Volkswagen Bora 2006 User Manual

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Service

Workshop Manual

Jetta 2005 ➤
Bora 2006 ➤

Electrical System

Edition 05.2005

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, CC

90 - Instruments, GCI

92 - Windscreen wash/wipe system

94 - Lights, lamps, switches - outside

96 - Lights, lamps, switches - inside

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 © 2010 Volkswagen AG, Wolfsburg MEX5R005820

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Jetta 2005 ➤ , Bora 2006 ➤

Electrical System - Edition 05.2005

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

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

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

1.2 Types of battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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

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

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

2.1 Procedure when checking the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.2 Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.3 Checking battery with magic eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.4 Checking low maintenance battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.5 Check no load voltage of battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.6 Battery tester with printer VAS 5097 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.7 Evaluating test result . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3 Charging battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.1 Battery charger VAS 5095 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.2 Battery charger VAS 5900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.3 Totally discharged batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4 Disconnecting and reconnecting batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.1 Disconnecting battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.2 Connecting battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5 Removing and installing battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

5.1 Models with a petrol engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Contents

5.2 Models with a diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

6 Torque settings: battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

7 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

7.1 Checking starter B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

7.2 Removing and installing starter, automatic gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

7.3 Removing and installing starter, automated shift gearboxes . . . . . . . . . . . . . . . . . . . . . . . . 58

7.4 Removing and installing starter, manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

8 Torque settings: starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

9 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

9.1 Fastening B+ wire to alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

9.2 Checking ribbed belt (poly V-belt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

9.3 Check alternator C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

9.4 Alternator, 1.6 l injection engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

9.5 Alternator, 1.6 l FSI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

9.6 Alternator, 2.0 l FSI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

9.7 Alternator, 2.0 l FSI turbo engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

9.8 Alternator 2.5 l injection engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

9.9 Alternator, 1.9 l TDI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

9.10 Alternator, 2,0 l TDI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

9.11 Removing and installing ribbed belt (poly V-belt) pulley on alternator . . . . . . . . . . . . . . . . 137

9.12 Voltage regulator for alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

10 Torque settings: alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

10.1 General torque settings for all vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

10.2 1.6 l injection engine and 2.0 l FSI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

10.3 2.0 l FSI turbo engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

10.4 1.9 l and 2.0 l TDI engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

10.5 2.5 l injection engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

11 Cruise control system (CCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

Contents i

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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005

11.1 Activating and deactivating cruise control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

90 - Instruments, GCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

1 Dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

1.1 Renewing dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

1.2 Removing and installing dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

1.3 Description of reverse side of dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

1.4 Warning lamp symbols in dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

2 Service interval display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

2.1 Resetting service interval display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

92 - Windscreen wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

1 Windscreen wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

1.1 Deactivating APP function of wiper motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

1.2 Removing and installing the windscreen wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

1.3 Removing and installing wiper arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

1.4 Adjusting wiper blade park position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

1.5 Removing and installing aerodynamic wipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

1.6 Removing and installing rain and light detector sensor G397 . . . . . . . . . . . . . . . . . . . . . . 163

2 Windscreen washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

2.1 Assembly overview of windscreen washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

2.2 Removing and installing reservoir for windscreen and headlight washer systems . . . . . . 166

2.3 Removing and installing washer pump V5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

2.4 Removing and installing windscreen washer spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

2.5 Adjusting front windscreen washer system spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

3 Headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

3.1 Assembly overview - headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

3.2 Removing and installing headlight washer system pump V11 . . . . . . . . . . . . . . . . . . . . . . 171

3.3 Removing and installing pop-up spray jet cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

3.4 Removing and installing spray jet assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

3.5 Adjusting headlight washer system jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

3.6 Bleeding the headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

4 Wash water line hose couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

4.1 Windscreen and rear window washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

4.2 Headlight washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

5 Hose repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

5.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

5.2 Repairing smooth pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

5.3 Repairing corrugated pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

6 Torque settings: Windscreen wash/wipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

94 - Lights, lamps, switches - outside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

1 Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

1.1 Assembly overview, Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

1.2 Removing and installing headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

1.3 Adjusting headlight installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

1.4 Renewing headlight bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

1.5 Servicing headlight securing lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

1.6 Adjusting headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

2 Main headlights with gas discharge bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

2.1 Assembly overview - gas discharge headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

2.2 Removing and installing headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

2.3 Adjusting headlight installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

2.4 Renewing headlight bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

2.5 Removing and installing headlight range control motor . . . . . . . . . . . . . . . . . . . . . . . . . . 198

ii Contents

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Electrical System - Edition 05.2005

2.6 Removing and installing gas discharge light control unit . . . . . . . . . . . . . . . . . . . . . . . . . . 198

2.7 Headlight range control unit J431 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

2.8 Vehicle level sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

2.9 Servicing headlight securing lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

2.10 Adjusting headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

3 Fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

3.1 Assembly overview - fog light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

3.2 Removing and installing fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

3.3 Removing and installing fog light bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

3.4 Adjusting fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

4 Removing and installing side marker in front bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

4.1 Removing and installing front side marker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

5 Mirror turn signal bulb and entry light in exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

5.1 Removing and installing turn signal bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

5.2 Removing and installing entry light in exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

6 Tail lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

6.1 Assembly overview - tail light in side panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

6.2 Removing and installing tail light in side panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

6.3 Removing and installing tail light bulb carrier in side panel . . . . . . . . . . . . . . . . . . . . . . . . 213

6.4 Assembly overview - tail light in tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

6.5 Removing and installing tail light in tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

6.6 Removing and installing tail light bulb carrier in tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

7 Number plate lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

7.1 Removing and installing number plate light X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

8 Additional brake light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

8.1 Removing and installing high level brake light bulb M25 . . . . . . . . . . . . . . . . . . . . . . . . . . 218

9 Steering column switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

9.1 Assembly overview - steering column switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

9.2 Removing and installing steering column switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

9.3 Steering column electronics control unit J527 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

9.4 Steering angle sender G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

10 Ignition switch and lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

10.1 Removing and installing steering lock housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

10.2 Removing and installing lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

10.3 Removing and installing ignition switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

11 Parking aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

11.1 Assembly overview - parking aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

11.2 Removing and installing parking aid control unit J446 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

11.3 Removing and installing parking aid sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

11.4 Removing and installing rear parking aid warning buzzer H15 . . . . . . . . . . . . . . . . . . . . . . 236

11.5 Final control diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

12 Torque settings: lights, bulbs, switches - exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

12.1 Torque settings: headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

12.2 Torque settings: fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

12.3 Torque settings - tail light in side panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

12.4 Torque settings - tail light in tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

12.5 Torque settings: vehicle level sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

96 - Lights, lamps, switches - inside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

1 Lights and switches in engine compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

1.1 Removing and installing bonnet contact switch F266 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

2 Lights and switches in dash panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

2.1 Removing and installing light switch E1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

2.2 Removing and installing glove compartment light W6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005

2.3 Removing and installing glove compartment light switch E26 . . . . . . . . . . . . . . . . . . . . . . 242

2.4 Removing and installing switches and instruments illumination regulator E20 . . . . . . . . . . 242

2.5 Removing and installing front passenger side airbag deactivated warning lamp K145 . . 243

2.6 Removing and installing hazard warning light switch E3 . . . . . . . . . . . . . . . . . . . . . . . . . . 244

2.7 Removing and installing left footwell light W9 and right footwell light W10 . . . . . . . . . . . . 244

2.8 Removing and installing key operated switch to deactivate front passenger side airbag E224

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

3 Lights and switches in front doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

3.1 Removing and installing window regulator switch in front passenger door E107 . . . . . . . . 248

3.2 Removing and installing switch module for driver side mirror adjustment . . . . . . . . . . . . . . 248

3.3 Removing and installing driver side interior locking button for central locking system E308

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

3.4 Components - front door locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

3.5 Removing and installing switch module for driver side window lift . . . . . . . . . . . . . . . . . . . . 250

3.6 Removing and installing remote release button for fuel filler flap and rear lid E463 and key

operated switch to block release of rear lid remote E232 . . . . . . . . . . . . . . . . . . . . . . . . . . 252

4 Lights and switches in rear doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254

4.1 Components - front door locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254

4.2 Removing and installing rear left window regulator switch, in door E52 and rear right window

regulator switch, in door E54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254

5 Lights and switches in luggage compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256

5.1 Removing and installing luggage compartment light W3 . . . . . . . . . . . . . . . . . . . . . . . . . . 256

5.2 Removing and installing rear lid lock unit F256 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

6 Lights and switches in roof trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

6.1 Removing and installing front interior light and reading light (vehicles with no sliding

sunroof) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

6.2 Removing and installing front interior light and reading light (vehicles with sliding sunroof)

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6.3 Rear interior and reading light (vehicles without ATAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

6.4 Rear interior and reading light (vehicles with ATAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

6.5 Removing and installing front passenger side illuminated vanity mirror W14 and driver side

illuminated vanity mirror W20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

6.6 Removing and installing garage door operating unit E284 . . . . . . . . . . . . . . . . . . . . . . . . 271

7 Lights and switches in centre console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272

7.1 Removing and installing TCS and ESP button E256 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272

8 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

8.1 Removing and installing treble tone horn H2 and bass tone horn H7 . . . . . . . . . . . . . . . . 274

8.2 Checking treble tone horn H2 and bass tone horn H7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

9 Immobilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

9.1 Immobilizer control unit J362 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

9.2 Immobilizer reader coil D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

9.3 Ignition key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

10 Anti-theft alarm system (ATAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

10.1 Activating and deactivating anti-theft alarm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

10.2 Removing and installing anti-theft alarm ultrasonic sensor G209 . . . . . . . . . . . . . . . . . . . . 278

10.3 Removing and installing vehicle inclination sender G384 . . . . . . . . . . . . . . . . . . . . . . . . . . 278

10.4 Central locking and anti-theft alarm system aerial R47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278

10.5 Alarm horn H12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279

97 - Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281

1 Vehicle Diagnosis, Testing and Information Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281

1.1 Connecting vehicle Diagnosis, Testing and Information System VAS 5051A . . . . . . . . . . 281

2 Removing and installing fuse holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

2.1 Removing and installing fuse holder on left of dash panel . . . . . . . . . . . . . . . . . . . . . . . . . . 283

3 Removing and installing relay carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285

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Jetta 2005 ➤ , Bora 2006 ➤

Electrical System - Edition 05.2005

3.1 Removing and installing relay carrier with safety cut-out on left of dash panel . . . . . . . . . . 285

3.2 Removing and installing relay carrier on onboard supply control unit, on left of dash panel

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286

4 Electronics boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288

4.1 Removing and installing electronics box on left in engine compartment . . . . . . . . . . . . . . 288

5 Control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292

5.1 Onboard supply control unit J519 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292

5.2 Data bus diagnostic interface J533 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294

5.3 Central control unit for convenience system J393 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

5.4 Trailer detector control unit J345 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299

6 Wiring harness and connector repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302

6.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302

6.2 General notes concerning repairs to vehicle electrical system . . . . . . . . . . . . . . . . . . . . . . 302

6.3 Notes on repairs to wiring harness and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302

6.4 Supplementary notes on repair of CAN bus wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303

6.5 Wiring harness repair set V.A.G 1978 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304

7 Renewal of aerial wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

7.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

7.2 Assembly overview - an aerial wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

7.3 Installing a new aerial wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

8 Torque settings: Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

8.1 Torque settings: Electronics box in left side of engine compartment . . . . . . . . . . . . . . . . . . 307

8.2 Torque settings trailer detector control unit J345 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

Contents v

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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005

vi Contents

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27 – Starter, current supply, CC

1 Battery

WARNING

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

Caution

To prevent damage to the battery and vehicle, the following
should be observed 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 as per instructions in this Manual.

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 vehicle electrical system.

Jetta 2005 ➤ , Bora 2006 ➤

Electrical System - Edition 05.2005

Note

Observe ⇒ Self-study programme No. 234 ; vehicle batteries .

1.2 Types of battery

1.2.1 Low maintenance battery

Low maintenance battery with liquid electrolyte (wet battery).
These batteries are recognised by the removable cell plugs.

Lead-acid battery, electrolyte level must be checked regularly and
topped-up with distilled water as required.

These batteries are often equipped with a magic eye. The magic
eye provides information concerning the level of the electrolyte
and the charge state of the battery.

1.2.2 Maintenance-free battery

Maintenance-free battery with liquid electrolyte (wet battery).
These batteries have a cover over the cells instead of cell plugs.
The cover seals the battery after initial filling during production.

Caution

Never under any circumstances remove the cover for the bat‐
tery cells. The battery housing will be damaged and the battery
is therefore unusable.

Lead-acid battery, where electrolyte need not be topped-up with
distilled water under normal conditions. This term is normally used
for batteries with a predetermined amount of electrolyte.

1. Battery 1

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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005

These batteries are often equipped with a magic eye. The magic
eye provides information concerning the level of the electrolyte
and the charge state of the battery.

1.2.3 Absorbent glass mat (AGM) battery

Maintenance-free battery with a contained electrolyte.

Lead-acid battery where the electrolyte is contained within a mi‐
croscopic glass mat (AGM). The battery is sealed and fitted with
valves.

AGM is the abbreviation for Absorbent Glass Mat.

Note

♦

The procedure for checking and testing gel and absorbent
glass mat batteries is identical.

♦

Always replace an absorbent glass mat battery with another
absorbent glass mat battery.

1.2.4 Gel battery

Maintenance-free battery with a contained electrolyte.

Lead-acid battery where the electrolyte is contained within a gel.
The battery is sealed and fitted with valves.

Note

♦

The procedure for checking and testing gel and absorbent
glass mat batteries is identical.

♦

Currently gel batteries are only used in motor homes/campers
at Volkswagen.

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, CC

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WARNING

♦ Untrained personal 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 personal 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

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

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

cutting operations and use naked lights in the vicinity of
batteries. Smoking is also prohibited. Sparks must also
prevented through electrostatic discharge, therefore al‐
ways earth through vehicle body etc. before touching
battery.

♦ Only work on batteries in well ventilated and suitable

rooms.

Jetta 2005 ➤ , Bora 2006 ➤

Electrical System - Edition 05.2005

1.3.2 Safety markings on battery

Safety markings on battery

1. - Fires, sparks, naked lights and smoking are prohibited. Avoid
sparks as well as electrostatic discharge when working with ca‐
bles 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.

1. Battery 3

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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005

1.4 Battery terminal connection

Caution

To prevent damage to the battery terminal clamps and battery
terminals, the following should be observed:

♦ The battery terminal clamps should only be fitted by hand

and without using force.

♦ Battery terminals should not be coated with grease.

♦ The battery terminal clamps should be fitted so that the

battery terminal is either flush with the clamp or protruding
from it.

♦ Once the battery terminal clamps have been tightened to

the specified torque, the threaded connections should not
be tightened any further.

The tightening torque for the battery terminal clamps -1- and the
additional clamps-2- can be found in this table “Tightening tor‐
ques: Battery” ⇒ page 36 .

4 Rep. Gr.27 - Starter, current supply, CC

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2 Checking battery

WARNING

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

Caution

To prevent damage to the battery and vehicle, the following
should be observed concerning types of battery ⇒ page 1 .

2.1 Procedure when checking the battery

Jetta 2005 ➤ , Bora 2006 ➤

Electrical System - Edition 05.2005

Carry out procedure in sequence as follows:

1. Visual check ⇒ page 5 .

2. Checking battery with a magic eye ⇒ page 6 or checking
a low maintenance battery ⇒ page 7 .

3. Check no load voltage of battery ⇒ page 10 .

4. Perform a battery load test using battery tester with printer

-VAS 5097 A- ⇒ page 12 .

2.2 Visual check

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

It is essential first to check the external condition, the terminals of
the battery and that the battery is seated securely visually before
performing more extensive tests.

WARNING

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
securing plate may damage the battery housing.

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

curing bolt to specified torque setting. ⇒ page 36

♦ Whether the battery housing is damaged: Check whether the

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 areas of the vehicle af‐
fected by leaked battery acid immediately with acid neutraliser
or a soap solution.

♦ Whether the battery terminals (battery wiring/cable connec‐

tions) are damaged. Check whether the battery terminals (bat‐
tery wire connections) are damaged. The necessary contact
at the terminal clamps cannot be guaranteed if the terminals
are damaged. When connecting clamps to the terminals, tight‐

2. Checking battery 5

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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005

en the clamps to the torque specified in this workshop manual.
If the clamps are not correctly seated and tightened, the wiring
could burn, which could result in electrical system malfunc‐
tions. Which will cause malfunctions in the electrical system.
Therefore it can no longer be guaranteed that the vehicle will
function correctly.

2.3 Checking battery with magic eye

WARNING

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

The magic eye (condition indicator) provides information on the
electrolyte level and condition (charge state) of the battery.

Batteries with a magic eye are produced in two versions:

♦ Low maintenance ⇒ page 1

♦ Maintenance-free ⇒ page 1

Note

Because the magic eye is located in only one cell, the display
applies only to this cell. An exact determination of battery's con‐
dition is only possible through a load test ⇒ page 12 .

– Before performing a visual check, tap the magic eye lightly and

carefully with the handle of a screwdriver.

The air bubbles, which can influence the display, will dissipate
when doing this. The colour display of the magic eye will therefore
be more accurate.

Note

♦

Air bubbles can form below the magic eye particularly when
the battery is being charged, including during normal vehicle
operation. These falsify the colour display of the magic eye.

♦

The magic eye can be located at various positions on the bat‐
tery.

Three different colour displays are possible:

♦ “Green”, battery is charged sufficiently.

♦ “Black”, Battery partly discharged, charge state < 65 % or

completely discharged.

♦ “Colourless or yellow”, battery must be renewed.

Note

♦

Charging battery with battery charger -VAS 5095 A-

⇒ page 15 .

♦

Charging battery with battery charger -VAS 5900-

⇒ page 19 .

6 Rep. Gr.27 - Starter, current supply, CC

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2.4 Checking low maintenance battery

WARNING

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

This battery is “low maintenance” this means the electrolyte level
must be checked and occasionally topped-up with distilled water
as required.

2.4.1 Checking electrolyte level of battery

Check electrolyte level on housing:

– Check electrolyte level via -min./ max.- marking on the battery

housing.

The electrolyte level is OK when the fluid level is at the max.
marking.

If the electrolyte level is below the -max.- marking:

– Replenished with distilled water ⇒ page 7 .

Check electrolyte level in the cells:

– Switch off the ignition and all electrical consumers.

– If fitted, remove the protective foil on the cell sealing plug.

Note

The foil with the warning notices must remain on the battery.

– Remove cell sealing plugs.

– Check the electrolyte level of the battery cells.

Jetta 2005 ➤ , Bora 2006 ➤

Electrical System - Edition 05.2005

The electrolyte level is OK when the fluid level -1- is the same
height as the plastic peg.

Note

The plastic peg corresponds to the max. marking.

If electrolyte level is OK:

– Check the cell sealing plugs and the O-ring seals for damage.

Damaged parts must be replaced.

– Seal the cells with the cell sealing plugs.

If the electrolyte level is under the plastic peg:

– Replenished with distilled water ⇒ page 7 .

2.4.2 Topping up with distilled water

Special tools and workshop equipment required

2. Checking battery 7

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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005

♦ Battery filler bottle -VAS 5045/-

Caution

♦ When filling up with undistilled water or electrolyte the bat‐

tery will be damaged. Top up with distilled water only.

♦ The battery may be damaged when the cells are overfilled.

When topping up use only the battery filling bottle -VAS
5045/- . The construction of the filler neck prevents an
overfilling of the battery cells.

– Check the electrolyte level of the battery ⇒ page 7 .

– Switch off the ignition and all electrical consumers.

– If fitted, remove the protective foil on the cell sealing plug.

Note

The foil with the warning notices must remain on the battery.

– Remove cell sealing plugs.

– Replenish with distilled water using battery filling bottle -VAS

5045/- . When the max. level is reached the flow is interrupted
automatically.

– Check the cell sealing plugs and the O-ring seals for damage.

Damaged parts must be replaced.

– Seal the cells with the cell sealing plugs.

– Check no load voltage of battery ⇒ page 10 .

– Perform battery load/discharge test ⇒ page 12 .

2.4.3 Check electrolyte density

Special tools and workshop equipment required

8 Rep. Gr.27 - Starter, current supply, CC

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♦ Commercially available hydrometer

– Check the electrolyte level of the battery ⇒ page 7 .

– Switch off the ignition and all electrical consumers.

– If fitted, remove the protective foil on the cell sealing plug.

Jetta 2005 ➤ , Bora 2006 ➤

Electrical System - Edition 05.2005

Note

The foil with the warning notices must remain on the battery.

– Remove cell sealing plugs.

– Draw electrolyte off a cell using a hydrometer until the float

swims unhindered.

The electrolyte density is determined by the float position in the
battery electrolyte. The value can be read from the float scale.

Electrolyte density Charge Voltage

1.28 g/cm

1,21 g/cm

1,18 g/cm

1,10 g/cm

3

3

3

3

Note

Checking electrolyte density directly after topping up with distilled
water will lead to erroneous results. Check electrolyte density only
after charging the battery.

– Check the cell sealing plugs and the O-ring seals for damage.

100 % 12,7 V

60 % 12,3 V

40 % 12,1 V

0 % 11,7 V

Damaged parts must be replaced.

– Seal the cells with the cell sealing plugs.

2. Checking battery 9

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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005

2.5 Check no load voltage of battery

WARNING

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

The no load voltage test is used to determine the capacity of the
battery.

Note

The battery must not be charged or discharged for at least 2 hours
before making the measurements. Charging or discharging dur‐
ing this period falsify the test result.

No load voltage Charge Condition of battery

11,70 V 0 % Discharged, no capacity. Heavily discharged.

12,20 V 50 % Over a period of time sulphate crystals build-up which can

12,35 V 65 % ♦ On batteries with a magic eye, the display will change

12.70 V 100 % Full capacity.

⇒ page 27 .

only be reversed using a considerable amount of energy.
At the same time the active mass expands greatly, which
can cause cracks, which leads to heavy corrosion at the
positive plate.

from green to black.

♦ The battery should be recharged on new/vehicles which

have been stored.

Special tools and workshop equipment required

♦ Hand multimeter -V.A.G 1526 B-

– Switch off ignition and all electrical consumers and pull out

ignition key.

– Disconnect negative terminal on battery ⇒ page 29 .

– Wait at least 2 hours. The battery must not be charged or dis‐

charged within this period.

– Check battery no load voltage with hand multimeter -V.A.G

1526 B- .

10 Rep. Gr.27 - Starter, current supply, CC

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Measured value Measure to be performed

No load voltage ≥ 12.5 V No load voltage is OK, perform

a battery load test ⇒ page 10 .

No load voltage < 12.5 V Charge battery ⇒ page 15 .

If the battery has been recharged as a result of the no load test,
proceed as follows:

– Wait at least 2 hours. The battery must not be charged or dis‐

charged within this period.

– Check battery no load voltage again with hand multimeter -

V.A.G 1526 B- .

If after the loading process the battery no load voltage is < 12.5 V,
renew battery ⇒ page 31 .

2.6 Battery tester with printer -VAS 5097 A-

WARNING

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

Jetta 2005 ➤ , Bora 2006 ➤

Electrical System - Edition 05.2005

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

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

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

(Deutsche Industrie Norm (German Industrial Standard))

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

(International Engineering Consortium)

♦ 136 - 855 A 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.

♦

Observe the ⇒ Instruction Manual for battery tester with printer

-VAS 5097 A- or sticker ⇒ Brief instructions for battery tester
with printer -VAS 5097 A- stuck on the unit or table Low-tem‐
perature current. ⇒ page 13

♦

Observe battery manufacture's handling instructions!

Note

1)

2. Checking battery 11

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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005

2.6.1 Description of battery tester with printer

-VAS 5097 A-

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 - Start tester

5 - Low-temperature current selection switch

6 - ON/OFF and functions switch

7 - Selection switch (battery tester to pick-off point on battery/
external test point in engine compartment)

8 - Button to advance paper

9 - Printer

2.6.2 Battery load test using battery tester

WARNING

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

Special tools and workshop equipment required

♦ Battery tester with printer -VAS 5097 A-

with printer -VAS 5097 A-

Perform battery load test:

– Switch off the ignition and all electrical consumers.

– Check no load voltage of battery ⇒ page 10 .

– Set low-temperature test current for battery in Ampere (A) ac‐

cording to DIN standard.

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

⇒ “2.6.3 Table: low-temperature test current”, page 13 or using

table on unit.

– Select low-temperature test current via low-temperature test

current selection switch ⇒ page 12 .

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

OFF and functions switch ⇒ page 12 .

– Connect red terminal “+” of unit to positive terminal.

12 Rep. Gr.27 - Starter, current supply, CC

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– Connect black terminal “-” of unit to negative terminal.

Note

Ensure test clamps have a good contact!

– Select point of connection of test terminals with selection

switch ⇒ page 12 .

1 - Connected directly to battery.

2 - Connected to external test points in engine compartment.

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

settings on the battery tester.

– Press start test button ⇒ page 12 .

The green LED lights up ⇒ page 12 . The test program runs
through automatically. The test result is printed out by the printer

⇒ page 14 .

– Switch off unit ⇒ page 12 .

– Remove test terminals.

Jetta 2005 ➤ , Bora 2006 ➤

Electrical System - Edition 05.2005

Note

♦

The test is completed after about 20 seconds.

♦

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

♦

Perform test once only. Repeating the test falsifies the results.

2.6.3 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

2. Checking battery 13

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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005

Low-temperature test current in A

EN/ SAE IEC ⇒ DIN

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.

490 - 499

2)

2.7 Evaluating test result

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 only lowers 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.

♦ This low voltage value remains over a long period and the

voltage only increases again slowly after the test has been
completed.

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

2.7.1 Comments concerning test print out

1 - Measuring range set on tester.

2 - Diagram -arrow- indicates battery condition.

3 - Test result.

4 - Battery voltage during load test.

5 - Vehicle data and date. Must be completed by test person‐

nel.

Note

♦

The print out is required for warranty purposes.

♦

Perform test once only. Repeating the test falsifies the results.

2.7.2 Assessing test results

Battery tester print out Measure to be performed

Starting power very good Battery OK
Start output good Battery OK
Starting power sufficient Charge battery ⇒ page 15
Starting power poor
Starting power very poor
Not capable of being tested

3) If after battery has been recharged “Starting output sufficient”, “Starting output
poor”, “Starting output very poor” or “Cannot be tested” is shown, the battery
should be renewed.

and repeat battery load test

3)

14 Rep. Gr.27 - Starter, current supply, CC

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3 Charging battery

WARNING

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

Caution

To prevent damage to the battery and vehicle, the following
should be observed concerning types of battery ⇒ page 1 .

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

♦

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

♦

Observe battery manufacture's handling instructions!

Jetta 2005 ➤ , Bora 2006 ➤

Electrical System - Edition 05.2005

3.1.1 Description of battery charger -VAS 5095 A-

Battery charger -VAS 5095- is suitable for charging

♦ Wet batteries (genuine VW batteries from 2004 with transpar‐

ent battery housing and black cover).

♦ Absorbent glass mat batteries (genuine VW batteries from

2004 with black housing).

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 posts, red terminal “+”, black terminal “-”

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

3. Charging battery 15

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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005

3.1.2 Charging battery with battery charger ­VAS 5095 A-

WARNING

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

Special tools and workshop equipment required

♦ Battery charger -VAS 5095 A-

Caution

Always set battery type 2.4 V/C (Volt/Cells) when charging!
This applies for all batteries.

Note

♦

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 the ignition and all electrical consumers.

– Check setting for battery type on type of battery switch

⇒ page 15 . Must be set to 2.4 V/C (Volt/Cells).

– Connect red terminal clamp “+” of charger unit to positive ter‐

minal on battery.

– Connect black terminal clamp “-” of charger unit to negative

terminal on battery.

– Switch on battery charger ⇒ page 15 .

The charging current indicators ⇒ page 15 -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 15 -4- the charger has switched
to "maintaining charge". The battery is fully charged.

– Switch off charging unit ⇒ page 15 .

– Remove charger unit terminals from battery terminals.

16 Rep. Gr.27 - Starter, current supply, CC

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

WARNING

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

♦

Observe notes in chapter ⇒ page 27 .

♦

The battery voltage must be at least 0.6 V.

– Charge battery ⇒ page 16 .

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

WARNING

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

When in support mode the battery charger -VAS 5095 A- replaces
a defective vehicle battery whilst it is being exchanged. The on‐
board supply remains intact. The vehicles electrical equipment
(e.g. electric windows) can be used.

Special tools and workshop equipment required

♦ Battery charger -VAS 5095 A-

Jetta 2005 ➤ , Bora 2006 ➤

Electrical System - Edition 05.2005

Caution

♦ Always set battery type 2.4 V/C (Volt/Cells) when in sup‐

port mode! This applies for all batteries.

♦ The battery charger -VAS 5095 A- terminal clamps must

remain in contact with the battery terminal clamps whilst
the battery is being exchanged.

3. Charging battery 17

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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005

– Switch off the ignition and all electrical consumers.

– Set support mode/normal mode change-over switch to

⇒ page 15 “support mode”.

– Connect red terminal clamp “+” of charger unit to positive ter‐

minal of vehicle.

– Connect black terminal clamp “-” of charger unit to negative

terminal of vehicle.

– Check setting for battery type on type of battery switch

⇒ page 15 . Must be set to 2.4 V/C (Volt/Cells).

– Switch on battery charger ⇒ page 15 .

The yellow LEDs ⇒ page 15 -6- and -3- light up.

Note

♦

A minimum load of 0.6 A (e.g. parking light) must be switched
on, otherwise support mode is not possible.

♦

During the support mode the current draw is limited to 5 A.

– Switch on vehicle parking light.

– Exchange battery ⇒ page 31 .

– Switch off charging unit ⇒ page 15 .

– Remove charger unit terminals from battery terminals.

– Set support mode/normal mode change-over switch to

⇒ page 15 “normal mode” again.

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

WARNING

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

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

– Proceed as for charging battery ⇒ page 16 .

Note

♦

When a battery is being charged in the buffer mode and a
consumer draws current from the battery, 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.

♦

Observe battery manufacture's maintenance instructions!

18 Rep. Gr.27 - Starter, current supply, CC

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3.2 Battery charger -VAS 5900-

WARNING

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

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- .

Jetta 2005 ➤ , Bora 2006 ➤

Electrical System - Edition 05.2005

Note

♦

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

♦

Observe battery manufacture's handling instructions!

3.2.1 Description of battery charger -VAS 5900-

Battery charger -VAS 5900- is suitable for charging

♦ Wet batteries (genuine VW batteries from 2004 with transpar‐

ent battery housing and black cover).

♦ Absorbent glass mat batteries (genuine VW batteries from

2004 with black housing).

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

Special tools and workshop equipment required

3. Charging battery 19

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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005

♦ Battery charger -VAS 5900-

Note

♦

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 the ignition and all electrical consumers.

– Connect charger unit plug to power supply. The last selected

operating mode will appear on display ⇒ page 19 .

– Set battery to respective operating mode with INFO.

In the display the symbol -1- for “standard charge for wet batter‐
ies” or the symbol -2- for “standard charge for gel/absorbent glass
mat batteries” will appear.

– Set battery capacity (Ah) of battery for charging using respec‐

tive button “Up” ↑ or “Down” ↓ .

– Connect red terminal clamp “+” to positive terminal on battery.

– Connect black terminal clamp “-” to negative terminal on 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.

20 Rep. Gr.27 - Starter, current supply, CC

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

Note

♦

In the battery type “standard charge” the parallel use of con‐
sumers 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:

– Press respective 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.

– Press respective 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 terminal clamp “-” of charger unit from neg‐

ative terminal on battery.

– Disconnect red terminal clamp “+” of charger unit from nega‐

tive terminal on battery.

– Pull charger unit plug out power supply socket.

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

WARNING

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

Jetta 2005 ➤ , Bora 2006 ➤

Electrical System - Edition 05.2005

Caution

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

If there is a requirement to use “service charge” the battery
must be disconnected from the onboard supply.

3. Charging battery 21

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Jetta 2005 ➤ , Bora 2006 ➤
Electrical System - Edition 05.2005

Caution

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

“Service charge” must only be used for:

♦ Wet batteries, where distilled water can be replenished.

♦ Gel/absorbent glass mat batteries.

Do not use operating mode “service charge” with maintenance­free wet batteries ⇒ page 1 .

The operating mode “service charge (SERV)” is only used on
suspect 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

♦ Battery charger -VAS 5900-

Note

♦

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 the ignition and all electrical consumers.

– Connect charger unit plug to power supply. The last selected

operating mode will appear on display ⇒ page 19 .

– Set battery to respective operating mode with INFO.

In the display the symbol -1- for “service charge for wet batteries”
or the symbol -2- for “service charge for gel/absorbent glass mat
batteries” will appear.

– Set battery capacity (Ah) of battery for charging using respec‐

tive button “Up” ↑ or “Down” ↓ .

– Connect red terminal clamp “+” to positive terminal on battery.

– Connect black terminal clamp “-” to negative terminal on 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.

22 Rep. Gr.27 - Starter, current supply, CC