Volkswagen Amarok Electrical System Workshop Manual

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Service

Workshop Manual

Amarok 2011 ➤

Electrical system

Edition 01.2011

Service Department. Technical Information

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Service

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

Re pa ir G ro up

27 - Starter, current supply, CCS

90 - Gauges, instruments

92 - Windscreen wash/wipe system

94 - Lights, bulbs, switches - exterior

96 - Lights, bulbs, switches - interior

97 - Wiring

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

All rights reserved.
No reproduction without prior agreement from publisher.

Copyright © 2011 Volkswagen AG, Wolfsburg D3E802838CF

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Amarok 2011 ➤

Electrical system - Edition 01.2011

Contents

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

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

1.1 Fundamentals for batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2 Types of batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.3 Warning notices and safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.4 Battery terminal connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2 Checking battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.1 Checking the various types of batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.2 Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.3 Checking colour indicator in battery cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.4 Absorbent glass mat battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.5 Battery tester with printer VAS 5097 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.6 Evaluating test result of battery load test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.7 Battery tester with printer VAS 6161 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.8 Current draw test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3 Charging battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.1 Battery charger VAS 5095 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.2 Battery charger VAS 5900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3.3 Battery charger VAS 5903 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

3.4 Battery charger VAS 5906 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

3.5 Solar panel VAS 6102A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

3.6 Totally discharged batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

4 Disconnecting and reconnecting battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

4.1 Disconnecting and reconnecting battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

4.2 Steps after connecting battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

5 Removing and installing battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

5.1 Removing and installing battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

5.2 Specified torques: battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

6 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

6.1 Checking starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

6.2 Removing and installing starter, 4-cylinder diesel engine with manual gearbox . . . . . . . . 57

6.3 Removing and installing starter, 4-cylinder TFSI petrol engine with manual gearbox . . . . 60

6.4 Specified torques: starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

7 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

7.1 Checking alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

7.2 Removing and installing alternator, 4-cylinder diesel engine with manual gearbox . . . . . . 65

7.3 Removing and installing alternator, 4-cylinder TSI petrol engine . . . . . . . . . . . . . . . . . . . . 69

7.4 Specified torques: alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

8 Repairing alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

8.1 Securing B+ cable on alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

8.2 Checking poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

8.3 Removing and installing voltage regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

8.4 Checking alternator carbon brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

8.5 Removing and installing pulley on alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

9 Cruise control system (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

9.1 Activating and deactivating cruise control system (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . . 77

9.2 CCS switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

90 - Gauges, instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

1 Dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

1.1 Renewing dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

1.2 Removing and installing dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Contents i

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Amarok 2011 ➤
Electrical system - Edition 01.2011

1.3 Adjusting functions on dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

2 Service interval display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

2.1 Resetting service interval display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

92 - Windscreen wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

1 Windscreen wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

1.1 Removing and installing wiper blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

1.2 Removing wiper arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

1.3 Removing wiper frame with linkage and wiper motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

1.4 Removing and installing windscreen wiper motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

1.5 Adjusting wiper blade park position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

2 Windscreen washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

2.1 Assembly overview - windscreen washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

2.2 Removing and installing filler pipe for windscreen washer reservoir . . . . . . . . . . . . . . . . . . 91

2.3 Removing and installing windscreen washer reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

2.4 Removing and installing windscreen wash pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

2.5 Removing and installing windscreen washer system spray jets . . . . . . . . . . . . . . . . . . . . . . 94

2.6 Checking spray jets for windscreen washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

2.7 Adjusting windscreen washer system spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

2.8 Washer fluid line hose couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

2.9 Hose repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

94 - Lights, bulbs, switches - exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

1 Headlight with H1 bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

1.1 Assembly overview - headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

1.2 Removing and installing headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

1.3 Renewing headlight bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

1.4 Headlight conversion for left-hand/right-hand traffic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

1.5 Adjusting headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

2 Headlight with H15 bulb and daytime running light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

2.1 Assembly overview - headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

2.2 Removing headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

2.3 Renewing headlight bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

2.4 Adjusting headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

2.5 Headlight conversion for left-hand/right-hand traffic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

3 Fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

3.1 Removing and installing fog light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

3.2 Removing and installing fog light bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

3.3 Adjusting fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

4 Side turn signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

4.1 Removing and installing turn signal repeater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

4.2 Removing side turn signal bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

5 Tail lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

5.1 Assembly overview - tail light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

5.2 Removing and installing tail light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

5.3 Renewing bulbs in tail light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

6 Number plate light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

6.1 Removing number plate light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

6.2 Renewing bulb of number plate light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

7 Additional brake light bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

7.1 Removing and installing additional brake light bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

8 Load area illumination bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

8.1 Removing and installing load area illumination bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

8.2 Renewing load area illumination bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

ii Contents

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Amarok 2011 ➤

Electrical system - Edition 01.2011

9 Steering column switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

9.1 Removing and installing steering column switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

9.2 Removing and installing airbag coil connector and return ring with slip ring . . . . . . . . . . . . 145

10 Lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

10.1 Removing and installing lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

11 Ignition/starter switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

11.1 Removing and installing ignition/starter switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

12 Steering lock housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

12.1 Removing and installing steering lock housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

13 12 V socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

13.1 Removing and installing 12 V socket on load area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

96 - Lights, bulbs, switches - interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

1 Switch in dash panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

1.1 Removing and installing light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

1.2 Removing and installing headlight range control regulator with switches and instruments

illumination regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

1.3 Removing and installing switches in centre of dash panel at top . . . . . . . . . . . . . . . . . . . . 158

1.4 Removing and installing switches in centre of dash panel at bottom . . . . . . . . . . . . . . . . . . 159

2 Switches in the doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

2.1 Removing and installing window regulator switches in driver door . . . . . . . . . . . . . . . . . . 161

2.2 Removing and installing electric window switches in front passenger and rear doors . . . . 162

2.3 Removing and installing mirror adjuster switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

2.4 Removing and installing driver side interior locking button for central locking system . . . . 163

3 Lights and switches in roof trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

3.1 Removing and installing front interior light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

3.2 Removing and installing centre interior light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

4 Cigarette lighter and 12 V sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

4.1 Removing and installing 12 V socket in centre dash panel . . . . . . . . . . . . . . . . . . . . . . . . 168

4.2 Removing and installing 12 V socket or cigarette lighter in centre dash panel at bottom . . 169

5 Horn or dual tone horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

5.1 Removing and installing horn or dual tone horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

6 Anti-theft alarm (ATA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

6.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

6.2 Functional description of the anti-theft alarm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

6.3 Assembly overview - anti-theft alarm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

6.4 Removing and installing alarm horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

6.5 Adaptations of anti-theft alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

97 - Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

1 Vehicle diagnosis, testing and information systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

1.1 Connecting vehicle diagnosis, testing and information system VAS 5051 . . . . . . . . . . . . 179

2 Fuse holder, relay carrier and electronics boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

2.1 Overview of fuse holders and relay carriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

2.2 Removing and installing relay carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

2.3 Removing and installing fuse holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

3 Control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

3.1 Removing and installing onboard supply control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

4 Wiring harness and connector repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

4.1 Wiring harness repair set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

4.2 Tool descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

4.3 General notes concerning repairs to vehicle electrical system . . . . . . . . . . . . . . . . . . . . . . 189

4.4 Repairs to wiring harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

4.5 Repairing connector housings and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

Contents iii

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Amarok 2011 ➤
Electrical system - Edition 01.2011

4.6 Releasing and dismantling connector housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

5 Contact surface cleaning set VAS 6410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

5.1 Using contact surface cleaning set VAS 6410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

6 Renewing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

6.1 Renewing LSF lambda probe (4-pin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

6.2 Renewing LSU Lambda probe (6-pin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

6.3 Types of protective tube on uniform Lambda probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

7 Renewal of aerial wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

7.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

7.2 Assembly overview - aerial wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

7.3 Installing a new aerial wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

iv Contents

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27 – Starter, current supply, CCS

1 Battery

WARNING

Danger of injury! Comply with the warning notices and safety
regulations ⇒ page 2 !

Caution

To prevent damage to the battery and vehicle, observe the fol‐
lowing concerning types of battery ⇒ page 1 .

1.1 Fundamentals for batteries

To ensure long use of the battery, the battery must be checked,
serviced and maintained according to the instructions in this man‐
ual.

Apart from supplying energy for starting the engine, the battery
has other tasks: it acts as a buffer and supplies electrical energy
to the complete electrical onboard supply of the vehicle.

Note

⇒ Self-study programme No. 234 ; Vehicle batteries - See pro‐
gramme.

1.2 Types of batteries

General notes

The description for the following batteries is for maintenance­free batteries. No stickers may be removed and do not replen‐
ish with distilled water. Only make visual inspections. Note the
battery test chapter ⇒ page 5 .

Caution

1.2.1 „Standard“ maintenance-free battery

Amarok 2011 ➤

Electrical system - Edition 01.2011

Maintenance-free battery with liquid electrolyte (wet battery)

This is a lead-acid battery with colour indicator in the cover to
monitor the battery acid level.

1.2.2 „Enhanced“ maintenance-free battery

This is a maintenance-free battery with liquid electrolyte (wet bat‐
tery), which is used for heavy duty applications in certain stop­start vehicles. The battery can be identified by the lettering „EFB“
on top of the battery housing. The „EFB“ battery is only used on
some engine/gearbox combinations.

„EFB“ stands for „enhanced flooded battery“.

1. Battery 1

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Amarok 2011 ➤
Electrical system - Edition 01.2011

Note

An „EFB“ battery may only be replaced with another „EFB“ bat‐
tery.

The „EFB“ battery also has a colour indicator in the cover to mon‐
itor the battery acid level.

1.2.3 Absorbent glass mat battery

Maintenance-free battery with a contained electrolyte

Lead-acid battery in which the electrolyte is contained within a
microscopic glass mat (AGM). The battery is sealed and fitted with
valves.

„AGM“ stands for „absorbent glass mat“.

Since the glass mat binds the electrolyte, these batteries do not
have a colour indicator to monitor the battery acid level. Absorb‐
ent glass mat batteries are identified by the abbreviation „AGM“
on the battery.

Note

Always replace an absorbent glass mat battery with another ab‐
sorbent glass mat battery.

1.3 Warning notices and safety regulations

1.3.1 Dangers when handling vehicle batter‐
ies

Recognition and avoidance of dangers

Batteries can be dangerous. These dangers can be avoided when
the warnings on the battery and in the owners/instruction manual
and in ELSA are observed.

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

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WARNING

♦ Untrained personnel e.g. apprentices, trainees etc. may

only work on batteries when supervised by a vehicle me‐
chanic/foreman or vehicle electrician/foreman.

♦ Acid is highly corrosive. There is a considerable danger of

acid burns if personnel do not handle batteries correctly.
Therefore suitable measures must be taken to ensure that
equipment/solutions etc. are available to neutralize acid
burns. A suitable solution is: e.g. a soap solution.

♦ If electrolyte leaks from a battery it may cause skin burns

and acid corrosion, rusting on the vehicle. This may dam‐
age safety relevant components on the vehicle.

♦ The gas which forms when charging and the gas which

♦ Batteries on which the colour indicator is neutral or light

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

♦ Only work on batteries in well ventilated and suitable

may escape through vent valves is explosive. In extreme
cases a battery may explode if the battery is not handled
correctly.

yellow must not be checked or charged. Do not slave/jump
start the vehicle! There is a risk of explosion while check‐
ing and charging the battery, including during slave start‐
ing.

cutting operations and use naked lights in the vicinity of
batteries. Smoking is also prohibited. Sparks generated
by electrostatic charging must also be avoided. Always
touch the vehicle body before touching the battery.

rooms.

1.3.2 Safety markings on battery

Safety markings on battery

1. - When handling batteries, fires, sparks, naked lights and
smoking are prohibited. Avoid sparks as well as electrostatic dis‐
charge when working with cables and electrical units. Avoid short
circuits. Therefore never lay a tool on a battery.

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

3. - Keep children away from acid and batteries.

4. - Disposal: old batteries are classed as hazardous waste. They
may only be disposed of through a suitable collection centre and
only in accordance with respective legislation.

5. - Never dispose of old batteries in household waste system!

6. - There is a danger of an explosion when working with batteries.
A highly explosive gas is produced when batteries are charged.

7. - Follow instructions concerning batteries, in ELSA "electrical
system" and in owner's manual.

8. - Battery acid is very caustic, therefore wear eye protection and
gloves when working with batteries. Do not tilt battery. Acid can
leak out of the gas vents of some batteries.

Amarok 2011 ➤

Electrical system - Edition 01.2011

1. Battery 3

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Amarok 2011 ➤
Electrical system - Edition 01.2011

1.4 Battery terminal connection

Caution

To prevent damage to the battery clamps and battery termi‐
nals, the following should be observed:

♦ The battery clamps should only be fitted by hand and with‐

out using force.

♦ Battery terminals should not be coated with grease.

♦ The battery clamps should be fitted so that the battery ter‐

minal is either flush with the clamp or protruding from it.

♦ Once the battery clamps have been tightened to the speci‐

fied torque, the threaded connections should not be tight‐
ened any further.

The specified torque for the battery terminal clamps -1- and ad‐
ditional clamps -2- can be obtained from the „Specified torque:
Battery“ table ⇒ page 55 .

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

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2 Checking battery

WARNING

Danger of injury! Comply with the warning notices and safety
regulations ⇒ page 2 !

Caution

To prevent damage to the battery and vehicle, observe the fol‐
lowing concerning types of battery ⇒ page 1 .

2.1 Checking the various types of batteries

2.1.1 Checking a battery with colour indicator

WARNING

Danger of injury! Observe warning notices and safety regula‐
tions ⇒ page 2 !

Carry out procedure in sequence as follows:

1. Visual check ⇒ page 6

2. Checking colour indicator in battery cover, „3 colour“,

⇒ page 6 or „2 colour“, ⇒ page 7

Amarok 2011 ➤

Electrical system - Edition 01.2011

WARNING

Batteries on which the colour indicator is neutral or light yellow
must not be checked or charged. Do not slave/jump start the
vehicle!

There is a risk of explosion while checking and charging the
battery, including during slave starting.

These batteries must be renewed.

3. Perform battery check using battery tester with printer -VAS
6161- ⇒ page 14 or battery discharge test using battery
tester with printer -VAS 5097 A- ⇒ page 10 .

4. Depending on the result of the battery test, „perform current
draw test“ ⇒ page 19 .

Note

For warranty claims: Battery tester with printer -VAS 5097 A- is
soon to be replaced in favour of battery tester -VAS 6161- .

2. Checking battery 5

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Amarok 2011 ➤
Electrical system - Edition 01.2011

2.2 Visual check

WARNING

Danger of injury! Observe warning notices and safety regula‐
tions ⇒ page 2 !

It is essential to visually inspect the external condition, to check
the terminals and to ensure proper attachment of the battery be‐
fore performing extensive tests.

Caution

♦ The battery will be damaged if the battery is not secured

correctly.

♦ Vibrations shorten the life of the battery, there is a danger

of an explosion, the cell plates may be damaged and the
clamping bracket may damage the battery housing.

♦ Check battery is securely seated, if necessary tighten se‐

curing bolt to specified torque.

Performing this test establishes:

♦ If battery housing is damaged Electrolyte can leak out if the

housing is damaged. If battery acid leaks out, serious damage
to the vehicle could be caused. Treat components affected by
leaked battery acid immediately with acid neutraliser or a soap
solution.

♦ Check whether the battery terminals (battery wire connec‐

tions) are damaged. The necessary contact on the battery
clamps cannot be guaranteed if the battery terminals are dam‐
aged. When connecting the battery clamps, tighten the battery
clamps to torque specified in this workshop manual „Electrical
system“ for the respective vehicle. If the battery clamps are
not correctly seated and tightened, the wiring may burn. Which
will cause malfunctions in the electrical system. Safe operation
of the vehicle is no longer guaranteed.

2.3 Checking colour indicator in battery cov‐
er

2.3.1 Checking colour indicator in battery cov‐
er, „3 colour“

WARNING

Danger of injury! Observe warning notices and safety regula‐
tions ⇒ page 2 !

General information about colour indicator:

Applies for all batteries with „1J0“, „7N0“ and „3B0“ indexes in
original equipment and for all replacement batteries 191 915 105
AB and from „000 915 105 AX“ index.

The colour indicator provides information about the electrolyte
level and the charge state of the battery.

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

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Before carrying out a visual check, tap the colour indicator in the
battery cover lightly and carefully using the handle of a screw‐
driver. The air bubbles, which can influence the display, will
dissipate when doing this. This will make the colour indicator
reading more accurate.

Amarok 2011 ➤

Electrical system - Edition 01.2011

Note

♦

Air bubbles can form under the sight glass especially when the
battery is being charged, i.e. also during normal vehicle oper‐
ation. These falsify the reading of the colour indicator.

♦

Since the colour indicator is only located in one battery cell,
the indicator also only applies to this battery cell. An exact de‐
termination of the battery condition is only possible through a
battery load test ⇒ page 10 or a battery test ⇒ page 14 .

♦

The colour indicator can be located at various positions on the
battery.

Three different colour displays are possible:

♦ »Green«, battery is charged sufficiently.

♦ »Black«, battery partly discharged, charge state < 65 % or

completely discharged

♦ »Colourless or light yellow«, battery must be renewed.

Batteries on which the colour indicator is neutral or light yellow
must not be checked or charged. Do not slave/jump start the

WARNING

vehicle!

There is a risk of explosion while checking and charging the
battery, including during slave starting.

These batteries must be renewed.

2.3.2 Checking colour indicator in battery cov‐
er, „2 colour“

WARNING

Danger of injury! Observe warning notices and safety regula‐
tions ⇒ page 2 !

General information about 2 colour indicator:

Introduction of the new 2 colour indicator will be gradual during
model year 2009, i.e. there will be a transition period for both in‐
dicators. On the new 2 colour indicator, »green« is no longer
included.

The 2 colour indicator provides information about the electrolyte
level of the battery.

The battery charge level can no longer be ascertained from the
colour indicator. To do this, a battery check must be performed

⇒ page 14 .

Before carrying out a visual check, tap the colour indicator in the
battery cover lightly and carefully using the handle of a screw‐
driver. The air bubbles, which can influence the display, will

2. Checking battery 7

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Amarok 2011 ➤
Electrical system - Edition 01.2011

dissipate when doing this. This will make the colour indicator
reading more accurate.

Note

♦

Air bubbles can form under the sight glass especially when the
battery is being charged, i.e. also during normal vehicle oper‐
ation. These falsify the reading of the colour indicator.

♦

Since the colour indicator is only located in one battery cell,
the indicator also only applies to this battery cell. Determining
the exact condition of the battery is only possible by means of
a battery test ⇒ page 14 .

♦

The colour indicator can be located at various positions on the
battery.

Two different colour displays are possible:

♦ »Black«, electrolyte level is OK.

♦ »Colourless or light yellow«, electrolyte level too low. The bat‐

tery must be renewed.

Batteries on which the colour indicator is neutral or light yellow
must not be checked or charged. Do not slave/jump start the
vehicle!

There is a risk of explosion while checking and charging the
battery, including during slave starting.

These batteries must be renewed.

2.4 Absorbent glass mat battery

Carry out procedure in sequence as follows:

1. Visual check ⇒ page 6

2. Perform battery check using battery tester with printer -VAS

WARNING

6161- ⇒ page 14 or battery discharge test using battery
tester with printer -VAS 5097 A- ⇒ page 10 .

3. Depending on the result of the battery load test, „perform
current draw test“ ⇒ page 19 .

Note

For warranty claims: Battery tester with printer -VAS 5097 A- is
soon to be replaced in favour of battery tester -VAS 6161- .

2.5 Battery tester with printer -VAS 5097 A-

Note

For warranty claims: Battery tester with printer -VAS 5097 A- is
soon to be replaced in favour of battery tester -VAS 6161- .

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

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WARNING

Danger of injury! Comply with the warning notices and safety
regulations ⇒ page 2 !

It is not necessary to remove or disconnect battery when using
battery tester with printer -VAS 5097 A- .

Battery tester with printer -VAS 5097 A- can be used to test 12 V
starter batteries according to

♦ 80 - 499 A low-temperature test current according to DIN

(Deutsche Industrie Norm (German Industrial Standard))

1)

♦ 95 - 574 A low-temperature test current according to IEC (In‐

ternational Engineering Consortium)

♦ 136 - 855 A low-temperature test current according to EN/ SAE

(European Norm/Standard of Automotive Engineers)

1) Batteries with a low-temperature test current of 520 A according to DIN can be
tested using setting for 499A according to DIN.

.

For test purposes the battery is loaded with a current which is
similar to the starting current required to start the vehicle. The
battery is assessed on this loading and the result is printed out.

Note

♦

Observe the ⇒ Instruction Manual for battery tester with printer

-VAS 5097 A- or the sticker ⇒ Brief instructions for battery
tester with printer -VAS 5097 A- stuck on the unit or the table
entitled Low-temperature current ⇒ page 12 .

♦

Observe battery manufacturer's handling instructions!

2.5.1 Description of battery tester with printer

Battery tester with printer -VAS 5097 A-

1 - Green LED, „unit operating“

2 - Red LED, „unit reverse-polarity connected“

3 - Red LED, „battery cannot be tested“, recharge battery.

4 - Ignition button

5 - Low-temperature test current selection switch

6 - ON/OFF and functions switch

7 - Selection switch (battery tester to pick-off point on battery/

-VAS 5097 A-

external test point in engine compartment)

8 - Paper feed button

9 - Printer

Amarok 2011 ➤

Electrical system - Edition 01.2011

2. Checking battery 9

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Amarok 2011 ➤
Electrical system - Edition 01.2011

2.5.2 Performing battery load test using bat‐

tery tester with printer -VAS 5097 A-

WARNING

Danger of injury! Comply with the warning notices and safety
regulations ⇒ page 2 !

Special tools and workshop equipment required

♦ Battery tester with printer -VAS 5097 A-

Note

Observe technical product information TPI 2012182 for battery
tester with printer -VAS 5097 A- .

Performing battery load test:

WARNING

Batteries on which the colour indicator is neutral or light yellow
must not be checked or charged. Do not slave/jump start the
vehicle!

There is a risk of explosion while checking and charging the
battery, including during slave starting.

These batteries must be renewed.

Note

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

– Switch off ignition and all electrical consumers.

– On vehicles with colour indicator, take reading from indicator

⇒ page 6 .

– Ascertain low temperature test current in amperes (A) accord‐

ing to DIN from details on battery and adjust setting range on
battery tester with printer -VAS 5097 A- according to table

⇒ „2.5.3 Table: low-temperature test current“, page 12 .

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

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Electrical system - Edition 01.2011

Note

If the battery values are shown in IEC or EN/SAE instead of DIN,
then convert figures using table

⇒ „2.5.3 Table: low-temperature test current“, page 12 or using

table on unit.

– Set low-temperature test current with low-temperature test

current selection switch ⇒ page 9 .

– Select measuring range 80 - 379 A or 380 - 499 A with ON/

OFF function switch ⇒ page 9 .

Note

Batteries with a low-temperature test current of 520 A according
to DIN can be tested using setting for 499A according to DIN.

– Connect red terminal „+“ of tester to positive terminal.

– Connect black terminal „-“ of tester to negative terminal.

Amarok 2011 ➤

Note

♦

Make sure test terminals make good contact!

♦

Observe technical product information TPI 2012182 for battery
tester with printer -VAS 5097 A- .

– Select connection point of test terminals with selection switch

⇒ page 9 .

1 - Connected directly to battery.

2 - Connected to external test points in engine compartment.

– Check whether the figures given on the battery are correct for

the settings on the battery tester.

– Press ignition button ⇒ page 9 .

The green LED lights up ⇒ page 9 . The test program runs through
automatically. The test result is printed out by the printer

⇒ page 12 . If the unit does not start (LED does not light up, no

print out), recharge battery ⇒ page 21 .

– Switch off unit ⇒ page 9 .

– Remove test terminals.

Note

♦

The test is completed after about 20 seconds.

♦

The result of the test is printed out by the printer.

♦

Only perform test once. Repeating the test falsifies the result.

♦

The tester requires approx. 30 minutes to cool down before it
is ready for the next test.

2. Checking battery 11

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Amarok 2011 ➤
Electrical system - Edition 01.2011

2.5.3 Table: low-temperature test current

Low-temperature test current in A

EN/ SAE IEC ⇒ DIN

136 – 17 95 – 124 ⇒ 80 – 104
178 – 219 125 – 154 ⇒ 105 – 129
220 – 261 155 – 184 ⇒ 130 – 154
262 – 303 185 – 214 ⇒ 155 – 179
304 – 345 215 – 244 ⇒ 180 – 204
346 – 387 245 – 274 ⇒ 204 – 229
388 – 429 275 – 304 ⇒ 230 – 254
430 – 471 305 – 334 ⇒ 255 – 279
472 – 513 335 – 364 ⇒ 280 – 304
514 – 555 365 – 394 ⇒ 305 –329
556 – 597 395 – 424 ⇒ 330 – 354
598 – 639 425 – 454 ⇒ 355 – 379
640 – 657 455 – 464 ⇒ 380 – 389
658 – 675 465 – 474 ⇒ 390 – 399
676 – 693 475 – 484 ⇒ 400 – 409
694 – 711 485 – 494 ⇒ 410 – 419
712 – 729 495 – 504 ⇒ 420 – 429
730 – 747 505 – 514 ⇒ 430 – 439
748 – 765 515 – 524 ⇒ 440 – 449
766 – 783 525 – 534 ⇒ 450 – 459
784 – 801 535 – 544 ⇒ 460 – 469
802 – 819 545 – 554 ⇒ 470 – 479
820 – 837 555 – 564 ⇒ 480 – 489
838 – 855 565 – 574 ⇒

2) Batteries with a low-temperature test current of 520 A according to DIN can be tested using setting for 499A according to DIN.

2.6 Evaluating test result of battery load test

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

♦ If the battery is OK, the voltage value drops only to the mini‐

mum voltage.

♦ If the battery is defective or has a low charge, the battery volt‐

age quickly drops below the minimum voltage.

♦ After the test, the voltage level remains low for a long period

of time. It only increases again slowly.

♦ Perform test once only. Repeating the test falsifies the result.

♦ The tester requires approx. 30 minutes to cool down before

carrying out another test or testing another battery to ensure
the results are not falsified.

490 – 499

2)

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

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2.6.1 Comments concerning test print out

1 - Test range selected on tester

2 - Diagram -arrow- indicates battery condition.

3 - Test result

4 - Battery voltage during load test

5 - Vehicle data and date are to be recorded on test printout by

♦

♦

2.6.2 Assessing test results

Printout from battery tester Measure to be performed

Starting capability very good Battery OK.
Starting capability good Battery OK.
Starting output sufficient Evaluation by carrying out a

person performing test

Note

The test printout is required for warranty claims.

Only perform test once. Repeating the test falsifies the result.

current draw test when charg‐
ing ⇒ page 19

Starting output poor Evaluation by carrying out a

current draw test when charg‐
ing ⇒ page 19

Starting output very poor Evaluation by carrying out a

current draw test when charg‐
ing ⇒ page 19

Cannot be tested Charge battery ⇒ page 21

and repeat test

Amarok 2011 ➤

Electrical system - Edition 01.2011

2. Checking battery 13

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Amarok 2011 ➤
Electrical system - Edition 01.2011

2.7 Battery tester with printer -VAS 6161-

General description:

Danger of injury! Observe warning notices and safety regula‐
tions ⇒ page 2 !

It is not necessary to remove or disconnect battery when using
battery tester with printer -VAS 6161- .

The battery tester with printer -VAS 6161- does not load the bat‐
tery any more. It works on the principle of dynamic conductance
acquisition.

Every battery type is stored in the tester.

Data can be stored on an SD card.

The battery tester with printer -VAS 6161- can be updated via an
interface or an SD card, thereby ensuring that all battery details
from Volkswagen are always up to date.

The integrated temperature sensor improves measurement qual‐
ity.

WARNING

A 2D scanner is available as an option to read data directly from
the 2D code of the battery.

Note

Observe the ⇒ operating manual of the battery tester with printer

-VAS 6161- .

2.7.1 Description of battery tester with printer

-VAS 6161-

1 - Integrated printer

2 - Operating lever for paper compartment

3 - Paper slot

4 - LCD screen with main menu

5 - Control panel with On/Off button

6 - Connection for battery test cable

7 - Memory card slot

8 - Infrared temperature sensor

9 - Data transmitter for PC

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

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2.7.2 Perform battery test with battery tester with printer -VAS 6161- .

WARNING

Danger of injury! Observe warning notices and safety regula‐
tions ⇒ page 2 !

Special tools and workshop equipment required

♦ Battery tester with printer -VAS 6161-

Performing battery test:

WARNING

Batteries on which the colour indicator is neutral or light yellow
must not be checked or charged. Do not slave/jump start the
vehicle!

Amarok 2011 ➤

Electrical system - Edition 01.2011

There is a risk of explosion while checking and charging the
battery, including during slave starting.

These batteries must be renewed.

– Switch off ignition and all electrical consumers.

– Checking colour indicator on batteries with colour indicator in

battery cover ⇒ page 6 .

– Switch on unit.

– Connect red terminal „+“ of tester to positive terminal.

– Connect black terminal „-“ of tester to negative terminal.

Note

Ensure test clamps have a good contact!

– Select one of the following functions:

♦ Maintenance test (only in new cars before registration, in sta‐

tionary and stock maintenance programme ⇒ page 16 )

♦ Warranty claims ⇒ page 17

♦ Service test for batteries no longer covered under warranty

and third party batteries ⇒ page 16

2. Checking battery 15

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Amarok 2011 ➤
Electrical system - Edition 01.2011

Note

♦

The test is completed after about 10 seconds.

♦

The result of the test is printed out by the printer.

♦

The tester requires no cooling phase before it is ready for the
next measurement.

2.7.3 Performing maintenance test

WARNING

Batteries on which the colour indicator is neutral or light yellow
must not be checked or charged. Do not slave/jump start the
vehicle!

There is a risk of explosion while checking and charging the
battery, including during slave starting.

These batteries must be renewed.

– Select „Maintenance test“ in the menu.

– Connect scanner.

Note

If no scanner is available, write vehicle identification number on
test printout by hand.

– Scan in vehicle identification number.

– Select „On battery terminal“ or „On jump-start point“.

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

in menu.

– Measure temperature. Hold temperature sensor about 5 cm

above terminal connection until temperature stabilises.

– Start test.

– Print out test log if necessary.

2.7.4 Performing service test for batteries no longer covered under warranty and third party batteries

WARNING

Batteries on which the colour indicator is neutral or light yellow
must not be checked or charged. Do not slave/jump start the
vehicle!

There is a risk of explosion while checking and charging the
battery, including during slave starting.

These batteries must be renewed.

– Select „Service test“ in the menu.

– Select „On battery terminal“ or „On jump-start point“.

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

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– Select battery type „Normal“, „AGM“, „2*6V“ or „Gel“.

– Select „CCA“, „JIS“, „DIN“, „SAE“, „IEC“ or „EN“ norm.

– Select battery value (current level in A).

– Measure temperature. Hold temperature sensor about 5 cm

above one battery terminal until temperature stabilises.

– Start test.

– Print out test log if necessary.

2.7.5 Performing test for warranty claims

Batteries on which the colour indicator is neutral or light yellow
must not be checked or charged. Do not slave/jump start the
vehicle!

There is a risk of explosion while checking and charging the
battery, including during slave starting.

These batteries must be renewed.

– Select „Guarantee test“ in the menu.

WARNING

– Select „In vehicle“ or „Outside vehicle“.

– Select „On battery terminal“ or „On jump-start point“.

– Scan in 2D code of battery or select „type“ in menu and battery

value (current level in A).

– Measure temperature. Hold temperature sensor about 5 cm

above one battery terminal until temperature stabilises.

– Start test.

– Print out test log if necessary.

Amarok 2011 ➤

Electrical system - Edition 01.2011

2. Checking battery 17

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Amarok 2011 ➤
Electrical system - Edition 01.2011

2.7.6 Comments concerning test print out

Note

Indicated on the test print-out is the firmware version number of
the battery tester, which in this instance is version number „V1.00
EU“, for example. Since versions are superseded relatively fre‐
quently, always be aware of the version number and ensure work
is always performed with the latest firmware. The latest firmware
is available for download from the ServiceNet.

1 - Type of test

2 - Battery test result

3 - Measured voltage

4 - Measured cold start value of battery

5 - Nominal cold start value of battery selected on tester

6 - Measured temperature of battery

7 - Installation location of battery

8 - Position of battery terminal clamp selected on tester

9 - Selected battery technology

Note

The test printout is required for warranty claims.

2.7.7 Assessing test results

Evaluating battery test results for guarantee and service tests

Battery test results Measures

Battery OK No measures on battery
Battery OK - recharge. Charge battery ⇒ page 21 . In

case of discharging, look for
fault

Perform current draw test Perform current draw test

⇒ page 19 . Fully charge bat‐

tery ⇒ page 21 and repeat
test.

Renew battery. Disconnect battery and repeat

test. The result „Renew battery“
may be caused by a weak cable

contact.
Battery cell defective - renew. Renew battery.
Check connection. Connect cable directly to bat‐

tery and not to jump start termi‐

nal.

Evaluating battery test results for maintenance test

Battery test results Measures

Battery OK No measure
Charge battery immediately. Charge battery fully

⇒ page 21 .

Mark as defective. Mark as defective.

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

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Battery test results Measures

Check tester connection. Disconnect battery and repeat

Check connection. Connect cable directly to bat‐

Noises Wait until measured value ap‐

2.8 Current draw test

WARNING

Batteries on which the colour indicator is neutral or light yellow
must not be checked or charged. Do not slave/jump start the
vehicle!

There is a risk of explosion while checking and charging the
battery, including during slave starting.

These batteries must be renewed.

Note

♦

Ensure that the correct charging mode is set on the charger

test. The result „Check tester
connection“ may be caused by
a weak cable contact.

tery and not to jump start termi‐
nal.

pears on display.

so that the current draw test is not falsified.

♦

VAS 5095 A ⇒ page 21

♦

VAS 5900 ⇒ page 26

♦

VAS 5903 ⇒ page 36

Amarok 2011 ➤

Electrical system - Edition 01.2011

To quickly ascertain the state of discharged batteries, the battery
current draw test whilst charging helps to determine whether the
battery must be replaced or fully recharged.

The current draw test should always be performed in conjunction
with the following results:

If the result of the test with battery tester with printer -VAS 5097A­leads to the following results:

1 - Starting output sufficient

2 - Starting output poor

3 - Starting output very poor

4 - Cannot be tested – charge battery and repeat test

- and when the tester will not switch on (no LED, no printout)

If the result of the test with battery tester with printer -VAS 6161­leads to the following result:

1 - Perform current draw test

Performing a current draw test whilst charging a battery will quick‐
ly establish whether a partly or fully discharged battery can be
recharged to return it to a serviceable condition.

Test prerequisites:

♦ When charging a battery, battery temperature must be at least

≥ +10 ℃.

2. Checking battery 19

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Amarok 2011 ➤
Electrical system - Edition 01.2011

♦ The charger must be capable of outputting a charge current of

at least 30 A, as for example with VAS 5095A, VAS 5900, VAS
5903

♦ The battery's current draw must be measured with a current

pick-up clamp, e.g. VAS 5051B/7, when charging with battery
charger -VAS 5095A- . Battery charger -VAS 5900- and bat‐
tery charger -VAS 5903- display the current draw on the unit.
Battery charger -VAS 5903- performs the current draw test
automatically with menu guidance.

– Connect battery to battery charger and start charging proce‐

dure.

– Measure charge current of battery after 5 minutes.

Test result

5 minutes after charging has commenced, the charge current
must be greater than 10% of the nominal capacity in amperes.

For example

For a 60 Ah battery the charge current must the higher than 6 A
after 5 minutes of starting the charging sequence.

– Battery is fully charged if charge current is greater than 10 %

of the nominal capacity in amperes.

– After 2 hours of battery resting time, perform a battery test

⇒ page 14 .

If the charge current, in amperes, lies below 10% of the rated
capacity 5 minutes after the start of charging (example for a 60
Ah battery < 6A), renew battery. In the event of warranty and
goodwill gestures, fill out the battery test sheet.

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

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3 Charging battery

WARNING

Danger of injury! Comply with the warning notices and safety
regulations ⇒ page 2 !

To prevent damage to the battery and vehicle, observe the fol‐
lowing concerning types of battery ⇒ page 1 .

Batteries on which the colour indicator is neutral or light yellow
must not be checked or charged. Do not slave/jump start the
vehicle!

There is a risk of explosion while checking and charging the
battery, including during slave starting.

These batteries must be renewed.

3.1 Battery charger -VAS 5095 A-

This chapter describes the basic functions of the battery charger

-VAS 5095 A- . For additional information refer to ⇒ Operating
instructions for battery charger -VAS 5095 A- .

Note

Caution

WARNING

Amarok 2011 ➤

Electrical system - Edition 01.2011

♦

The effective charge current can not be read on these units.
The charge current must be read externally using a pick-up
clamp.

♦

Observe ⇒ operating instructions for battery charger -VAS
5095 A- .

3.1.1 Description of battery charger -VAS 5095 A-

The battery charger -VAS 5095- is suitable for charging all 12V
batteries supplied by Volkswagen.

3. Charging battery 21

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Amarok 2011 ➤
Electrical system - Edition 01.2011

The battery charger charges without peaks in amperage or volt‐
age. This will not adversely effect the onboard electronics. The
battery can remain in the vehicle while it is being charged and
need not be disconnected.

Battery charger -VAS 5095 A-

1 - ON / OFF switch (0 = charger OFF)

2 - Charging current indicator (I > 12 A)

3 - Charging current indicator, battery partially charged > 90 %

4 - Maintaining charge; lights up green when battery is fully charg‐
ed

5 - Malfunction indicator

6 - Support mode indicator

7 - Support mode/normal mode changer-over switch

8 - Charger cable, red terminal „+“, black terminal „-“

9 - Battery type change-over switch (on base of charger unit)

3.1.2 Charging battery with battery charger ­VAS 5095 A-

WARNING

Danger of injury! Comply with the warning notices and safety
regulations ⇒ page 2 !

Special tools and workshop equipment required

♦ Battery charger -VAS 5095 A-

Caution

Always set battery type 2.4 V/C (volts/battery cell) when charg‐
ing! This applies for all batteries.

Note

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

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

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WARNING

Batteries on which the colour indicator is neutral or light yellow
must not be checked or charged. Do not slave/jump start the
vehicle!

There is a risk of explosion while checking and charging the
battery, including during slave starting.

These batteries must be renewed.

– Switch off ignition and all electrical consumers.

– Check battery type setting on battery type change-over switch

⇒ page 21 . Must be set to 2.4 V/C (volts/battery cell).

– Connect red charger terminal „+“ of charger to positive termi‐

nal of battery.

– Connect black charger terminal „-“ of charger to negative ter‐

minal of battery.

– Switch on charger ⇒ page 21 .

The charging current indicators ⇒ page 22 -2- and -3- light up
yellow. When only the light emitting diode (LED) -3- lights up yel‐
low, battery is partially discharged (approx. 90 %).

If the LED lights up green ⇒ page 22 -4- the charger has switched
to "maintaining charge". The battery is fully charged.

– Switch off charger ⇒ page 21 .

– Remove charger terminals from battery clamps.

3.1.3 Charging totally discharged battery with battery charger -VAS 5095 A-

WARNING

Danger of injury! Comply with the warning notices and safety
regulations ⇒ page 2 !

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

Note

♦

Follow instructions in chapter ⇒ page 49 .

♦

The battery voltage must be at least 0.6 V.

Amarok 2011 ➤

Electrical system - Edition 01.2011

3. Charging battery 23

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Amarok 2011 ➤
Electrical system - Edition 01.2011

WARNING

Batteries on which the colour indicator is neutral or light yellow
must not be checked or charged. Do not slave/jump start the
vehicle!

There is a risk of explosion while checking and charging the
battery, including during slave starting.

These batteries must be renewed.

– Charge battery ⇒ page 22 .

3.1.4 Charging battery in support mode with battery charger -VAS 5095 A-

General notes:

The support mode provides the onboard supply with power when
the battery is removed or disconnected.

For further information, refer to the ⇒ operating manual VAS
5095A .

The support mode is suitable in the following situations:

♦ Support mode of onboard supplies without installed battery

♦ Power conservation when renewing the battery

♦ Ancillaries test without battery

WARNING

Danger of injury! Comply with the warning notices and safety
regulations ⇒ page 2 !

WARNING

Batteries on which the colour indicator is neutral or light yellow
must not be checked or charged. Do not slave/jump start the
vehicle!

There is a risk of explosion while checking and charging the
battery, including during slave starting.

These batteries must be renewed.

– Switch off ignition and all electrical consumers.

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

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Caution

♦ The terminal polarity protection in operating mode „charg‐

ing totally discharged batteries/support mode“ is not ac‐
tive. Connect battery charger terminal clamps correctly to
battery terminals.

♦ It can cause sparks through a short-circuit.

♦ Danger of explosion

♦ Ensure charger terminals are fitted securely.

♦ Do not press

START / STOP

button if charger unit cables

are connected incorrectly. The charger unit may be dam‐
aged.

– Removing battery.

Caution

When battery is removed, ensure there is no contact between
terminal clamp connected to positive clamp and body earth.
Also ensure there is no contact between battery clamps.

Amarok 2011 ➤

Electrical system - Edition 01.2011

– Connect red charger terminal „+“ to positive terminal of vehi‐

cle.

– Connect black charger terminal „-“ to negative terminal of ve‐

hicle.

– Check battery type setting on support mode/normal mode

changer-over switch ⇒ page 21 . It must be switched on sup‐
port mode.

– Check that connections of charger terminals have correct po‐

larity.

– Switch on charger.

The battery charger starts with support mode.

End battery support mode:

– Switch off charger.

– Disconnect black charger terminal „-“ of charger from negative

terminal of vehicle.

– Disconnect red charger terminal „+“ of charger from positive

terminal of vehicle.

– Pull out mains plug of charger.

3.1.5 Charging battery in maintenance mode with battery charger -VAS 5095 A-

WARNING

Danger of injury! Comply with the warning notices and safety
regulations ⇒ page 2 !

3. Charging battery 25

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Amarok 2011 ➤
Electrical system - Edition 01.2011

WARNING

Batteries on which the colour indicator is neutral or light yellow
must not be checked or charged. Do not slave/jump start the
vehicle!

There is a risk of explosion while checking and charging the
battery, including during slave starting.

These batteries must be renewed.

In the buffer mode the battery charger -VAS 5095 A- is charged
correctly and is maintained in a fully charged condition.

– Procedure same as for battery charging ⇒ page 22 .

Note

♦

If the battery is discharged in buffer mode via an electrical
consumer, the battery charger -VAS 5095 A- automatically
compensates the charge.

♦

The buffer mode can be continued for an unlimited period.

♦

The battery is always ready for use.

3.2 Battery charger -VAS 5900-

WARNING

Danger of injury! Comply with the warning notices and safety
regulations ⇒ page 2 !

WARNING

Batteries on which the colour indicator is neutral or light yellow
must not be checked or charged. Do not slave/jump start the
vehicle!

There is a risk of explosion while checking and charging the
battery, including during slave starting.

These batteries must be renewed.

This chapter describes the basic functions of the battery charger

-VAS 5900- . For additional information refer to ⇒ Operating in‐
structions for battery charger -VAS 5900- .

Note

♦

The effective charge current can be read directly on this bat‐
tery charger.

♦

Observe ⇒ operating instructions for battery charger -VAS
5900- .

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

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3.2.1 Description of battery charger -VAS 5900-

The battery charger -VAS 5900- is suitable for charging all 12V
batteries supplied by Volkswagen.

Battery charger -VAS 5900-

1 - Display

2 - Adjustment button „Up“ ↑

3 - Adjustment button „Down“ ↓
4 - START / STOP
5 - INFO

3.2.2 Charging battery with battery charger ­VAS 5900-

WARNING

Danger of injury! Comply with the warning notices and safety
regulations ⇒ page 2 !

WARNING

Batteries on which the colour indicator is neutral or light yellow
must not be checked or charged. Do not slave/jump start the
vehicle!

There is a risk of explosion while checking and charging the
battery, including during slave starting.

These batteries must be renewed.

Special tools and workshop equipment required

♦ Battery charger -VAS 5900-

Amarok 2011 ➤

Electrical system - Edition 01.2011

Note

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

– Switch off ignition and all electrical consumers.

– Plug in mains plug of charger. The last selected operating

mode will appear on display ⇒ page 27 .

3. Charging battery 27

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Amarok 2011 ➤
Electrical system - Edition 01.2011

– Set battery to respective operating mode with INFO .

On the display, the symbol -1- for „standard charging of wet bat‐
teries“ or the symbol -2- for „standard charging of gel/absorbent
glass mat batteries“ will appear.

– Set battery capacity (Ah) of battery to be charged using cor‐

responding button „Up“ ↑ or „Down“ ↓ .

– Connect red charger terminal „+“ to positive terminal of battery.

– Connect black charger terminal „-“ to negative terminal of bat‐

tery.

The charger unit recognises the voltage required for the connec‐
ted battery (6 V, 12 V or 24 V) and initiates the charging sequence.

At a charge condition of approx. 80 - 85 % the battery charger
switches to the „final charge“ mode. The fourth bar appears in
display -1-. The battery is ready for use.

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

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At a charge condition of 100 % all bars appear in display.

Note

♦

In „standard charge“ operating mode, the parallel operation of
consumers while charging is possible. The charging period will
be longer.

♦

The battery charger will switch to maintenance mode after
about 1-7 hours, depending on type of battery. To achieve a
100 % charge, the battery should remain connected for this
period.

Possible faults and fault rectification:

1 - Displayed battery voltage is not as per nominal voltage:

– Hold down corresponding button „Up“ ↑ or „Down“ ↓ until

charging sequence starts.

2 - Displayed battery voltage is not as per nominal voltage –

charging sequence already started:

– Press START / STOP twice.

– Hold down corresponding button „Up“ ↑ or „Down“ ↓ until

charging sequence starts again.

3 - Battery charger does not detect a battery, when battery volt‐

age is less than 2 V:

Display remains unchanged.

The operating mode and ampere hours (Ah) as set are displayed.

Ending battery charging sequence:
– Press START / STOP .

– Disconnect black charger terminal „-“ of charger from negative

terminal of battery.

– Disconnect red charger terminal „+“ of charger from positive

terminal of battery.

– Pull out mains plug of charger.

3.2.3 Charging battery in service mode with battery charger -VAS 5900-

WARNING

Amarok 2011 ➤

Electrical system - Edition 01.2011

Danger of injury! Comply with the warning notices and safety
regulations ⇒ page 2 !

Caution

The operating mode „service charge“ is not permitted on VW
vehicles as the voltage peaks will damage the onboard elec‐
tronics.

If „service charge“ operating mode is used nevertheless, the
battery must be disconnected from the onboard supply.

3. Charging battery 29

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Amarok 2011 ➤
Electrical system - Edition 01.2011

WARNING

Batteries on which the colour indicator is neutral or light yellow
must not be checked or charged. Do not slave/jump start the
vehicle!

There is a risk of explosion while checking and charging the
battery, including during slave starting.

These batteries must be renewed.

Caution

When charging always set the battery charger to the correct
type of battery ⇒ Operating instructions for battery charger ­VAS 5900- !

The „service mode“ is suitable for:

♦ Wet batteries on which the colour indicator permits battery

charging.

The operating mode „service charge (SERV)“ is only used on
sulphated batteries. The battery is charged at a voltage of
>14.4 V. This can result in a partial reduction of the sulphated
layer. After charging, it is essential that the colour indicator is
checked before continuing to use the battery ⇒ page 6 .

Special tools and workshop equipment required

♦ Battery charger -VAS 5900-

Note

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

– Switch off ignition and all electrical consumers.

– Plug in mains plug of charger. The last selected operating

mode will appear on display ⇒ page 27 .

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

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.

– Set battery to respective operating mode with INFO .

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

– Set battery capacity (Ah) of battery to be charged using cor‐

responding button „Up“ ↑ or „Down“ ↓ .

– Connect red charger terminal „+“ to positive terminal of battery.

– Connect black charger terminal „-“ to negative terminal of bat‐

tery.

The charger unit recognises the voltage required for the connec‐
ted battery (6 V, 12 V or 24 V) and initiates the charging sequence.

At a charge condition of approx. 80 - 85 % the charger unit
switches to the „final charge“ mode. The fourth bar appears in
display -1-. The battery is ready for use.

Note

The success of the „service charge“ depends on the severity of
the sulphation of the battery

Possible faults and fault rectification:

1 - Displayed battery voltage is not as per nominal voltage:

– Hold down corresponding button „Up“ ↑ or „Down“ ↓ until

charging sequence starts.

2 - Displayed battery voltage is not as per nominal voltage –

charging sequence already started:

– Press START / STOP twice.

Amarok 2011 ➤

Electrical system - Edition 01.2011

– Hold down corresponding button „Up“ ↑ or „Down“ ↓ until

charging sequence starts.

3 - Battery charger does not detect a battery, when battery volt‐

age is less than 2 V:

Display remains unchanged.

The operating mode and ampere hours (Ah) as set are displayed.

Ending battery charging sequence:
– Press START / STOP .

– Disconnect black charger terminal „-“ of charger from negative

terminal of battery.

– Disconnect red charger terminal „+“ of charger from positive

terminal of battery.

– Pull out mains plug of charger.

3.2.4 Charging totally discharged battery with battery charger -VAS 5900-

WARNING

Danger of injury! Comply with the warning notices and safety
regulations ⇒ page 2 !

3. Charging battery 31

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Amarok 2011 ➤
Electrical system - Edition 01.2011

WARNING

Batteries on which the colour indicator is neutral or light yellow
must not be checked or charged. Do not slave/jump start the
vehicle!

There is a risk of explosion while checking and charging the
battery, including during slave starting.

These batteries must be renewed.

Caution

♦ The terminal polarity protection in operating mode „charg‐

ing totally discharged batteries/support mode“ is not ac‐
tive. Connect battery charger terminal clamps correctly to
battery terminals.

♦ When charging always set the battery charger to the cor‐

rect type of battery ⇒ Operating instructions for battery
charger -VAS 5900- !

♦ Totally discharged battery is not recognised by battery

charger ⇒ page 49 .

♦ Do not press

are connected incorrectly. The charger unit may be dam‐
aged.

Batteries with a voltage of less than 2 volts will not be recognised
automatically by battery charger -VAS 5900- .

Special tools and workshop equipment required

♦ Battery charger -VAS 5900-

START / STOP

Note

button if charger unit cables

♦

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

♦

If the battery has cell sealing plugs, do not open them while
the battery is being charged.

– Switch off ignition and all electrical consumers.

– Plug in mains plug of charger. The last selected operating

mode will appear on display ⇒ page 27 .

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

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.

– Set battery to respective operating mode with INFO .

On the display, the symbol -1- for „Service charge for wet batter‐
ies“ or symbol -2- for „Service charge for gel/absorbent glass mat
batteries“ will appear.

– Set battery capacity (Ah) of battery to be charged using cor‐

responding button „Up“ ↑ or „Down“ ↓ .

– Connect red charger terminal „+“ to positive terminal of battery.

– Connect black charger terminal „-“ to negative terminal of bat‐

tery.

– Press START / STOP for approx. 5 seconds. The menu

„charging totally discharged batteries/support mode“ will be
activated.

– Press „Up“ ↑ or „Down“ ↓ button to set appropriate battery

voltage (6 V, 12 V or 24 V).

Note

If a button is not pressed within 5 seconds, the charger will return
to the main menu (select operating mode).

– Confirm selected battery voltage with START / STOP .

Then follows the enquiry for "is charger cable terminal polarity
correct".

– Check that connections of charger terminals have correct po‐

larity.

– Confirm that connections of charger terminals have correct

polarity with START / STOP .

Charger will start charging sequence for totally discharged bat‐
tery.

Ending battery charging sequence:
– Press START / STOP .

– Disconnect black charger terminal „-“ of charger from negative

terminal of battery.

– Disconnect red charger terminal „+“ of charger from positive

terminal of battery.

– Pull out mains plug of charger.

Amarok 2011 ➤

Electrical system - Edition 01.2011

3.2.5 Charging battery in support mode with battery charger -VAS 5900-

General notes:

The support mode provides the onboard supply with power when
the battery is removed or disconnected.

For further information, refer to the ⇒ operating manual VAS
5900 .

The support mode is suitable in the following situations:

♦ Support mode of onboard supplies without installed battery

♦ Power conservation when renewing the battery

♦ Ancillaries test without battery

3. Charging battery 33

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.

Amarok 2011 ➤
Electrical system - Edition 01.2011

WARNING

Danger of injury! Comply with the warning notices and safety
regulations ⇒ page 2 !

WARNING

Batteries on which the colour indicator is neutral or light yellow
must not be checked or charged. Do not slave/jump start the
vehicle!

There is a risk of explosion while checking and charging the
battery, including during slave starting.

These batteries must be renewed.

– Switch off ignition and all electrical consumers.

Caution

♦ The terminal polarity protection in operating mode „charg‐

ing totally discharged batteries/support mode“ is not ac‐
tive. Connect battery charger terminal clamps correctly to
battery terminals.

♦ It can cause sparks through a short-circuit.

♦ Danger of explosion

♦ Ensure charger terminals are fitted securely.

♦ Do not press

START / STOP

are connected incorrectly. The charger unit may be dam‐
aged.

– Removing battery.

– Plug in mains plug of charger. The last selected operating

mode will appear on display ⇒ page 27 .

Caution

When battery is removed, ensure there is no contact between
terminal clamp connected to positive clamp and body earth.
Also ensure there is no contact between battery clamps.

– Connect red charger terminal „+“ to positive terminal of vehi‐

cle.

– Connect black charger terminal „-“ to negative terminal of ve‐

hicle.

button if charger unit cables

– Press START / STOP for approx. 5 seconds. The menu

„charging totally discharged batteries/support mode“ will be
activated.

– Press „Up“ ↑ or „Down“ ↓ button to set appropriate battery

voltage (6 V, 12 V or 24 V).

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

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Note

If a button is not pressed within 5 seconds, the charger will return
to the main menu (select operating mode).

– Confirm selected battery voltage with START / STOP .

Then follows the enquiry for "is charger cable terminal polarity
correct".

– Check that connections of charger terminals have correct po‐

larity.

– Confirm that connections of charger terminals have correct

polarity with START / STOP .

The battery charger starts with support mode.

End battery support mode:
– Press START / STOP .

– Disconnect black charger terminal „-“ of charger from negative

terminal of vehicle.

– Disconnect red charger terminal „+“ of charger from positive

terminal of vehicle.

– Pull out mains plug of charger.

Amarok 2011 ➤

Electrical system - Edition 01.2011

3.2.6 Charging battery in maintenance mode with battery charger -VAS 5900-

WARNING

Danger of injury! Comply with the warning notices and safety
regulations ⇒ page 2 !

WARNING

Batteries on which the colour indicator is neutral or light yellow
must not be checked or charged. Do not slave/jump start the
vehicle!

There is a risk of explosion while checking and charging the
battery, including during slave starting.

These batteries must be renewed.

When the battery is fully charged the battery charger -VAS 5900­switches to maintenance mode.

– Procedure same as for battery charging ⇒ page 27 .

3. Charging battery 35

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Amarok 2011 ➤
Electrical system - Edition 01.2011

At a charge condition of 100 % all bars appear in display.

Note

♦

When a battery is being charged in the maintenance mode and
an electrical consumer draws current from the battery, the
battery charger -VAS 5900- automatically compensates the
charge.

♦

The maintenance mode can be continued for an unlimited pe‐
riod.

♦

The battery is always ready for use.

♦

Observe battery manufacturer's maintenance instructions as
well.

3.3 Battery charger -VAS 5903-

Danger of injury! Comply with the warning notices and safety
regulations ⇒ page 2 !

Batteries on which the colour indicator is neutral or light yellow

WARNING

WARNING

must not be checked or charged. Do not slave/jump start the
vehicle!

There is a risk of explosion while checking and charging the
battery, including during slave starting.

These batteries must be renewed.

This chapter describes the basic functions of the battery charger

-VAS 5903- . For additional information refer to ⇒ Operating in‐
structions for battery charger -VAS 5903- .

Note

Observe ⇒ operating instructions for battery charger -VAS 5903- .

3.3.1 Description of battery charger -VAS 5903-

The battery charger -VAS 5903- is suitable for charging all 12V
batteries supplied by Volkswagen.

Battery charger -VAS 5903-

1 - Display

2 - Adjustment button „Up“ ↑

3 - Adjustment button „Down“ ↓
4 - START / STOP
5 - INFO

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

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3.3.2 Charging battery with battery charger ­VAS 5903-

WARNING

Danger of injury! Comply with the warning notices and safety
regulations ⇒ page 2 !

Batteries on which the colour indicator is neutral or light yellow
must not be checked or charged. Do not slave/jump start the
vehicle!

There is a risk of explosion while checking and charging the
battery, including during slave starting.

These batteries must be renewed.

Special tools and workshop equipment required

♦ Battery charger -VAS 5903-

WARNING

Amarok 2011 ➤

Electrical system - Edition 01.2011

Note

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

– Switch off ignition and all electrical consumers.

– Plug in mains plug of charger. The last selected operating

mode will appear on display ⇒ page 36 .

– Set battery to respective operating mode with INFO .

On the display, the symbol -1- for „standard charging of wet bat‐
teries“ or the symbol -2- for „standard charging of gel/absorbent
glass mat batteries“ will appear.

– Set battery capacity (Ah) of battery to be charged using cor‐

responding button „Up“ ↑ or „Down“ ↓ .

– Connect red charger terminal „+“ to positive terminal of battery.

– Connect black charger terminal „-“ to negative terminal of bat‐

tery.

The charger unit recognises the voltage required for the connec‐
ted battery (6 V, 12 V or 24 V) and initiates the charging sequence.

3. Charging battery 37

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Amarok 2011 ➤
Electrical system - Edition 01.2011

At a charge condition of approx. 80 - 85 % the battery charger
switches to the „final charge“ mode. The fourth bar appears in
display -1-. The battery is ready for use.

At a charge condition of 100 % all bars appear in display.

Note

♦

During „standard charge“ battery mode, the parallel operation
of consumers while charging is possible. The charging period
will be longer.

♦

The battery charger will switch to maintenance mode after
about 1-7 hours, depending on type of battery. To achieve a
100 % charge, the battery should remain connected for this
period.

Possible faults and fault rectification:

1 - Displayed battery voltage is not as per nominal voltage:

– Hold down corresponding button „Up“ ↑ or „Down“ ↓ until

charging sequence starts.

2 - Displayed battery voltage is not as per nominal voltage –

charging sequence already started:

– Press START / STOP twice.

– Hold down corresponding button „Up“ ↑ or „Down“ ↓ until

charging sequence starts again.

3 - Battery charger does not detect a battery, when battery volt‐

age is less than 2 V:

Display remains unchanged.

The battery type and ampere hours (Ah) as set is displayed.

Ending battery charging sequence:
– Press START / STOP .

– Disconnect black charger terminal „-“ of charger from negative

terminal of battery.

– Disconnect red charger terminal „+“ of charger from positive

terminal of battery.

– Pull out mains plug of charger.

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

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3.3.3 Charging battery in refresh charge mode with battery charger -VAS 5903-

WARNING

Danger of injury! Comply with the warning notices and safety
regulations ⇒ page 2 !

WARNING

Batteries on which the colour indicator is neutral or light yellow
must not be checked or charged. Do not slave/jump start the
vehicle!

There is a risk of explosion while checking and charging the
battery, including during slave starting.

These batteries must be renewed.

The operating mode „refresh charge“ is not permitted on VW
vehicles as the voltage peaks will damage the onboard elec‐
tronics.

Caution

If „refresh charge“ operating mode is used nevertheless, the
battery must be disconnected from the onboard supply.

Caution

When charging always set the battery charger to the correct
type of battery ⇒ Operating instructions for battery charger ­VAS 5903- !

The „refresh charge“ mode is suitable for:

♦ Wet batteries, where distilled water can be replenished.

Do not use „Refresh Charge“ mode for maintenance-free wet
batteries.

Amarok 2011 ➤

Electrical system - Edition 01.2011

The „refresh charge (Refr)“ operating mode is only used on sus‐
pect defective batteries (e.g. sulphation). The battery will be
charged to maximum specific gravity and the plates will be reac‐
tivated (dissipation of sulphur layer).

Special tools and workshop equipment required

3. Charging battery 39

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Amarok 2011 ➤
Electrical system - Edition 01.2011

♦ Battery charger -VAS 5900-

Note

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

– Switch off ignition and all electrical consumers.

– Plug in mains plug of charger. The last selected operating

mode will appear on display ⇒ page 36 .

– Set battery to respective operating mode with INFO .

In the display the symbol -1- for „Refresh Charge for wet batteries“
or symbol -2- for „Refresh Charge for gel/absorbent glass mat
batteries“ will appear.

– Set battery capacity (Ah) of battery to be charged using cor‐

responding button „Up“ ↑ or „Down“ ↓ .

– Connect red charger terminal „+“ to positive terminal of battery.

– Connect black charger terminal „-“ to negative terminal of bat‐

tery.

The charger unit recognises the voltage required for the connec‐
ted battery (6 V, 12 V or 24 V) and initiates the charging sequence.

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

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At a charge condition of approx. 80 - 85 % the charger unit
switches to the „final charge“ mode. The fourth bar appears in
display -1-. The battery is ready for use.

Note

The success of the „refresh charge“ depends on the severity of
the sulphation of the battery.

Possible faults and fault rectification:

1 - Displayed battery voltage is not as per nominal voltage:

– Hold down corresponding button „Up“ ↑ or „Down“ ↓ until

charging sequence starts.

2 - Displayed battery voltage does not agree with nominal volt‐

age – charging sequence already started:

– Press START / STOP twice.

– Hold down corresponding button „Up“ ↑ or „Down“ ↓ until

charging sequence starts.

3 - Battery charger does not detect a battery, when battery volt‐

age is less than 2 V:

Display remains unchanged.

The operating mode and ampere hours (Ah) as set are displayed.

Ending battery charging sequence:
– Press START / STOP .

– Disconnect black charger terminal „-“ of charger from negative

terminal of battery.

– Disconnect red charger terminal „+“ of charger from positive

terminal of battery.

– Pull out mains plug of charger.

Amarok 2011 ➤

Electrical system - Edition 01.2011

3.3.4 Charging totally discharged battery with battery charger -VAS 5903-

WARNING

Danger of injury! Comply with the warning notices and safety
regulations ⇒ page 2 !

WARNING

Batteries on which the colour indicator is neutral or light yellow
must not be checked or charged. Do not slave/jump start the
vehicle!

There is a risk of explosion while checking and charging the
battery, including during slave starting.

These batteries must be renewed.

3. Charging battery 41

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Amarok 2011 ➤
Electrical system - Edition 01.2011

Caution

♦ The terminal polarity protection in operating mode „charg‐

ing totally discharged batteries/support mode“ is not ac‐
tive. Connect battery charger terminal clamps correctly to
battery terminals.

♦ When charging always set the battery charger to the cor‐

rect type of battery ⇒ Operating instructions for battery
charger -VAS 5903- !

♦ Totally discharged battery is not recognised by battery

charger ⇒ page 49 .

♦ Do not press

START / STOP

button if charger unit cables

are connected incorrectly. The charger unit may be dam‐
aged.

Batteries with a voltage of less than 2 volts will not be recognised
automatically by battery charger -VAS 5903- .

Special tools and workshop equipment required

♦ Battery charger -VAS 5903-

Note

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

– Switch off ignition and all electrical consumers.

– Plug in mains plug of charger. The last selected operating

mode will appear on display ⇒ page 36 .

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

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– Set battery to respective operating mode with INFO .

On the display, the symbol -1- for „Service charge for wet batter‐
ies“ or symbol -2- for „Service charge for gel/absorbent glass mat
batteries“ will appear.

– Set battery capacity (Ah) of battery to be charged using cor‐

responding button „Up“ ↑ or „Down“ ↓ .

– Connect red charger terminal „+“ to positive terminal of battery.

– Connect black charger terminal „-“ to negative terminal of bat‐

tery.

– Press START / STOP for approx. 5 seconds. The menu

„charging totally discharged batteries/support mode“ will be
activated.

– Press „Up“ ↑ or „Down“ ↓ button to set appropriate battery

voltage (6 V, 12 V or 24 V).

Note

If a button is not pressed within 5 seconds, the charger will return
to the main menu (select operating mode).

Amarok 2011 ➤

Electrical system - Edition 01.2011

– Confirm selected battery voltage with START / STOP .

Then follows the enquiry for "is charger cable terminal polarity
correct".

– Check that connections of charger terminals have correct po‐

larity.

– Confirm that connections of charger terminals have correct

polarity with START / STOP .

Charger will start charging sequence for totally discharged bat‐
tery.

Ending battery charging sequence:
– Press START / STOP .

– Disconnect black charger terminal „-“ of charger from negative

terminal of battery.

– Disconnect red charger terminal „+“ of charger from positive

terminal of battery.

– Pull out mains plug of charger.

3.3.5 Charging battery in support mode with battery charger -VAS 5903-

General notes:

The support mode provides the onboard supply with power when
the battery is removed or disconnected.

For further information, refer to the ⇒ operating manual VAS
5903 .

The support mode is suitable in the following situations:

♦ Support mode of onboard supplies without installed battery

♦ Power conservation when renewing the battery

♦ Ancillaries test without battery

3. Charging battery 43

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Amarok 2011 ➤
Electrical system - Edition 01.2011

WARNING

Danger of injury! Comply with the warning notices and safety
regulations ⇒ page 2 !

WARNING

Batteries on which the colour indicator is neutral or light yellow
must not be checked or charged. Do not slave/jump start the
vehicle!

There is a risk of explosion while checking and charging the
battery, including during slave starting.

These batteries must be renewed.

– Switch off ignition and all electrical consumers.

Caution

♦ The terminal polarity protection in operating mode „charg‐

ing totally discharged batteries/support mode“ is not ac‐
tive. Connect battery charger terminal clamps correctly to
battery terminals.

♦ It can cause sparks through a short-circuit.

♦ Danger of explosion

♦ Ensure charger terminals are fitted securely.

♦ Do not press

START / STOP

are connected incorrectly. The charger unit may be dam‐
aged.

– Removing battery.

– Plug in mains plug of charger. The last selected operating

mode will appear on display ⇒ page 27 .

Caution

When battery is removed, ensure there is no contact between
terminal clamp connected to positive clamp and body earth.
Also ensure there is no contact between battery clamps.

– Connect red charger terminal „+“ to positive terminal of vehi‐

cle.

button if charger unit cables

– Connect black charger terminal „-“ to negative terminal of ve‐

hicle.

– Press START / STOP for approx. 5 seconds. The menu

„charging totally discharged batteries/support mode“ will be
activated.

– Press „Up“ ↑ or „Down“ ↓ button to set appropriate battery

voltage (6 V, 12 V or 24 V).

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

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Note

If a button is not pressed within 5 seconds, the charger will return
to the main menu (select operating mode).

– Confirm selected battery voltage with START / STOP .

Then follows the enquiry for "is charger cable terminal polarity
correct".

– Check that connections of charger terminals have correct po‐

larity.

– Confirm that connections of charger terminals have correct

polarity with START / STOP .

The battery charger starts with support mode.

End battery support mode:
– Press START / STOP .

– Disconnect black charger terminal „-“ of charger from negative

terminal of vehicle.

– Disconnect red charger terminal „+“ of charger from positive

terminal of vehicle.

– Pull out mains plug of charger.

3.3.6 Charging battery in maintenance mode

Danger of injury! Comply with the warning notices and safety
regulations ⇒ page 2 !

Batteries on which the colour indicator is neutral or light yellow
must not be checked or charged. Do not slave/jump start the
vehicle!

There is a risk of explosion while checking and charging the
battery, including during slave starting.

These batteries must be renewed.

with battery charger -VAS 5903-

WARNING

WARNING

When the battery is fully charged the battery charger -VAS 5903­switches to maintenance mode.

– Procedure same as for battery charging ⇒ page 37 .

Amarok 2011 ➤

Electrical system - Edition 01.2011

3. Charging battery 45

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Amarok 2011 ➤
Electrical system - Edition 01.2011

At a charge condition of 100 % all bars appear in display.

Note

♦

When a battery is being charged in the maintenance mode and
an electrical consumer draws current from the battery, the
battery charger -VAS 5903- automatically compensates the
charge.

♦

The maintenance mode can be continued for an unlimited pe‐
riod.

♦

The battery is always ready for use.

♦

Observe battery manufacturer's maintenance instructions as
well.

3.4 Battery charger -VAS 5906-

3.4.1 General description

Battery charger - VAS 5906-

WARNING

Danger of injury! Observe warning notices and safety regula‐
tions ⇒ page 2 !

WARNING

Batteries on which the colour indicator is neutral or light yellow
must not be checked or charged. Do not slave/jump start the
vehicle!

There is a risk of explosion while checking and charging the
battery, including during slave starting.

These batteries must be renewed.

Battery charger -VAS 5906- has been specially developed for
charging in vehicle onboard supply during vehicle presentation.

It has an automatic charging characteristic for starter batteries, 3

- 300 AH.

The maximum charging voltage 14.4 V is not exceeded. All elec‐
trical loads are supported by up to 30 A by the trickle charging.

For sustained operation, battery charger -VAS 5906- changes to
trickle charging once battery is fully charged.

Tester starts fully automatically and does not require any settings.
All that is required is to connect crocodile clips and mains cable.

For further information, refer to the ⇒ operating manual VAS
5906 .

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

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3.4.2 Charging battery with battery charger ­VAS 5906-

WARNING

Danger of injury! Observe warning notices and safety regula‐
tions ⇒ page 2 !

WARNING

Batteries on which the colour indicator is neutral or light yellow
must not be checked or charged. Do not slave/jump start the
vehicle!

There is a risk of explosion while checking and charging the
battery, including during slave starting.

These batteries must be renewed.

Amarok 2011 ➤

Electrical system - Edition 01.2011

3. Charging battery 47

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Amarok 2011 ➤
Electrical system - Edition 01.2011

Overview of operating panel:

1 - Charge condition display 25 %.

2 - Charge condition display 50 %.

3 - Charge condition display 75 %.

4 - Charge condition display 100 %.

5 - Display ready

6 - Start/stop and Setup buttons for interrupting and resuming

charging process. Entry to Setup menu and selection of
characteristic type (press for 10 s).

7 - Malfunction display.

– Place charger in engine compartment or under vehicle.

– Connect mains cable to charger and plug it into mains.

Charger is in no-load operation - ready light is on.

WARNING

Danger of injury! Observe warning notices and safety regula‐
tions ⇒ page 2 !

– Switch off ignition.

– Connect red charging cable to positive terminal „+“ on battery.

Note

In vehicles with start/stop function and battery monitor control unit

-J367- fitted, black terminal clamp must be connected to body
earth. Connecting it to battery negative terminal will cause start/
stop system to malfunction.

– Connect black charging cable to negative terminal „-“ on bat‐

tery.

Charging starts after about 2 seconds.

Number of LEDs lit indicates charge condition of battery. Battery
has been charged up once all lights are lit.

When battery is fully charged, battery charger -VAS 5906- auto‐
matically switches over to trickle charging.

Caution

Danger of sparking if charging terminals are removed too soon.
Terminate charging by pressing start/stop button.

– Press start/stop button to terminate charging.

– Disconnect black charging cable from negative terminal „-“ on

battery.

– Disconnect red charging cable from positive terminal „+“ on

battery.

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

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3.5 Solar panel -VAS 6102A-

3.5.1 Charging battery in maintenance mode
with solar panel -VAS 6102A-

Solar panel VAS 6102A

General description:

Solar panel -VAS 6102A- supports onboard supply and prevents
spontaneous battery discharging.

Solar panel -VAS 6102A- achieves max. voltage of 14.3 V and a
charging current of max. 255 mA.

Solar panel -VAS 6102A- is allowed to be used for charging all
rechargeable lead or lead gel batteries.

Solar panel -VAS 6102A- is connected to diagnostic connection
in vehicle.

A green LED is integrated in the frame to indicate its function. The
brighter the LED, the higher the charging current.

Integrated electronics prevent battery overcharging.

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

– Place underside on dash panel -2-.

Amarok 2011 ➤

Electrical system - Edition 01.2011

Note

Solar panel -VAS 6102A- is not allowed to lie fully on dash panel.
It is only allowed to be positioned with the bottom edge for sup‐
port. Placing it fully on the surface can result in discolouration of
the dash panel.

– Pull attachment string tight so that solar panel -VAS 6102A- is

positioned close to windscreen.

– Connect solar panel -VAS 6102A- to diagnostic connection of

vehicle. Connect in same way as vehicle diagnosis tester

⇒ page 179 .

– Check function of solar panel -VAS 6102A- . Green LED indi‐

cates function of solar panel -VAS 6102A- .

3.6 Totally discharged batteries

Danger of injury! Observe warning notices and safety regula‐

WARNING

tions ⇒ page 2 !

Batteries on which the colour indicator is neutral or light yellow
must not be checked or charged. Do not slave/jump start the
vehicle!

There is a risk of explosion while checking and charging the
battery, including during slave starting.

These batteries must be renewed.

A battery is deemed „completely discharged“ if the open-circuit
voltage is less than 11.6 V.

3. Charging battery 49

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Amarok 2011 ➤
Electrical system - Edition 01.2011

Caution

♦ Totally discharged batteries freeze prematurely.

♦ Frozen batteries should no longer be used.

Note

♦

Totally discharged batteries in vehicles before registration
must be exchanged prior to delivery. Preliminary damage can‐
not be excluded.

♦

Batteries that have not been used for a long period of time
discharge themselves, e.g. those fitted in stored vehicles.

♦

In totally discharged batteries, the electrolyte is comprised al‐
most entirely of water because the acid content is so low.

♦

Totally discharged batteries sulphate, that means, the entire
plate surfaces of the battery harden.

♦

If a battery is recharged shortly after it has totally lost its
charge, the sulphation will mostly dissipate.

♦

If these batteries are not recharged, the plates continue to
harden and the ability to recharge is reduced. The result of
which is a reduction in the battery output.

– Check battery no-load voltage ⇒ page 21 .

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

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4 Disconnecting and reconnecting bat‐

tery

WARNING

Danger of injury! Comply with the warning notices and safety
regulations ⇒ page 4 !

4.1 Disconnecting and reconnecting battery

A battery with colour indicator and either covered cell plugs or no
cell plugs is installed in the vehicle ex-factory on the left in the
engine compartment.

Note

♦

The order in which the work steps is carried out should be
followed carefully.

♦

Disconnecting the battery earth strap (open circuit) provides a
safe working environment for repairs to the electrical system.

♦

The battery positive wire need only be disconnected for re‐
moval of the battery. However, you should in any case observe
the notes on connecting the battery.

Special tools and workshop equipment required

♦ Torque wrench -V.A.G 1331-

Amarok 2011 ➤

Electrical system - Edition 01.2011

4.1.1 Disconnecting battery

Carry out the following work:

– Switch off ignition and all electrical loads, and pull out ignition

key.

After waiting 60 seconds:

Disconnect battery in following sequence:

4. Disconnecting and reconnecting battery 51

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Amarok 2011 ➤
Electrical system - Edition 01.2011

– First disconnect battery earth cable -arrow- from battery neg‐

ative terminal.

– Unclip cover of fuse holder on positive terminal using a suita‐

ble screwdriver -arrows-.

– Remove cover of fuse holder -1- on positive terminal.

– Remove securing nut -arrow- from fuse holder. Remove fuse

holder and put it to one side.

– Then disconnect the battery positive wire on battery positive

terminal.

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

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4.1.2 Connecting battery:

Caution

Battery terminal clamps must be fitted only by hand without
force to prevent damage to battery housing.

Battery terminals must not be greased.

Carry out the following work:

– Fit positive cable clamp onto battery positive terminal.

– Tighten battery positive terminal clamp securing bolt to 6 Nm.

– Install fuse holder on battery positive terminal.

– Connect battery negative terminal clamp to negative terminal

of battery.

– Tighten securing bolt of battery negative terminal clamp to 6

Nm.

– Perform steps according to table ⇒ page 53 .

4.2 Steps after connecting battery

Procedure Performed

Using ignition key, switch ignition:
on and then off again
Read fault memory:
⇒ Guided fault finding using VAS 5051
Steering angle sender - carry out zero

compensation:
⇒ Guided fault finding using VAS 5051
Clock:
Check clock setting, adjust if necessary.
Electric window regulators:
Fully open and then close all windows.
Functional check:
All electrical consumers

Chart can be printed out as required.

Amarok 2011 ➤

Electrical system - Edition 01.2011

4. Disconnecting and reconnecting battery 53

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Amarok 2011 ➤
Electrical system - Edition 01.2011

5 Removing and installing battery

WARNING

Danger of injury! Comply with the warning notices and safety
regulations ⇒ page 2 !

5.1 Removing and installing battery

5.1.1 Removing:

Special tools and workshop equipment required

♦ Torque wrench -V.A.G 1331-

Carry out the following work:

– Switch off ignition and all electrical loads, and pull out ignition

key.

– Disconnect battery ⇒ page 51 .

– Disconnect hose for central gas venting, if present, from bat‐

tery.

– Unscrew securing screw -arrow- and remove battery carrier.

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

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.

– Swivel up battery handles -arrows-.

– Grip battery on handles and lift it out.

5.1.2 Installing:

Caution

A loosely fitted battery creates the following dangers:

♦ Reduced service life due to damage from vibration (dan‐

ger of explosion)

♦ The cells in the battery will be damaged if the battery is

not secured correctly.

♦ Damage to battery housing by securing bracket (possibil‐

ity of acid leaking, with high consequential costs)

♦ Poor crash safety

Amarok 2011 ➤

Electrical system - Edition 01.2011

Installation is carried out in the reverse sequence. Observe the
following when doing this:

– Insert holder and tighten securing bolt -arrow- to a specified

torque of 23 Nm.

When doing this, ensure that hose for central gas venting (if fitted)
is installed on battery and is not trapped during installation. Only
then can the battery vent freely.

– After installing battery, check it is firmly seated. A loosely fitted

battery creates the following dangers:

♦ Shortened service life due to damage from vibration (danger

of explosion)

♦ The plates in the battery cells will be damaged if the battery is

not secured correctly.

♦ Damage to battery housing by securing bracket (possibility of

acid leaking, with high consequential costs)

♦ Poor crash safety

– Connecting battery ⇒ page 53 .

Note

When batteries are connected, the procedure described in the
workshop manual must be strictly followed ⇒ page 51 .

5.2 Specified torques: battery

Threaded connection

Terminal clamps battery -A- M6 6 Nm

Specified torques

5. Removing and installing battery 55

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Amarok 2011 ➤
Electrical system - Edition 01.2011

Threaded connection

Specified torques

Bracket securing bolt battery -A- M 8x35 23 Nm

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

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6 Starter

Caution

To disconnect and connect the battery, the procedure descri‐
bed in the workshop manual should be strictly adhered to

⇒ page 51 .

Amarok 2011 ➤

Electrical system - Edition 01.2011

6.1 Checking starter

– Connecting vehicle diagnosis, testing and information system

-VAS 5051- ⇒ page 179

– Select „Guided fault finding“ in vehicle diagnosis, testing and

information system -VAS 5051- .

– Using „GoTo“ button, select „Functions/component“ and the

following menu options in succession:

♦ Body

♦ Electrical system

♦ 27 - Starter, current supply

♦ Electrical components

♦ B - Starter

6.2 Removing and installing starter, 4-cylin‐

Caution

Please note the following points during all assembly work, in
particular in the engine compartment, due to the narrow instal‐
lation conditions:

♦ Route electrical wiring so that original wiring layout is re‐

der diesel engine with manual gearbox

stored.

♦ Make sure there is adequate clearance from all moving or

hot components.

Special tools and workshop equipment required

♦ Torque wrench (5 - 50 Nm) -V.A.G 1331-

6. Starter 57

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Amarok 2011 ➤
Electrical system - Edition 01.2011

♦ Torque wrench (40 - 200 Nm) -V.A.G 1332-

6.2.1 Removing:

Caution

To disconnect and connect the battery, the procedure descri‐
bed in the workshop manual should be strictly adhered to

⇒ page 51 .

Carry out the following work:

– Switch off ignition and all electrical loads, and pull out ignition

key.

– Disconnect battery ⇒ page 51 .

– Remove underbody guard.

In order to tighten the securing bolts of the starter with a torque
wrench during installation, it is necessary to remove the particu‐
late filter so that sufficient space can be provided for the tool.

– Removing particulate filter ⇒ Rep. gr. 26 .

– Unclip sheathing of cable connections -arrows- to starter and

pull down.

– Release terminal 50 connector -1- from starter and pull off.

Unscrew securing nut -2- of terminal 30 from starter.

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

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– Unscrew earth connection from starter -arrow-.

– Remove securing bolts -arrows- from starter. The best way to

reach upper bolt is from gearbox side. The best way to reach
lower bolt is from engine side.

– To remove starter, unscrew bracket of coolant line from engine

at top -arrow-.

– Unscrew oil return connection piece -1- and place to one side.

Wipe up any escaping engine oil with a cloth. Also unscrew
bracket of coolant line -2- and push coolant line upwards.

– Release oil return line from turbocharger at bottom. Push oil

return line a little away from cylinder block so that starter can
be guided out.

Amarok 2011 ➤

Electrical system - Edition 01.2011

6. Starter 59

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Amarok 2011 ➤
Electrical system - Edition 01.2011

– Rotate starter -1- a little if required and remove it forwards.

6.2.2 Installing:

Installation is carried out in the reverse sequence. Observe the
following when doing this:

– Tighten threaded connections to specified torque given in as‐

sembly overview ⇒ page 63 .

6.3 Removing and installing starter, 4-cylin‐
der TFSI petrol engine with manual
gearbox

Caution

Please note the following points during all assembly work, in
particular in the engine compartment, due to the narrow instal‐
lation conditions:

♦ Route electrical wiring so that original wiring layout is re‐

stored.

♦ Make sure there is adequate clearance from all moving or

hot components.

Special tools and workshop equipment required

♦ Torque wrench (5 - 50 Nm) -V.A.G 1331-

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

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♦ Torque wrench (40 - 200 Nm) -V.A.G 1332-

6.3.1 Removing:

Caution

To disconnect and connect the battery, the procedure descri‐
bed in the workshop manual should be strictly adhered to

⇒ page 51 .

Carry out the following work:

– Switch off ignition and all electrical loads, and pull out ignition

key.

– Disconnect battery ⇒ page 51 .

– Remove underbody guard.

– Removing catalytic converter ⇒ Rep. gr. 26 .

– Unscrew bolts -arrows- on heat shield above starter and re‐

move heat shield.

– Unscrew earth cable connection -arrow- on starter.

Amarok 2011 ➤

Electrical system - Edition 01.2011

6. Starter 61

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Amarok 2011 ➤
Electrical system - Edition 01.2011

– Detach guide tube for wiring connections from starter by un‐

screwing gearbox securing bolt -arrow-.

– Unclip wiring connections on plastic bracket on top of gearbox.

– Release and pull off terminal 50 connector -arrow- on starter.

– Unscrew terminal 30 securing nut -arrow- on starter.

– Unscrew earth connection from starter -arrow-.

– Unscrew securing bolt -arrow- on starter. The best way to

reach upper bolt is from gearbox side.

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

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– Unscrew securing bolt -arrow- on starter. The best way to

reach lower bolt is from engine side.

– Guide out starter in direction of -arrow- between engine sup‐

port and gear casing (gearbox).

Amarok 2011 ➤

Electrical system - Edition 01.2011

6.3.2 Installing:

Installation is carried out in the reverse sequence. Observe the
following when doing this:

DANGER!

When connecting terminal 30 on starter, it is essential that con‐
nection terminal 30 -2- is turned on mounting pin in direction of
arrow until it comes into contact with plastic stop -1- on starter.
Tighten nut in this position.

If this is not done, the terminal 30 connection of the starter may
come into contact with the turbocharger housing, which in turn
would cause a short circuit between the starter motor and the
battery.

– Tighten threaded connections to torque specified in assembly

overview ⇒ page 63 .

6.4 Specified torques: starter

Threaded connection

Securing bolts of starter -B- M12 75 Nm
Securing nuts for positive ca‐

ble or negative cable and ca‐
ble bracket

Specified torques

20 Nm

6. Starter 63

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Amarok 2011 ➤
Electrical system - Edition 01.2011

7 Alternator

Caution

Please note the following points during all assembly work, in
particular in the engine compartment, due to the narrow instal‐
lation conditions:

♦ Route electrical wiring so that original wiring layout is re‐

stored.

♦ Make sure there is adequate clearance from all moving or

hot components.

7.1 Checking alternator

– Connecting vehicle diagnosis, testing and information system

-VAS 5051- ⇒ page 179

– Select „Guided fault finding“ in vehicle diagnosis, testing and

information system -VAS 5051- .

– Using „GoTo“ button, select „Functions/component“ and the

following menu options in succession:

♦ Body

♦ Electrical system

♦ 27 - Starter, current supply

♦ Electrical components

♦ C - Alternator

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

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7.2 Removing and installing alternator, 4­cylinder diesel engine with manual gear‐
box

7.2.1 Assembly overview - alternator

1 - Hexagon bolt with washer
and threaded element

❑ M4 x 20, M4 x 15.
❑ 2 Nm

2 - Protective cap for alternator

3 - Cross-head screws

❑ M4 x 20.
❑ 2 Nm

4 - Protective cap for carbon
brushes

5 - Voltage regulator

❑ Removing and installing

voltage regulator

⇒ page 73

6 - Alternator

❑ Removing and installing

alternator ⇒ page 65

❑ Checking alternator

⇒ page 64

❑ Securing B+ wire to al‐

ternator ⇒ page 73

❑ Removing and installing

poly V-belt pulley on al‐
ternator ⇒ page 75

7 - Poly V-belt

8 - Hexagon head flange bolts

❑ M8 x 90.
❑ 20 Nm

Amarok 2011 ➤

Electrical system - Edition 01.2011

7.2.2 Removing and installing alternator

Caution

When batteries are disconnected and reconnected, the proce‐
dure described in the workshop manual must be strictly ob‐
served ⇒ page 51 .

Special tools and workshop equipment required

7. Alternator 65

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Amarok 2011 ➤
Electrical system - Edition 01.2011

♦ Torque wrench -V.A.G 1331-

♦ Locking pin -T10060 A-

Removing:

Carry out the following work:

– Switch off ignition and all electrical loads, and pull out ignition

key.

– Disconnect battery ⇒ page 51 .

– Loosen poly V-belt ⇒ Power unit; Rep. gr. 13 ; Dismantling

and assembling engine .

– Remove charge pressure pipes -1- in area of alternator.

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

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– Unscrew bracket of coolant line from engine at top -arrow-.

– Push coolant line -1- to one side and secure to fuel line using

a cable tie -2-.

– Unlock and separate connector of DF cable -1-.

– Lever off deflector cap -2-.

– Unscrew securing nut and B+ cable below it from connection

thread of alternator.

Amarok 2011 ➤

Electrical system - Edition 01.2011

– Remove both securing bolts -arrows- of alternator.

– Remove alternator from bracket and turn it so rear side is fac‐

ing upwards.

7. Alternator 67

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Amarok 2011 ➤
Electrical system - Edition 01.2011

– Use a long screwdriver to release retaining clip -arrow- of wir‐

ing connector from alternator.

– Remove alternator -1- upwards out of engine compartment.

Installing:

Installation is carried out in reverse order of removal. Observe the
following when doing this:

Caution

♦ When fitting used poly V-belts observe the direction of ro‐

tation marked on removal!

♦ Before installing poly V-belt, ensure that all ancillaries (al‐

ternator, air conditioner compressor) are secure.

♦ When fitting belt, ensure that poly V-belt seats correctly in

pulleys!

– Drive threaded sleeve -A- about 4 mm in direction of arrow out

of alternator housing.

– Tighten threaded connections to specified torque given in as‐

sembly overview ⇒ page 72 .

Caution

When batteries are disconnected and reconnected, the proce‐
dure described in the workshop manual must be strictly ob‐
served ⇒ page 51 .

– Connecting battery ⇒ page 51 .

– Start engine and check belt running.

– Stop engine.

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

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Amarok 2011 ➤

Electrical system - Edition 01.2011

7.3 Removing and installing alternator, 4­cylinder TSI petrol engine

7.3.1 Assembly overview - alternator

1 - Hexagon head flange bolt

❑ M8x110
❑ 20 Nm

2 - Cross-head screws

❑ M4x19
❑ 2 Nm

3 - Washer

❑ M5

4 - Cross-head screw

❑ M5x21
❑ 4.5 Nm

5 - Hexagon nut

❑ M8
❑ 15 Nm

6 - Hexagon nut, flat

❑ M8

7 - Protective cap for alternator

8 - Cross-head screw

9 - Voltage regulator

❑ M4x13
❑ 2 Nm

❑ Removing and installing

voltage regulator

⇒ page 73

10 - Alternator

❑ Removing and installing

alternator ⇒ page 70

❑ Checking alternator

⇒ page 64

❑ Securing B+ wire to alternator ⇒ page 73
❑ Removing and installing poly V-belt pulley ⇒ page 75

11 - Poly V-belt

❑ Removing and installing ⇒ Power unit; Rep. gr. 13 ; Dismantling and assembling engine
❑ Checking ⇒ page 73
❑ Poly V-belt routing ⇒ Power unit; Rep. gr. 13 ; Dismantling and assembling engine

7. Alternator 69

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Amarok 2011 ➤
Electrical system - Edition 01.2011

7.3.2 Removing and installing alternator

Caution

When batteries are disconnected and reconnected, the proce‐
dure described in the workshop manual must be strictly ob‐
served ⇒ page 51 .

Special tools and workshop equipment required

♦ Torque wrench -V.A.G 1331-

♦ Bit -T40098-

♦ Hose clamps up to 25 mm dia. -3094-

Removing:

Carry out the following work:

– Switch off ignition and all electrical loads, and pull out ignition

key.

– Disconnect battery ⇒ page 51 .

– Loosen poly V-belt ⇒ Power unit; Rep. gr. 13 ; Dismantling

and assembling engine .

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

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– Unscrew hose connection on charge pressure pipe -2- and pull

off. Unscrew bolt -1- and place charge pressure pipe to one
side.

– Clamp off coolant hose on upper radiator connection using

hose clamps up to 25 mm -3094- and pull off.

– Unscrew bolts -arrows- on top of alternator and place bracket

with radiator hose to one side.

– Disconnect connector -1-.

Amarok 2011 ➤

Electrical system - Edition 01.2011

– Unscrew bolts -arrows- on bottom of alternator.

– Swing alternator to side.

7. Alternator 71

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Amarok 2011 ➤
Electrical system - Edition 01.2011

– Unscrew positive connection -2-.

– Remove alternator upwards.

Installing:

Installation is carried out in reverse order of removal. Observe the
following when doing this:

Caution

♦ When fitting used poly V-belts observe the direction of ro‐

tation marked on removal!

♦ Before installing poly V-belt, ensure that all ancillaries (al‐

ternator, air conditioner compressor) are secure.

♦ When fitting belt, ensure that poly V-belt seats correctly in

pulleys!

– Tighten threaded connections to specified torque given in as‐

sembly overview ⇒ page 72 .

Caution

When batteries are disconnected and reconnected, the proce‐
dure described in the workshop manual must be strictly ob‐
served ⇒ page 51 .

– Connecting battery ⇒ page 51 .

– Start engine and check belt running.

– Stop engine.

7.4 Specified torques: alternator

Threaded connection

B+ cable on alternator M8 15 Nm
Tensioning element securing

bolts
Alternator bracket to cylinder

block

Specified torques

M8 20 Nm

M8 20 Nm

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

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8 Repairing alternator

Caution

To disconnect and connect the battery, the procedure descri‐
bed in the workshop manual should be strictly adhered to

⇒ page 51 .

8.1 Securing B+ cable on alternator

The specified torque for the battery positive cable -arrow- secur‐
ing nut is 15 Nm.

Caution

If the battery positive cable is not tightened to the specified
torque, the following risks exist:

♦ The battery will not be charged fully.

♦ Vehicle electrics or electronics fail completely (break‐

down).

♦ Danger of fires from sparks

♦ Damage to electronic components and control units due

to excessive voltage

8.2 Checking poly V-belt

Carry out the following work:

– Crank engine at vibration damper on pulley using a socket.

– Check poly V-belt for:

♦ Sub-surface cracks (cracks, core ruptures, cross sectional

♦ Layer separation (top layer, cord strands)

♦ Base break-up

♦ Fraying of cord strands

♦ Flank wear (material wear, frayed flanks, flank brittleness -

♦ Traces of oil and grease

If faults are found, it is essential for the poly V-belt to be re‐
newed. This will avoid possible breakdowns or operating prob‐
lems.

8.3 Removing and installing voltage regula‐

breaks)

glassy flanks-, surface cracks)

Caution

tor

Amarok 2011 ➤

Electrical system - Edition 01.2011

Special tools and workshop equipment required

8. Repairing alternator 73

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Amarok 2011 ➤
Electrical system - Edition 01.2011

♦ Torque wrench (5 - 50 Nm) -V.A.G 1331-

Removing:

Carry out the following work:

– Remove alternator.

– Unscrew nuts -1- and bolt -2- and remove deflector cap -3-.

– Remove securing bolts -arrows- of voltage regulator.

– Carefully remove voltage regulator from alternator.

Installing:

Installation is carried out in the reverse sequence. Observe the
following when doing this:

– Tighten nuts -1- of deflector cap -3- to 15 Nm.

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

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8.4 Checking alternator carbon brushes

Note

The carbon brushes are permanently attached to the voltage reg‐
ulator. In the event of repair, renew voltage regulator.

Carry out the following work:

– Removing voltage regulator ⇒ page 73 .

– Measure length of carbon brushes, dimension -a-.

Carbon brushes Length -a-

New 12 mm
Wear limit 5 mm
Tolerances to one another +1 mm

8.5 Removing and installing pulley on alter‐
nator

Special tools and workshop equipment required

♦ Torque wrench (40 - 200 Nm) -V.A.G 1332-

♦ Multipoint adapter -3400-

Amarok 2011 ➤

Electrical system - Edition 01.2011

Removing:

Carry out the following work:

– Remove alternator.

– Clamp alternator in a vice.

8. Repairing alternator 75

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Amarok 2011 ➤
Electrical system - Edition 01.2011

– Remove deflector cap from belt pulley.

– Screw in multipoint adapter 3400 -1- with ring spanner (17

mm) in belt pulley -2- of alternator. Then insert multipoint bit ­M10- -3- in alternator shaft.

– Unscrew threaded connection whilst counterholding with ring

spanner.

– Hold pulley stationary by hand and turn alternator input shaft

Installing:

Installation is carried out in the reverse sequence. Observe the
following when doing this:

– First screw belt pulley on drive shaft of alternator by hand onto

For assembly of belt pulley, torque wrench must be modified as
follows:

– Release socket drive -1- and pull off grip -2-.

– Turn torque wrench grip -2- 180° and reinsert socket drive.

– Set turning direction of torque wrench to anti-clockwise at

until pulley can be removed.

stop.

socket drive.

– Counterhold multipoint adapter 3400 -1- using ring spanner

(17 mm). Tighten poly V-belt by turning drive shaft of alternator
anticlockwise using the torque wrench -2-. Tightening torque
is 80 Nm.

– Clip deflector cap in place on belt pulley.

– Install alternator.

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

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9 Cruise control system (CCS)

9.1 Activating and deactivating cruise con‐
trol system (CCS)

– Connecting vehicle diagnosis, testing and information system

-VAS 5051- ⇒ page 179 .

– Select „Guided fault finding“ in vehicle diagnosis, testing and

information system -VAS 5051- .

– Using „GoTo“ button, select „Functions/component“ and the

following menu options in succession:

♦ Drive

♦ Select the engine installed in each case

♦ 01 - On Board Diagnostic capable systems

♦ Motronic engine management system (petrol engine)

♦ Diesel direct injection system and glow plug system EDC 16

(for diesel engine)

♦ Functions

♦ Activating and deactivating cruise control system (CCS)

9.2 CCS switch

The injection control unit also controls the functions of the cruise
control system. The cruise control system is operated using the
CCS switch -E45- in the steering column switch.

The self-diagnosis of the CCS switch -E45- is carried out using
the vehicle diagnosis, testing and information system ­VAS 5051- .

– Connecting vehicle diagnosis, testing and information system

-VAS 5051- ⇒ page 179 .

– Select „Guided fault finding“ in vehicle diagnosis, testing and

information system -VAS 5051- .

– Using „GoTo“ button, select „Functions/component“ and the

following menu options in succession:

♦ Drive

♦ 01 - On Board Diagnostic capable systems

♦ Electrical components

♦ CCS switch -E45-

Removing and installing steering column switch ⇒ page 143 .

Amarok 2011 ➤

Electrical system - Edition 01.2011

9. Cruise control system (CCS) 77

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.

Amarok 2011 ➤
Electrical system - Edition 01.2011

90 – Gauges, instruments

1 Dash panel insert

Note

The control unit in the dash panel insert -J285- , control unit for
immobiliser -J362- and the diagnosis interface for data bus -J533­are integrated in the dash panel insert and cannot be renewed
individually.

Fault detection and fault display:

The dash panel insert is equipped with self-diagnosis to ease fault
finding.

For fault finding, use vehicle diagnosis, testing and information
system -VAS 5051- in „Guided fault finding“ mode.

1.1 Renewing dash panel insert

Note

♦

If a new dash panel insert is installed in the vehicle, the control
unit of the dash panel insert must be adjusted to the different
combination possibilities depending on the associated country
settings, number of cylinders and engine type.

♦

To adapt the integrated immobiliser to the engine control unit,
the data from the engine control unit has to be stored in the
replacement dash panel insert.

♦

After installing a new dash panel insert, all ignition keys must
be adapted.

– Connecting vehicle diagnosis, testing and information system

-VAS 5051- ⇒ page 179

– Select „Guided fault finding“ in vehicle diagnosis, testing and

information system -VAS 5051- .

– Using „GoTo“ button, select „Functions/component“ and the

following menu options in succession:

♦ Body

♦ Electrical system

♦ 01 - On Board Diagnostic capable systems

♦ Dash panel insert

♦ Functions of dash panel insert

♦ Adapting/renewing dash panel insert

1.2 Removing and installing dash panel in‐

Special tools and workshop equipment required

sert

78 Rep. gr.90 - Gauges, instruments

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♦ Socket -T10113-

Removing:

Note

If dash panel insert is to be renewed ⇒ page 78 .

Carry out the following work:

– Switch off ignition and all electrical loads, and pull out ignition

key.

– Using electric or mechanical adjustment mechanism, extend

steering wheel completely and move to lowest position.

– Unclip trim between steering column and dash panel insert

-arrows-.

Amarok 2011 ➤

Electrical system - Edition 01.2011

– Using socket -T10113- , unscrew securing bolts -arrows- of

dash panel insert.

Note

Steering wheel and steering column trim do not have to be re‐
moved to do this.

– Take out dash panel insert.

1. Dash panel insert 79

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Amarok 2011 ➤
Electrical system - Edition 01.2011

– Disconnect connector -A- on rear of dash panel insert by

pressing clip and moving bar -B- in -direction of arrow-.

Note

The dash panel insert must not be dismantled.

Installing:

Installation is carried out in the reverse sequence. Observe the
following when doing this:

– Connect connector and insert dash panel insert into dash pan‐

el insert aperture.

– Tighten securing bolts -arrows- of dash panel insert using

socket -T10113- .

Torque setting: 1.5 Nm.

– Following installation, check functions of dash panel insert.

1.3 Adjusting functions on dash panel insert

– Connecting vehicle diagnosis, testing and information system

-VAS 5051- ⇒ page 179

– Select „Guided fault finding“ in vehicle diagnosis, testing and

information system -VAS 5051- .

– Using „GoTo“ button, select „Functions/component“ and the

following menu options in succession:

♦ Body

♦ Electrical system

♦ 01 - On Board Diagnostic capable systems

♦ Dash panel insert

♦ Functions of dash panel insert

– Select corresponding step on vehicle diagnosis, testing and

information system -VAS 5051- .

80 Rep. gr.90 - Gauges, instruments

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2 Service interval display

2.1 Resetting service interval display

Resetting the service interval display ⇒ Maintenance ; Booklet
11 or ⇒ page 80

Amarok 2011 ➤

Electrical system - Edition 01.2011

2. Service interval display 81

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Amarok 2011 ➤
Electrical system - Edition 01.2011

92 – Windscreen wash/wipe system

1 Windscreen wiper system

Note

Additional information in ⇒ Maintenance ; Booklet 11 .

1.1 Removing and installing wiper blades

1.1.1 Removing:

Carry out the following work:

To remove the wiper blades, the wiper arms should be placed in
the „service/winter position“. The „service/winter position“ is acti‐
vated within 10 seconds after ignition is switched off by pressing
windscreen wiper lever in „tip wipe“ position ⇒ Operating manual
of vehicle .

– Switch off ignition and all electrical loads, and pull out ignition

key.

– Fold windscreen wiper arm -2- away from windscreen.

Note

♦

Avoid bending windscreen wiper arm and blade.

♦

Avoid wiper arm springing back unintentionally and damaging
the glass.

– Look for a position between windscreen wiper arm and wiper

blade where joint can easily be removed (this may differ from
what is shown in illustration).

– Push wiper blade securing spring -1- in the direction of

-arrow 1-.

– Disengage windscreen wiper blade -1- and remove it from

wiper arm -2- in direction of -arrow 2-.

1.1.2 Installing:

– Attach windscreen wiper blade -1- in the opposite sequence.

When doing this, make sure that longer windscreen wiper
blade is mounted on driver side.

– Look for a position between windscreen wiper arm and wiper

blade where joint can easily be installed (this may differ from
what is shown in illustration).

– Insert joint piece of wiper blade -1- into guide of wiper arm

-2-.

– Press securing spring -arrow 1- thereby pushing the joint piece

into the guide -arrow 2- until it is positioned fully in the guide.

– Fold windscreen wiper arm back against windscreen.

– Check park position of windscreen wiper blades and adjust if

necessary ⇒ page 89 .

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

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1.2 Removing wiper arms

Special tools and workshop equipment required

♦ Torque wrench (5 - 50 Nm) -V.A.G 1331-

1.2.1 Removing:

Carry out the following work:

– Lever off cap -arrow- using screwdriver.

– Loosen hexagon nut -arrow- but do not remove completely.

– Move wiper arm lightly until it becomes loose.

– Unscrew hexagon nut fully and pull wiper arm off wiper arm

shaft.

– Remove second wiper arm in same way.

Amarok 2011 ➤

Electrical system - Edition 01.2011

1.2.2 Installing:

– Put wiper arms on their shafts on driver and front passenger

sides.

– Screw securing nut loosely onto wiper arm shaft.

Note

♦

The securing nut of the wiper arm shaft should not be tightened
until the windscreen wiper blade parking position has been
adjusted.

♦

If wiper arms are secured with self-locking nuts, these must be
renewed on reinstallation.

1. Windscreen wiper system 83

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Amarok 2011 ➤
Electrical system - Edition 01.2011

– Adjust wiper blade park position ⇒ page 89 .

– Tighten securing nuts of wiper arms to 20 Nm.

– Fit caps.

1.3 Removing wiper frame with linkage and wiper motor

Special tools and workshop equipment required

♦ Torque wrench (5 - 50 Nm) -V.A.G 1331-

Note

♦

On RHD vehicles, the wiper blades are a mirror image of those
on LHD vehicles.

♦

In order for wiper frame to be removed with linkage and wiper
motor, wiper arms and plenum chamber cover must be re‐
moved.

♦

Before removing wiper arms, make sure that wiper motor is in
park position. Only then can the wiper arm park position be
correctly set when installing.

1.3.1 Removing:

Carry out the following work:

– Move wipers to park position.

– Switch off ignition and all electrical loads, and pull out ignition

key.

– Removing wiper arms ⇒ page 83

The plenum chamber cover is inserted into a guide rail beneath
the windscreen.

– Remove end sections -arrow- from rubber guide rail on left and

right.

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

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.

– Unclip angle piece -arrow- of washer fluid line from plenum

chamber cover.

– Carefully unclip plenum chamber cover upwards -arrows-.

Note

Amarok 2011 ➤

Electrical system - Edition 01.2011

For reasons of clarity, the figure shows a plenum chamber cover
which has been removed.

– Remove cover.

– Remove securing bolts -arrows-.

– Remove wiper linkage from plenum chamber and turn so that

connector -arrow- can be pulled off.

– Remove wiper frame complete.

1.3.2 Installing:

Installation is carried out in the reverse sequence. Observe the
following when doing this:

– Tighten securing bolts for wiper frame to 5 Nm.

1. Windscreen wiper system 85

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Amarok 2011 ➤
Electrical system - Edition 01.2011

1.4 Removing and installing windscreen wiper motor

Special tools and workshop equipment required

♦ Release lever -80-200-

Note

♦

On RHD vehicles, the wiper blades are a mirror image of those
on LHD vehicles.

♦

In order for wiper motor to be removed, wiper frame must be
removed with linkage and wiper motor.

1.4.1 Removing:

Carry out the following work:

– Move wipers to park position.

– Switch off ignition and all electrical consumers.

– Removing wiper arms ⇒ page 83

The plenum chamber cover is inserted into a guide rail beneath
the windscreen.

– Remove end sections -arrow- from rubber guide rail on left and

right.

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

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.

Electrical system - Edition 01.2011

– Unclip angle piece -arrow- of washer fluid line from plenum

chamber cover.

– Carefully unclip plenum chamber cover upwards -arrows-.

Note

For reasons of clarity, the figure shows a plenum chamber cover
which has been removed.

– Remove cover.

Note

Make sure that the wiper crank is in such a position that no se‐
curing bolts of the bearing are hidden. Therefore, before removing
wiper frame with linkage and wiper motor, switch on windscreen
wipers and have an assistant observe wiper crank. Then, at a
suitable moment (no mounting bolt concealed), switch off the ig‐
nition.

Amarok 2011 ➤

– Switch off ignition and all electrical loads, and pull out ignition

key.

– Remove securing bolts -arrows-.

– Remove wiper linkage from plenum chamber and turn so that

connector -arrow- can be pulled off.

– Remove wiper frame complete.

1. Windscreen wiper system 87

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Amarok 2011 ➤
Electrical system - Edition 01.2011

– Use release lever -80-200- to lever drive rods -1- and -2- of

wiper arms off crank -3- of wiper motor.

– Unscrew wiper motor from wiper frame -arrows-.

1.4.2 Installing:

Note

On new wiper motors, the wiper crank is already set to the correct
installation position. Therefore, do not operate the wiper motor
electrically until the entire wiper unit has been installed.

– On new wiper motor -1- unscrew securing bolts -2- out of pre-

tapped holes in bracket.

– Lubricate seals -1- (small outer ∅) and -2- (larger outer ∅)

using grease from repair kit (see illustration).

– Insert wiper motor into bracket of wiper linkage and align in

upper part of bracket.

– Put on upper part of bracket and position self-tapping securing

bolts -3-. When installing, ensure that the bolts are not canted
in the pre-tapped holes and ensure that the wiper linkage is
engaged correctly in the upper part of the bracket.

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

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.

– Insert wiper motor into bracket of wiper linkage -2- and align

in upper part of bracket in line with locking bracket.

– Put on upper part of bracket and position self-tapping securing

bolts -3-. When installing, ensure that the bolts are not canted
in the pre-tapped holes and ensure that the wiper linkage is
engaged correctly in the upper part of the bracket.

– Next, tighten securing bolts to 8 Nm.

– Press lubricated seal -4- (small outer ∅) over ball head of

crank -5- of wiper motor.

– Press articulated rod for right wiper -3- over ball head of wiper

motor.

– Press lubricated seal -2- (larger outer ∅) onto articulated rod

-3-.

Note

Pay attention to installation position of seals during installation.

– Press articulated rod of left side -1- onto ball head.

– Attach connector to wiper motor.

– Install wiper frame with linkage and wiper motor ⇒ page 84 .

– To maintain end position of wiper motor, switch windscreen

wiper to stage 1 for approx. 3 seconds.

– Switch off ignition. Install plenum chamber cover and wiper

arms ⇒ page 83 .

1.5 Adjusting wiper blade park position

1.5.1 Adjusting wiper blade park position

Special tools and workshop equipment required

♦ Torque wrench (5 - 50 Nm) -V.A.G 1331-

Amarok 2011 ➤

Electrical system - Edition 01.2011

Note

On RHD vehicles, the wiper blades are a mirror image of those
on LHD vehicles.

1. Windscreen wiper system 89

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Amarok 2011 ➤
Electrical system - Edition 01.2011

Carry out the following work:

– Adjust wiper arms so that ends of wiper blades are located on

windscreen in area of markings -A- or -B-.

– Tighten securing nuts of wiper arms to 20 Nm.

– Allow windscreen wiper system to operate in wipe/wash func‐

tion as a test. When doing this, make sure that wiper blades
do not strike against upper or lower end positions. If neces‐
sary, correct windscreen wiper blade end position again.

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

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Electrical system - Edition 01.2011

2 Windscreen washer system

Note

Additional information in ⇒ Maintenance ; Booklet 11 .

2.1 Assembly overview - windscreen washer system

1 - Left and right-hand wind‐
screen wiper arms

2 - Spray jets for windscreen
washer system

❑ Vertical adjustment on‐

ly, setting spray jets

⇒ page 95

❑ Removing and installing

⇒ page 94 .

❑ Checking ⇒ page 95

3 - Wiper frame with linkage
and wiper motor

❑ Removing and installing

⇒ page 84 .

4 - Y-piece

❑ Distribution of washer

fluid line to windscreen
spray jets

5 - Windscreen wash pump ­V59-

❑ Removing and installing

⇒ page 93 .

6 - Washer fluid reservoir

❑ Removing and installing

⇒ page 92 .

7 - Connection piece

❑ Connection to washer

fluid lines for spray jet
for windscreen washer
system

Amarok 2011 ➤

2.2 Removing and installing filler pipe for windscreen washer reservoir

2.2.1 Removing:

Carry out the following work:

– Drain windscreen washer reservoir until water level has drop‐

ped below opening for filler pipe.

2. Windscreen washer system 91

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Amarok 2011 ➤
Electrical system - Edition 01.2011

– Remove securing bolt -arrow- of filler pipe.

– Pull filler pipe -B- out of windscreen washer reservoir -A- in

-direction of arrow-.

2.2.2 Installing:

Installation is carried out in the reverse sequence. Observe the
following when doing this:

– Check seal at base of filler pipe for signs of damage, renew if

necessary.

– Insert filler pipe in windscreen washer reservoir onto stop (use

lubrication if necessary). When doing this, note position of anti­rotation tab.

– Tighten securing bolt for filler pipe to 2 Nm.

2.3 Removing and installing windscreen washer reservoir

2.3.1 Removing:

Carry out the following work:

– Switch off ignition and all electrical loads, and pull out ignition

key.

Removing and installing filler pipe for windscreen washer reser‐
voir ⇒ page 91 .

– Remove front right wheel housing trim.

– Pull black hose connector off windscreen wash pump.

– Collect leaking fluid in accordance with regulations.

– Disconnect electric cable connectors for windscreen wash

pump.

– Unclip wiring connector attachment from bracket of wind‐

screen washer reservoir.

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

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– Remove bolts -arrows- from windscreen washer reservoir.

– Remove windscreen washer reservoir.

Note

For improved clarity, installation location of windscreen washer
reservoir is shown in illustration without wing.

2.3.2 Installing:

Installation is carried out in the reverse sequence. Observe the
following when doing this:

– Check seal at base of filler pipe for signs of damage, renew if

necessary.

– Insert filler pipe in windscreen washer reservoir onto stop (use

lubrication if necessary). When doing this, note position of anti­rotation tab.

– Tighten securing bolts of reservoir for windscreen and head‐

light washer system to 3.5 Nm.

2.4 Removing and installing windscreen wash pump

Windscreen wash pump is mounted on windscreen washer res‐
ervoir on right wheel housing.

2.4.1 Removing:

Carry out the following work:

– Switch off ignition and all electrical loads, and pull out ignition

key.

– Remove front right wheel housing trim.

– Remove windscreen wash pump -A- from windscreen washer

reservoir in -direction of arrow-.

– Pull black hose connector off windscreen wash pump.

– Collect leaking fluid in accordance with regulations.

– Disconnect electric cable connectors for windscreen wash

pump.

2.4.2 Installing:

Amarok 2011 ➤

Electrical system - Edition 01.2011

Install in reverse order of removal.

2. Windscreen washer system 93

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Amarok 2011 ➤
Electrical system - Edition 01.2011

2.5 Removing and installing windscreen washer system spray jets

2.5.1 Removing:

Carry out the following work:

– Lever out spray jet using a suitable screwdriver at points

marked with -arrows-.

– Pull out retaining clip -1- in direction of arrow -A-.

– Disconnect hose connection -1- from spray jet -2-.

2.5.2 Installing:

– Push hose connection together.

– Clip spray jet into mounting hole.

– Check spray jet ⇒ page 95 .

– Adjusting washer jets if necessary ⇒ page 95 .

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