals are part of the wiring
loom repair set - VAS 1978 B- and previous sets.

Assembly of single cable seals

⇒ “3.3 Assembly of single cable seals”, page 46 .

2.3.4 Wire stripper - VAS 1978/3-

The wire stripper - VAS 1978/3- is used to strip and cut wires
correctly.

The wire stripper is part of the wiring loom repair set - VAS 1978
B- and previous sets.

The wire stripper has an adjustable stop in its jaws that can be
adjusted to the correct length of the wire insulation to be removed.

Stripping
Set the adjustable stop in the jaws to the correct dimension for

the length to be stripped.

Place the end of the wire from the front up to the stop in the jaws
and press the wire stripper until completely closed.

Open the stripper again and remove the stripped end of the wire.

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If necessary, use the side cutter function on the top side of the
wire stripper to cut wires.

2.3.5 Hot-air blower, 220 V, 50 Hz - VAS
1978/14-

Caution

When shrinking the crimp connectors, make sure the hot noz‐
zle of the hot-air blower does not damage any other cables,
plastic parts or insulating materials.

Follow the operating instructions of the hot-air blower!

The hot-air blower, 220 V, 50 Hz - VAS 1978/14- is used in con‐
junction with the shrink adapter for hot-air blower - VAS 1978/15­to shrink the crimp connectors. After crimping, the crimp
connector must be shrunk with the hot-air blower in order to pre‐
vent moisture from penetrating.

The hot-air blower, 220 V, 50 Hz - VAS 1978/14- is part of the
wiring loom repair set - VAS 1978 B- and previous sets.

Example of use

⇒ “2.7 Line break with single repair point”, page 41 .

2.3.6 Crimping pliers - VAS 1978/1A-

The crimping pliers - VAS 1978/1A- or the crimping pliers (base
body) - VAS 1978/1-2-- together with the head adapter 0.35-2.5
mm/2 - VAS 1978/1-1-- or the head adapter 4.0-6.0 mm/2 - VAS
1978/2A- are used to press the crimp connectors from the wiring
loom repair sets.

Example of use of the crimping pliers

⇒ “2.6 Repairing wires with a cross-section of up to 0.35 mm2 ”,
page 39 .

The following head adapters are available for the crimping pliers

- VAS 1978/1-2-- :

♦

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

♦

Head adapter 4.0 mm2 - 6.0 mm2 -VAS 1978/2A­♦ Head adapter for JPT contacts - VAS 1978/9-1-­The crimping pliers to crimp contacts on single cables when re‐

pairing wire cross-sections of 0.35 mm 2 - VAS 1978/9-1-- are
used in conjunction with the

⇒ “2.6 Repairing wires with a cross-section of up to 0.35 mm2 ”,
page 39 .

Swapping head adapter
– Open the crimping pliers completely.

head adapter for JPT contacts

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– Unlatch the two locking pins -arrows- from the base body of

the crimping pliers.

– Insert the required head adapter from above -arrow- into the

base body of the crimping pliers.

– Lock the head adapter into the base body of the crimping pliers

by pushing in the pins -arrow-.

2.4 Repair of airbag and belt tensioner ca‐
bles

Note

♦

Observe the general instructions for the repair on the vehicle
electrics

⇒ “2.1 General instructions for the repair on the vehicle elec‐
trics”, page 31 .

♦

Observe the general instructions for the wiring loom and plug
repair

⇒ “2.2 General instructions for wiring loom and plug repair ”,
page 32 .

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WARNING

Faulty repairs to the airbag and belt tensioner wiring loom can
lead to the malfunction of the occupant protection.

♦ Only use cables of the airbag and belt tensioner wiring

loom from the auxiliary measuring set, see

⇒ “2 Wiring loom repair”, page 31 using original parts

(socket housings, plugs and cables see ⇒ Electronic
Catalogue of Original Parts ).

♦ Do not carry out any repairs to the cables of the individual

airbag units.

♦ In case of damage to the cables or plugs at the airbag

units, the related airbag units must be replaced for rea‐
sons of safety.

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Note

♦

A maximum of two repair points can be repaired when repair‐
ing wires for pyrotechnical components. Repair points in‐
crease the electrical resistance in the cable and can trigger
faults in the self-diagnosis of the system.

♦

Do not wrap the repair point again in the vehicle's own wiring
loom and visibly mark the repair point with yellow insulating
tape.

♦

Repairs in the area of the airbag or belt tensioner should only
be carried out maximum 30 cm from the next socket housing.
Altogether this procedure of marking with yellow insulating
tape allows a quick overview of previous repairs.

♦

Both cables to the trigger units (airbags) have a stroke length
of 20±5 mm when twisting. It is mandatory to comply with
these stroke lengths for the lengths of the twisted cables to be
repaired.

♦

Both cables to the trigger units (airbags) must have the same
length when undertaking repair work. The stroke length of

-A- = 20 mm must be respected when the cables -1- and -2­are twisted.

♦

Thus, there must be no cable piece (in the area of the crimp
connectors -arrow-) longer than -B- = 100 mm without twisting
the cables.

2.5 Repair of CAN bus lines

Note

♦

Observe the general instructions for the repair on the vehicle
electrics

⇒ “2.1 General instructions for the repair on the vehicle elec‐
trics”, page 31 .

♦

Observe the general instructions for the wiring loom and plug
repair

⇒ “2.2 General instructions for wiring loom and plug repair ”,
page 32 .

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

0.35 mm2 or 0.5 mm2 is used as a CAN bus line.

The colour codings of the CAN bus lines are given in the following
table:

CAN High line, drive orange/black
CAN High line, comfort orange/green
CAN High line, infotainment orange/purple
CAN - Low - line, all orange/brown

♦ Both CAN bus lines must have the same length when under‐

taking repair work. The stroke length of -A- = 20 mm must be
respected when the cables -1- and -2- are twisted.

♦ Thus, there must be no cable piece (in the area of the crimp

connectors -arrow-) longer than -B- = 50 mm without twisting
the cables.

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2.6 Repairing wires with a cross-section of
up to 0.35 mm

Special tools and workshop equipment required
♦ Crimping pliers, complete - VAS 1978/1 A-

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

When repairing wires with a cross-section of up to 0.35 mm2, new
contacts must always be crimped with the crimping pliers for JPT
contacts - VAS 1978/9A- or the crimping pliers (base body) - VAS
1978/1-2- with mounted head adapter for JPT contacts - VAS
1978/9-1- . As a result of the low amperages of these wires in the
micro- to milli-range, incorrectly crimped contacts cause contact
resistances and faults or complete failure of the applicable sys‐
tem. The most frequent uses of these contacts are as follows:

2

♦ Lambda probe
♦ Speed sensor
♦ Air mass meter
Using the above tools ensures that the connection is correct be‐

tween crimp contact, wire and single cable seal. The tool may only
be used for the described purpose.

Note

Normal and gold-plated contacts must be crimped to the repair
wire. The same type as used in the series must also be used as
repair contact.

Crimping a new contact with single cable seal
– Insert head adapter for JPT contacts - VAS 1978/9-1- into the

crimping pliers (base body) - VAS 1978/1-2-

⇒ “2.3.6 Crimping pliers VAS 1978/1A ”, page 35 .

– Fit the single cable seal onto the repair wire -arrow-.

Note

The smaller diameter of the single cable seal must point in the
direction of the contact to be crimped (see Fig.).

2. Wiring loom repair 39

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– Open the crimping pliers and place the end of the repair wire

into the stripping opening -arrow- of the crimping pliers.

– Complete close the crimping pliers.

– Open the crimping pliers again -arrow- and remove the strip‐

ped end of the wire.

– Slide the single cable seal in the direction of the stripped end

of the wire until it is sealed flush with the wire insulation (see
Fig.).

– Place the new crimp contact into the support -arrow- on the

crimping pliers.

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– Insert the stripped end of the wire with the positioned single

cable seal into the crimp contact -arrow- until it lies against the
“wire stop”.

– Crimp the contact, wire and single cable seal by closing the

crimping pliers completely.

– Open the crimping pliers again and remove the fully crimped

contact.

– Crimping has been performed correctly if the wire and single

cable seal in the contact is cleanly crimped and there is a
stamp on the back side, which indicates that crimping has
been performed correctly and with the correct tool.

2.7 Line break with single repair point

Repair point with single crimp connector
– Expose the wire to be repaired (approx. 20 cm to each side of

the repair point).

– If necessary, remove the ties of the wiring loom, using the

folding knife.

– Cut out the damage section of the wire with the wire stripper -

VAS 1978/3- .

Note

If the two ends of the single cable in the vehicle are too short after
cutting out the damaged section of wire for repair with a single
crimp connector, install a correct length of repair wire with two
crimp connectors

⇒ “2.8 Line break with two repair points”, page 43 .

2. Wiring loom repair 41

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– Strip the ends of the wire by 6-7 mm with the wire stripper.

– Slide crimp connectors onto the two stripped ends of the ve‐

hicle's single cable and crimp them with the crimping pliers.

Note

♦

You must ensure that the correct crimping recess is used for
the crimp connector ⇒ “2.3.1 Stop plier with insert”, page 33 .

♦

The insulation of the cable must not be crimped at the same
time.

After crimping, the crimp connector must be shrunk with the hot­air blower in order to prevent moisture from penetrating.

– Place the shrink adapter for hot-air blower - VAS 1978/15- onto

the hot-air blower - VAS 1978/14- .

– Heat the crimp connector with the hot-air blower lengthways

from the centre to the outside until it is completely sealed and
the adhesive is coming out at the ends.

Caution

When shrinking the crimp connectors, make sure the hot noz‐
zle of the hot-air blower does not damage any other cables,
plastic parts or insulating materials.

Follow the operating instructions of the hot-air blower!

Note

♦

Ensure that the crimp connectors are not positioned immedi‐
ately next to each other if there are multiple wires to be
repaired. Arrange the crimp connectors slightly offset to en‐
sure that the wiring loom does not become too big.

♦

If the repair point has been wrapped previously, the point must
be re-wrapped with yellow insulating tape after repair.

♦

Attach the repaired wiring loom, in necessary, with a cable
strap to avoid rattling when driving.

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2.8 Line break with two repair points

Repair point with intermediate wire
– Expose the wire to be repaired at two points (approx. 20 cm

to each side of each repair point).

– If necessary, remove the ties of the wiring loom, using the

folding knife.

– Lay the yellow repair wire next to the damaged wiring loom

and cut the repair wire to the required length with the wire
stripper - VAS 1978/3- .

– Cut the damage section of wire out of the vehicle's single ca‐

ble.

– Strip the ends of the wire by 6-7 mm with the wire stripper.
– Slide the crimp connector on one side onto the vehicle's single

cables and on the other side onto the repair wire.

– Use the crimping pliers to crimp the crimp connector with the

two ends of wire.

– Repeat this procedure on the other end of the repair wire.

Note

♦

You must ensure that the correct crimping recess is used for
the crimp connector ⇒ “2.3.1 Stop plier with insert”, page 33 .

♦

The insulation of the cable must not be crimped at the same
time.

After crimping, the crimp connector must be shrunk with the hot­air blower in order to prevent moisture from penetrating.

2. Wiring loom repair 43

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– Place the shrink adapter for hot-air blower - VAS 1978/15- onto

the hot-air blower - VAS 1978/14- .

– Heat the crimp connector with the hot-air blower lengthways

from the centre to the outside until it is completely sealed and
the adhesive is coming out at the ends.

Caution

When shrinking the crimp connectors, make sure the hot noz‐
zle of the hot-air blower does not damage any other cables,
plastic parts or insulating materials.

Follow the operating instructions of the hot-air blower!

Note

♦

Ensure that the crimp connectors are not positioned immedi‐
ately next to each other if there are multiple wires to be
repaired. Arrange the crimp connectors slightly offset to en‐
sure that the wiring loom does not become too big.

♦

If the repair point has been wrapped previously, the point must
be re-wrapped with yellow insulating tape after repair.

♦

Attach the repaired wiring loom, in necessary, with a cable
strap to avoid rattling when driving.

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3 Repairing socket housings and con‐

nectors

⇒ “3.1 Notes on repairing socket housings and connectors”, page
45

⇒ “3.2 Repairing contacts in socket housings”, page 45
⇒ “3.3 Assembly of single cable seals”, page 46

3.1 Notes on repairing socket housings and connectors

Note

♦

The general general instructions for repairing vehicle electrics

⇒ “2.1 General instructions for the repair on the vehicle elec‐
trics”, page 31 and the general instructions for wiring loom and

plug repair

⇒ “2.2 General instructions for wiring loom and plug repair ”,
page 32 must be followed.

♦

The appropriate crimp contacts are assigned to the socket
housings on the basis of the part number stamped on the
socket housing. The part numbers of the socket housings are
listed on the plate (electrical connection elements) in the ⇒
ETKA - Electronic Catalogue of Original Parts with the appli‐
cable crimp contacts.

♦

Damaged socket housings must always be replaced.

3.2 Repairing contacts in socket housings

– Open and, if necessary, unlock the secondary lock of the

socket housing first ⇒ “4.2 Secondary lock”, page 49 .

– Unlock the contact (primary lock) with the suitable release tool

⇒ “4.3 Primary lock”, page 50 .

– Pull the contact on the single cable out of the socket housing.
– Take the yellow repair wire with the correct contact from the

wiring loom repair kit for the repair.
– Expose the repair point of the vehicle's wiring loom (approx.

20 cm to each side of the repair point).
– If necessary, remove the ties of the wiring loom, using the

folding knife.
– Insert the new contact of the repair wire into the socket housing

until it clicks into place.
– Fit the single cable seal onto the repair wire.

Note

The small diameter of the single cable seal must point to the
socket housing.

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– Slide single cable seal -A- with the correct assembly tool -B-

into the socket housing -arrow-

⇒ “3.3 Assembly of single cable seals”, page 46 .

– Shorten the repair wire and single cable of the vehicle's wiring

loom as required with the wire stripper - VAS 1978/3- .

– Strip the ends of the repair wire and the vehicle's single cable

by 6-7 mm with the wire stripper.

– Crimp the stripped ends of the repair wire and single cable of

the vehicle's wiring loom with the crimping pliers and a crimp
connector, as described in section

⇒ “2.7 Line break with single repair point”, page 41 .

3.3 Assembly of single cable seals

Note

♦

Single cable seals prevent water and dirt getting into the sock‐
et housing. They are installed e.g. in the engine compartment
and must always be reinstalled after repair.

♦

As standard in the series, the single cable seal is crimped with
the contact on the wire, but this is not the case for repair wires.
Before crimping the repair wire, therefore, the single cable seal
must be pushed onto the wire.

♦

Single cable seals must always match the wire cross-section
of the repair wire that is used. The outer diameter of the single
cable seal is matched to the diameter of the socket housing
chamber. Only perform assembly with the correct assembly
tool.

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Assembly of the single cable seal
– Use the correct release tool -A- to release the contact lock and

then pull the wire with the single cable seal backwards out of

the socket housing -arrow-.

– Cut off the old contact with single cable seal from the vehicle's

wiring loom.

– Slide the repair wire with the new contact into the correct

chamber of the socket housing -arrow- until it locks into place.

– Slide the single cable seal -A- onto the free end of the repair

wire -arrow-.

Note

The small diameter of the single cable seal must point to the
socket housing.

3. Repairing socket housings and connectors 47

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– Slide the single cable seal -A- with the correct assembly tool

-A- up to the stop into the socket housing -arrow-.

– Shorten the repair wire and single cable of the vehicle's wiring

loom as required with the wire stripper - VAS 1978/3- .

– Strip the ends of the repair wire and the vehicle's single cable

by 6-7 mm with the wire stripper.

– Crimp the stripped ends of the repair wire and single cable of

the vehicle's wiring loom with the crimping pliers and a crimp
connector, as described in section

⇒ “2.7 Line break with single repair point”, page 41 .

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4 Unlocking and disassembling socket

housings

⇒ “4.1 Notes on unlocking and disassembling socket housings”,
page 49

⇒ “4.2 Secondary lock”, page 49
⇒ “4.3 Primary lock”, page 50

4.1 Notes on unlocking and disassembling

socket housings

Note

♦

The general general instructions for repairing vehicle electrics

⇒ “2.1 General instructions for the repair on the vehicle elec‐

trics”, page 31 and the general instructions for wiring loom and

plug repair

⇒ “2.2 General instructions for wiring loom and plug repair ”,

page 32 must be followed.

♦

Always use the correct release tools for unlocking. The contact

must not be pulled out of the socket housings with force under

any circumstances.

♦

Damaged socket housings must always be replaced.

♦

Small screwdrivers must be used to release secondary locks.

♦

Additional information about the fitting locations of connectors

⇒ Current flow diagrams, Electrical fault finding and Fitting lo‐

cations

4.2 Secondary lock

The secondary lock is a housing lock that secures all the wires in
a socket housing. If a secondary lock is present on a socket hous‐
ing, it must always be opened or removed with the applicable tool
before unlocking and pulling out individual crimp contact.

The secondary lock has a different colour than the rest of the
socket housing. This makes it easier to recognise the secondary
lock and highlights its particular function.

The types of socket housing shown here are only a selection that
is intended to clarify the different functions of secondary locks by
way of example.

Example 1:
The housing lock is unlocked by removing a “crest” -arrow-.
Example 2:

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The housing lock is unlocked by opening a “flap” -arrow-.
Example 3:

The housing lock is unlocked by unlatching a “slide” -arrow-.

4.3 Primary lock

The primary lock is the lock for a single crimp contact in the socket
housing.

Any applicable housing locks (secondary locks) must be unlocked
or removed with the correct tool before unlocking the contacts

⇒ “4.2 Secondary lock”, page 49 .

The following types of primary lock shown here are only a selec‐
tion that is intended to clarify the different functions of primary
locks by way of example.

♦ ⇒ “4.3.1 Round plug connector systems”, page 50
♦ ⇒ “4.3.2 Flat plug connector systems”, page 51
♦ ⇒ “4.3.3 Special connector systems”, page 53

4.3.1 Round plug connector systems

Note

Any applicable housing locks (secondary locks) must be unlocked
or removed with the correct tool before unlocking the contacts

⇒ “4.2 Secondary lock”, page 49 .

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– Guide the correct release tool for the socket housing into the

unlocking channel on the socket housing.
– Take the contact on the wire and press it gently into the socket

housing -arrow-.

Note

Pressing the contact in the direction of the socket housing lifts the
snap-in pins of the contact away from the housing shoulder and
they can then be unlocked with the release tool.

– Press the release tool in the direction of the socket housing

-arrow- at the same time and pull the unlocked contact out of

the socket housing.

– The release tool can be pulled back out of the socket housing

after the contact has been removed.

4.3.2 Flat plug connector systems

Note

Any applicable housing locks (secondary locks) must be unlocked
or removed with the correct tool before unlocking the contacts

⇒ “4.2 Secondary lock”, page 49 .

Flat plug connector system with a snap-in pin
– Guide the correct release tool for the socket housing into the

unlocking channel on the socket housing.
– Take the contact on the wire and press it gently into the socket

housing -arrow-.

Note

Pressing the contact in the direction of the socket housing lifts the
snap-in pin of the contact away from the housing shoulder and it
can then be unlocked with the release tool.

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– Press the release tool in the direction of the socket housing

arrow at the same time and pull the unlocked contact out of
the socket housing -arrow-.

Flat plug connector system with two snap-in pins
– Guide the correct release tool for the socket housing into the

unlocking channel on the socket housing.

– Take the contact on the wire and press it into the socket hous‐

ing up to the stop -arrow-.

Note

Pressing the contact in the direction of the socket housing lifts the
snap-in pins of the contact away from the housing shoulder and
they can then be unlocked with the release tool.

– Press the release tool in the direction of the socket housing

arrow at the same time and pull the unlocked contact out of
the socket housing -arrow-.

Asymmetrical
– Guide the correct release tool for the socket housing into the

unlocking channel on the socket housing.

– Take the contact on the wire and press it gently into the socket

housing -arrow-.

Note

Pressing the contact in the direction of the socket housing lifts the
snap-in pins of the contact away from the housing shoulder and
they can then be unlocked with the release tool.

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– Press the release tool in the direction of the socket housing

arrow at the same time and pull the unlocked contact out of

the socket housing -arrow-.

4.3.3 Special connector systems

Note

Any applicable housing locks (secondary locks) must be unlocked
or removed with the correct tool before unlocking the contacts

⇒ “4.2 Secondary lock”, page 49 .

FASTON contacts
– Guide the correct release tool for the socket housing into the

unlocking channel on the socket housing.
– Take the contact on the wire and press it into the socket hous‐

ing up to the stop.

Note

Pressing the contact in the direction of the socket housing lifts the
snap-in pins of the contact away from the housing shoulder and
they can then be unlocked with the release tool.

– Press the release tool in the direction of the socket housing

arrow at the same time and pull the unlocked contact out of

the socket housing -arrow-.

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GT 150/280 contacts
– Guide the correct release tool for the socket housing into the

socket housing under the snap-in pin.

– Press the tool into the socket housing up to the stop -arrow-.

The contact is ejected from the socket housing.

Contacts with snap-in pins
– Insert the release tool under the socket housing's snap-in pin.
– Press through the release tool up to the stop with a slight lift

-arrow-

The contact is ejected from the socket housing.

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5 Repairing optical fibres

⇒ “5.1 General points”, page 55
⇒ “5.2 Preparing optical fibres”, page 55
⇒ “5.3 Removing and installing optical fibre in the housing”, page

60

5.1 General points

The exact point of failure is very hard to find. The damaged optical
fibre must be replaced by laying a line parallel to the defective
optical fibre.

Note

♦

The "Targeted fault-finding" or "Targeted functions" menu

items on the vehicle diagnostic tester can be used to deter‐

mine the components between which the optical fibre is dam‐

aged.

♦

An optical fibre that has already been repaired is "yellow".

Method for preparing and laying a new optical fibre.

Caution

Optical fibres must not have any sharp kinks. The bending ra‐
dius must not be less than 25 mm.

Optical fibres must not be laid over sharp edges.
The end of optical fibres must not be dirty or touched with bare

fingers.
Optical fibres must not be heated.
You must not twist together two optical fibres or one optical

fibre with a copper wire.
Protect the connector and connection cable against dirt. Use

protective caps from the case.

5.2 Preparing optical fibres

Special tools and workshop equipment required
♦ Optical fibre repair set - VAS 6223B-

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Caution

Optical fibres must not have any sharp kinks. The bending ra‐
dius must not be less than 25 mm.

Optical fibres must not be laid over sharp edges.
The end of optical fibres must not be dirty or touched with bare

fingers.
Optical fibres must not be heated.
You must not twist together two optical fibres or one optical

fibre with a copper wire.
Protect the connector and connection cable against dirt. Use

protective caps from the case.

Mount the tool head for the optical fibre pliers - VAS 6223/1- .
– Press out the securing pins -arrows-.

– Mount the tool head -arrow- and press the securing pins back

in.

Cutting optical fibre to length
– Determine the length of optical fibre that is required.
– Open the optical fibre pliers and insert optical fibre -1- into the

cutting support -arrow-.

– Close the optical fibre pliers to cut the optical fibre to length.

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Stripping
– Open the optical fibre pliers - VAS 6223/1- .
– Bring the stripping lever to the bottom position -arrow-.

– Place the optical fibre into the stripping support.

• The optical fibre must be flush with the rear side of the cutting

pliers.
– Close the optical fibre pliers up to the fixed top and hold them

closed.
– Swivel the stripping lever upwards -arrow- and take out the

optical fibre.
Cutting accurately (creating the optical abutting face)

– Slide the optical fibre -1- into the cutting support.

• The insulation -arrow- must be flush with the stop of the cutting

station.
– Close the optical fibre pliers - VAS 6223/1- and take out the

line.

– Visually inspect the line -1- to see that is has been correctly

cut and there is no burring on the abutting face.

Note

♦

Only lay the optical fibre on a completely clean surface/base

or hold it in your hand.

♦

Use protective caps if there is a risk that the optical fibre's

abutting face may be contaminated.

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Attaching a brass pin contact to optical fibre
– Swap the tool head -arrow-.

– Slide the locking mechanism on the optical fibre pliers

-arrow- until the word “stift (pin)” is visible.

– Place a brass pin contact -1- into the support.
– Close the locking lever on the optical fibre pliers -arrow-.

– Slide the optical fibre into the brass pin contact -arrow- up to

the sprung stop and close the optical fibre pliers.

– Open the optical fibre pliers and remove the optical fibre with

brass pin contact.

Caution

Optical fibre must not be kinked or bent at a large angle (min‐
imum bending radius of 25 mm).

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

optical fibre -1-.

• A total of 4 crimp points must be visible on the brass connect‐

ing pin.

• It must not be possible to pull the brass pin contact off the

optical fibre by hand.

• The abutting face of the optical fibre is 0.01...0.1 mm behind

the brass pin contact (visual check).

Note

♦

Quick couplings are available in the ⇒ Electronic Catalogue

of Original Parts to connect optical fibre.

♦

Removing and installing the new optical fibre in the harness

connector

⇒ “5.3 Removing and installing optical fibre in the housing”,

page 60

Mounting the corrugated tube onto the optical fibre
– Cut the corrugated tube to the correct length.

• Use the cutting pliers - VAS 6228- or a sharp knife for cutting.

• Do not cut the corrugated tube with a side cutter under any

circumstances.

• The corrugated tube must be cut through on the “wave

peak” (see -arrow-), not on the “wave trough”.

• The corrugated tube must audibly lock into the optical fibre

housing when assembled.

– Guide the optical fibre as shown in the Fig. into the corrugated

tube assembly pliers - VAS 6223/10- .
– Place the corrugated tube assembly pliers on the slit in the

corrugated tube.
– Slide the corrugated tube assembly pliers in the slit along the

corrugated tube. The optical fibre is then inserted into the cor‐

rugated tube.

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5.3 Removing and installing optical fibre in the housing

Removing
– Disconnect the connectors for the optical fibre from the appli‐

cable control unit.
– Unlock the lock in the optical fibre connector -1- by pressing.
– Unlock the secondary lock -2- with a small screwdriver and

remove the optical fibre.

Caution

♦ Use protective caps from the optical fibre repair set - VAS

6223B- to protect the optical fibre against dust and dirt.

♦ Use a new housing, as the secondary lock can be dam‐

aged when removing the optical fibre.

♦ Observe the arrows on the base module for the correct

“IN” and “OUT” assignment.

Install
Installation is performed in the reverse order, pay attention to the

following points:
– Install the optical fibre as per the markings.
– Slide the corrugated tube into the connector housing until it

audibly locks into place.

– Close the open connector -2- for the optical fibre with the pro‐

tective cap -1- from the optical fibre repair set - VAS 6223B- .

Note

The protective cap prevents the abutting face of the optical fibre
becoming dirty or suffering mechanical damage, which would
otherwise impair the transfer of light.

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6 Contact surface cleaning set - VAS

6410-

⇒ “6.1 Use contact surface cleaning set VAS 6410 ”, page 61
⇒ “6.2 Repairing the cable eyes”, page 61
⇒ “6.3 Repairing screwed connections”, page 63
⇒ “6.4 Cleaning the battery pole terminals and battery poles”,

page 64
⇒ “6.5 Preserving”, page 65

6.1 Use contact surface cleaning set - VAS 6410-

It is possible to carry out repair work in the area of the contact
transmitters on the wiring looms for screwed connections in the
high current circuit as well as when connecting the battery using
the contact surface cleaning set - VAS 6410- (starter and charge
current, earth cables, battery pole terminals and battery poles).

Note

The illustrations for the repair work can only be seen as an ex‐
ample.

Contact surface cleaning set - VAS 6410-

6.2 Repairing the cable eyes

Note

♦

It is not permitted to use rust solvent, contact spray or grease
on the cable eyes as the tightening torque via the thread to the
screwed connection is exceeded through the missing static
friction and leads to the fracture of the screwed connection.

♦

The grey grinding pads are suitable for slight contaminations
and “soft surfaces”.

♦

The red grinding pads are suitable for heavy contaminations
and “hard surfaces”.

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WARNING

Danger of injury!
Observe the warning instructions and safety precautions when

working on the battery

⇒ “1.3 Warning instructions and safety precautions when work‐
ing on the battery”, page 4 .

– Disconnect battery earth strap ⇒ Electrical System; Rep. gr.

27 .

– Unscrew the cap nut and remove the cable eye from the

screwed connection.

– Check the cable eye for corrosion, contamination, damage

etc.

– Select the appropriate adapter and the corresponding grinding

pad.

Note

The grinding block can also be used as an alternative.

Caution

Carefully clean the cable eye so that the tin layer is not exces‐
sively worn off.

An intermediate visual inspection of the cleaned surface is re‐
quired during the cleaning process, because of the different
thicknesses of the tin layers.

If the tin layer is severely worn off so that the underlying copper
is revealed, increased galvanic corrosion effects can occur.

– Position a suitable adapter on the cable eye and grind off the

corrosion and contaminations with rotary movements. Contin‐
uously check the cleaned surface.

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– Check the burr on the cable eye and remove with the reamer

if necessary.

– Position again the cable eye and screw on to the recommen‐

ded tightening torque.

Note

Optimal contact is ensured if the components to be bolted are
screwed to the recommended tightening torque after cleaning.

– After tightening the connection, treat it with the appropriate

preservative product ⇒ “6.5 Preserving”, page 65 .

– Pay attention to the sequence when connecting the battery ⇒

Electrical System; Rep. gr. 27. .

6.3 Repairing screwed connections

Note

♦

It is not permitted to use rust solvent, contact spray or grease
on the screwed connection as the tightening torque via the
thread to the screwed connection is exceeded through the
missing static friction and leads to the fracture of the screwed
connection.

♦

The grey grinding pads are suitable for slight contaminations
and “soft surfaces”.

♦

The red grinding pads are suitable for heavy contaminations
and “hard surfaces”.

WARNING

Danger of injury!
Observe the warning instructions and safety precautions when

working on the battery

⇒ “1.3 Warning instructions and safety precautions when work‐
ing on the battery”, page 4 .

– Disconnect battery earth strap ⇒ Electrical System; Rep. gr.

27 .

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– Unscrew the cap nut and remove the cable eye from the

screwed connection.

– Check the screwed connection for corrosion, contamination

and damage.

– Select the appropriate adapter and the corresponding grinding

pad.

Caution

Carefully clean the screwed connection so that the tin layer is
not excessively worn off.

An intermediate visual inspection of the cleaned surface is re‐
quired during the cleaning process, because of the different
thicknesses of the tin layers.

If the tin layer is severely worn off so that the underlying copper
is revealed, increased galvanic corrosion effects can occur.

– Position a suitable adapter on the screwed connection and

grind off the corrosion and contaminations with rotary move‐
ments. Continuously check the cleaned surface.

– Screw on the cleaned connection, if necessary with torsion

stop, to the recommended tightening torque.

– Preserve the connections with the appropriate preservative

product ⇒ “6.5 Preserving”, page 65 .

– Pay attention to the sequence when connecting the battery ⇒

Electrical System; Rep. gr. 27 .

6.4 Cleaning the battery pole terminals and battery poles

WARNING

Danger of injury!
Observe the warning instructions and safety precautions when

working on the battery

⇒ “1.3 Warning instructions and safety precautions when work‐
ing on the battery”, page 4 .

Note

It is not permitted to use rust solvent, contact spray or grease on
the battery pole terminals as the tightening torque via the thread
to the screwed connection is exceeded through the missing static
friction and leads to the fracture of the screwed connection.

– Disconnect battery ⇒ Electrical System; Rep. gr. 27 .
– Check the battery pole terminals for corrosion or contamina‐

tion.

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– The battery pole terminals are cleaned with rotary movements

using the wire brush of the battery pole cleaner.

– The battery poles are cleaned with rotary movements using

the bottom side of the battery pole cleaner.

– After cleaning, pay attention to the sequence when connecting

the battery ⇒ Electrical System; Rep. gr. 27 .

6.5 Preserving

Caution

Lack of preservation leads to errors and damage to the on­board power supply.

Risk of corrosion.

Note

♦

All screwed connections must be tightened to the recommen‐
ded tightening torque.

♦

While preserving, the attached hose must always be used on
the preservation can.

♦

The preservative wax is used for the cold area.

♦

The cavity preservative product is used for the warm area.

♦

The preservative product acts independently on the affected
areas through the capillary effect.

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– Hold the injector underneath the cable eye and spray all

around the bolt and the cable eye.

– Hold the injector above the cable eye and spray all around the

bolt and the cable eye.

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7 Replace the lambda probe

⇒ “7.1 Replace the LSF lambda probe (4-pole)”, page 67
⇒ “7.2 Replace the LSU lambda probe (6-pole)”, page 68
⇒ “7.3 Protective pipe variants of the unit lambda probes”,

page 68

7.1 Replace the LSF lambda probe (4-pole)

Note

♦

Where necessary, repair the attachment parts enclosed with
the unit probe, cable ties or marking tapes after presenting the
faulty probe.

♦

The cables on the lambda probe must not be repaired as this
can lead to malfunction.

– Remove the faulty lambda probe ⇒ Engine; Rep. gr. 24 .
– Place the two lambda probes next to each other so that the

sensor housing is at one height, see fig.

– Fix the excess length of the unit probe (approx. 50 - 250 mm)

by tying it back to the length of the cable ties -1-.

– Check whether the timing case of the lambda probe is com‐

patible with the on-board network side.

– Where necessary, replace the on-board connector with the

supplied connector housing of the Lambda probe.

Note

♦

The timing case must be replaced on older vehicles. On new
vehicles, the coding of the timing case matches.

♦

Observe the plug assignment. To improve the overview, the
individual pins in the new housing must be marked with a col‐
our coding.

♦

Additional information can be found on the new lambda probe.

– Install the new Lambda probe in the vehicle.

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7.2 Replace the LSU lambda probe (6-pole)

Note

♦

Where necessary, repair the attachment parts enclosed with
the unit probe, cable ties or marking tapes after presenting the
faulty probe.

♦

The cables on the lambda probe must not be repaired as this
can lead to malfunction.

– Remove the faulty lambda probe ⇒ Engine; Rep. gr. 24 .
– Place the two lambda probes next to each other so that the

sensor housing is at one height, see fig.

– Fix the excess length of the unit probe (approx. 50 - 250 mm)

by tying it back to the length of the cable ties -1-.

– Install the new Lambda probe in the vehicle.

7.3 Protective pipe variants of the unit lamb‐
da probes

Note

In addition to identification via part number, another identification
can also be placed on the protective pipe.

Variant D1, 6 openings each 3.5 mm

Only used for LSF Lambda probes- 4-pin.

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Variant DS, 6 openings each 2 mm

Are used on lambda probes LSF - 4-pin and LSU - 6-pin.

Variant D4, 12 openings each 1.4 mm

Are used on lambda probes LSF - 4-pin and LSU - 6-pin.

7. Replace the lambda probe 69