VOLKSWAGEN BORA 2006 (03) PDF Document

To ensure long use of the battery in a VOLKSWAGEN BORA 2006, 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.

The types of batteries include:

Low maintenance battery with liquid electrolyte (wet battery). These batteries are recognized by the removable cell plugs. The electrolyte level must be checked regularly and topped-up with distilled water as required. These batteries are often equipped with a magic eye.

Maintenance-free battery with liquid electrolyte (wet battery). These batteries have a cover over the cells instead of cell plugs, and the cover seals the battery after initial filling during production. Do not under any circumstances remove the cover for the battery cells, as the battery housing will be damaged and the battery will be unusable.

Absorbent glass mat (AGM) battery, which is a maintenance-free battery with a contained electrolyte. The electrolyte is contained within a microscopic glass mat (AGM), and the battery is sealed and fitted with valves.

Gel battery, which is a maintenance-free battery with a contained electrolyte where the electrolyte is contained within a gel. The battery is sealed and fitted with valves. Currently, gel batteries are only used in motor homes/campers at Volkswagen.

The following dangers and safety regulations apply:

Untrained personnel may only work on batteries when supervised by a vehicle mechanic/foreman or vehicle electrician/foreman.

Acid is highly corrosive, posing a danger of acid burns if batteries are not handled correctly. Suitable measures must be taken to ensure that equipment/solutions are available to neutralize acid burns (e.g., a soap solution).

If electrolyte leaks from a battery, it may cause skin burns and acid corrosion, rusting on the vehicle, potentially damaging safety-relevant components.

The gas that forms when charging is explosive. In extreme cases, a battery may explode if not handled correctly.

It is prohibited to cause sparks through grinding, welding, cutting operations, or using naked lights in the vicinity of batteries. Smoking is also prohibited. Sparks must also be prevented through electrostatic discharge by earthing through the vehicle body before touching the battery.

Only work on batteries in well-ventilated and suitable rooms.

The safety markings on the battery are:

1. Fires, sparks, naked lights, and smoking are prohibited. Avoid sparks and electrostatic discharge when working with cables and electrical units. Avoid short circuits, never lay a tool on a battery.

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

3. Keep children away from acid and batteries.

4. Disposal: old batteries are classed as hazardous waste and may only be disposed of through a suitable collection centre according to respective legislation.

5. Never dispose of old batteries in the household waste system.

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

7. Follow instructions concerning batteries in ELSA “electrical system” and in the owner’s manual.

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

To prevent damage to the battery terminal clamps and battery terminals:

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.

Carry out the procedure in sequence as follows:

Visual check.

Checking battery with a magic eye or checking a low maintenance battery.

Check no load voltage of battery.

Perform a battery load test using battery tester with printer -VAS 5097 A- .

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.

Caution regarding battery securing and vibration:

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 if the battery is securely seated; if necessary, tighten the securing bolt to the specified torque setting.

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 affected by leaked battery acid immediately with acid neutraliser or a soap solution.

Check whether the battery terminals (battery wiring/cable connections) are damaged. The necessary contact at the terminal clamps cannot be guaranteed if the terminals are damaged. When connecting clamps to the terminals, tighten the clamps to the torque specified in this workshop manual. If the clamps are not correctly seated and tightened, the wiring could burn, resulting in electrical system malfunctions, and the vehicle may no longer function correctly.

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.

Check electrolyte level on housing:

Check the electrolyte level via the -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, replenish with distilled water.

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 (the foil with the warning notices must remain on the battery). Remove cell sealing plugs. Check the electrolyte level of the battery cells. The electrolyte level is OK when the fluid level is the same height as the plastic peg (which corresponds to the max. marking).

If the 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, replenish with distilled water.

The procedure to check electrolyte density is:

Check the electrolyte level of the battery.

Switch off the ignition and all electrical consumers.

If fitted, remove the protective foil on the cell sealing plug (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, and the value can be read from the float scale.

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.

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

The table showing electrolyte density, charge, and voltage is:

The no load voltage test is used to determine the capacity of the battery. The battery must not be charged or discharged for at least 2 hours before making the measurements, as charging or discharging during this period falsifies the test result.

The procedure is:

Switch off ignition and all electrical consumers and pull out ignition key.

Disconnect the negative terminal on the battery.

Wait at least 2 hours; the battery must not be charged or discharged within this period.

Check battery no load voltage with a hand multimeter -V.A.G 1526 B- .

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

The table showing no load voltage, charge, and condition of battery is:

If the no load voltage is ≥ 12.5 V, the no load voltage is OK, and a battery load test should be performed. If the no load voltage is < 12.5 V, charge the battery. If the battery has been recharged and the no load test result is < 12.5 V, renew the battery.

The 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).

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

To perform the battery load test:

Switch off the ignition and all electrical consumers.

Check the no load voltage of the battery.

Set the low-temperature test current for the battery in Ampere (A) according to DIN standard. If the battery values are shown in IEC or EN/ SAE instead of DIN, convert figures using the table “Low-temperature test current” or using the table on the unit.

Select the low-temperature test current via the low-temperature test current selection switch.

Select measuring range 80 – 379 A or 380 – 499 A with the ON/OFF and functions switch.

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

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

Select the point of connection of the test terminals with the selection switch: 1 – Connected directly to battery, 2 – Connected to external test points in the engine compartment.

Check that the figures given on the battery are correct for the settings on the battery tester.

Press the start test button. The green LED lights up, and the test program runs through automatically. The test result is printed out by the printer.

Switch off the unit.

Remove the test terminals.

Note that the test is completed after about 20 seconds, the result is printed out by the printer, and the test should be performed once only, as repeating the test falsifies the results.

The descriptions for the battery tester with printer -VAS 5097 A- are:

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

The assessment of test results is:

The battery charger -VAS 5095 A- has the following components:

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 charged

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)

The procedure for charging the battery:

Ensure the battery has 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 the setting for battery type on the type of battery switch (must be set to 2.4 V/C (Volt/Cells)).

Connect the red terminal clamp “+” of the charger unit to the positive terminal on the battery.

Connect the black terminal clamp “-” of the charger unit to the negative terminal on the battery.

Switch on the battery charger. The charging current indicators (2 and 3) light up yellow. When only the light emitting diode (LED) -3- lights up yellow, the battery is partially discharged (approx. 90 %). If the LED lights up green (4), the charger has switched to “maintaining charge”, meaning the battery is fully charged.

Switch off the charging unit.

Remove the charger unit terminals from the battery terminals.

The charger unit automatically recognizes totally discharged batteries and initiates a gentle charging procedure with a low charging current, automatically adapted to the charge condition of the battery.

Observe notes in the relevant chapter.

The battery voltage must be at least 0.6 V.

Charge the battery as instructed for charging the battery.

Support mode replaces a defective vehicle battery whilst it is being exchanged, keeping the onboard supply intact so that the vehicle’s electrical equipment can be used.

The procedure is:

Switch off the ignition and all electrical consumers.

Set the support mode/normal mode change-over switch to “support mode”.

Connect the red terminal clamp “+” of the charger unit to the positive terminal of the vehicle.

Connect the black terminal clamp “-” of the charger unit to the negative terminal of the vehicle.

Check the setting for battery type on the type of battery switch (must be set to 2.4 V/C (Volt/Cells)).

Switch on the battery charger. The yellow LEDs (6 and 3) light up.

Note that a minimum load of 0.6 A (e.g., parking light) must be switched on, otherwise support mode is not possible, and during support mode, the current draw is limited to 5 A.

Switch on the vehicle parking light.

Exchange the battery.

Switch off the charging unit.

Remove the charger unit terminals from the battery terminals.

Set the support mode/normal mode change-over switch to “normal mode” again.

In buffer mode, the battery charger -VAS 5095 A- charges the battery correctly and maintains it in a fully charged condition. Proceed as for charging the battery.

Note that 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, and the battery is always ready for use. Observe battery manufacturer’s maintenance instructions!

The battery charger -VAS 5900- is suitable for charging:

Wet batteries (genuine VW batteries from 2004 with transparent battery housing and black cover).

Absorbent glass mat batteries (genuine VW batteries from 2004 with black housing).

The battery charger -VAS 5900- has the following components:

1 – Display

2 – Adjustment button “Up” ↑

3 – Adjustment button “Down” ↓

4 – START / STOP

5 – INFO

The procedure for charging the battery:

Ensure 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 the charger unit plug to power supply. The last selected operating mode will appear on the display.

Set the battery to the respective operating mode with INFO. The display will show symbol -1- for “standard charge for wet batteries” or symbol -2- for “standard charge for gel/absorbent glass mat batteries”.

Set the battery capacity (Ah) of the battery for charging using the respective button “Up” ↑ or “Down” ↓ .

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

Connect the black terminal clamp “-” to the negative terminal on the battery.

The charger unit recognizes the voltage required for the connected 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, and the fourth bar appears in display -1-. The battery is ready for use.

Possible faults and fault rectification are:

If the displayed battery voltage is not as per the nominal voltage: Press the respective button “Up” ↑ or “Down” ↓ until the charging sequence starts.

If the displayed battery voltage is not as per the nominal voltage and the charging sequence already started: Press START / STOP twice, then press the respective button “Up” ↑ or “Down” ↓ until the charging sequence starts again.

If the battery charger does not detect a battery when the battery voltage is less than 2 V: The display remains unchanged. The battery type and ampere hours (Ah) as set is displayed.

Ending battery charging sequence:

Press START / STOP .

Disconnect the black terminal clamp “-” of the charger unit from the negative terminal on the battery.

Disconnect the red terminal clamp “+” of the charger unit from the negative terminal on the battery.

Pull the charger unit plug out of the power supply socket.

The operating mode “service charge” is not permitted on VW vehicles as the voltage peaks will damage the onboard electronics. If there is a requirement to use “service charge”, the battery must be disconnected from the onboard supply.

The procedure for charging in service mode:

Set the battery to the respective operating mode with INFO. The display will show symbol -1- for “service charge for wet batteries” or symbol -2- for “service charge for gel/absorbent glass mat batteries”.

Set the battery capacity (Ah) of the battery for charging using the respective button “Up” ↑ or “Down” ↓ .

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

Connect the black terminal clamp “-” to the negative terminal on the battery.

Press START / STOP for approximately 5 seconds. The menu ““charging totally discharged batteries/support mode” will be activated.

Press the respective button “Up” ↑ or “Down” ↓ to set the respective battery voltage (6 V, 12 V or 24 V).

Confirm the selected battery voltage with START / STOP. Then the enquiry for “is charger cable terminal polarity correct” follows.

Check the polarity of the charger unit cables.

Confirm the polarity of the charger unit cables with START / STOP. The charger will start the charging sequence for the totally discharged battery.

Ending battery charging sequence:

Press START / STOP .

Disconnect the black terminal clamp “-” of the charger unit from the negative terminal on the battery.

Disconnect the red terminal clamp “+” of the charger unit from the negative terminal on the battery.

Pull the charger unit plug out of the power supply socket.

A battery is designated “totally discharged” when the “no load” voltage is less than 12.2 V. Totally discharged batteries freeze prematurely and frozen batteries should no longer be used.

Caution: Totally discharged batteries freeze prematurely. Frozen batteries should no longer be used.

Note on totally discharged batteries: Batteries that have not been used for a long time (e.g., stored vehicles) will self-discharge. In totally discharged batteries, the electrolyte is comprised almost entirely of water because the acid content is so low. Totally discharged batteries sulphate, meaning the entire plate surfaces of the battery harden. If a battery is recharged shortly after it has totally lost its charge, the sulphation will dissipate. If these batteries are not recharged, the plates continue to harden, and the ability to recharge is reduced, resulting in a reduction in the battery output.

The procedure is:

Check the no load voltage of the battery.

Charge the battery.

Charging battery with battery charger -VAS 5095 A- or with battery charger -VAS 5900-.

Support mode replaces a defective vehicle battery whilst it is being exchanged, keeping the onboard supply intact so that the vehicle’s electrical equipment can be used.

Caution: The terminal polarity protection in operating mode “charging totally discharged batteries/support mode” is not active. Connect battery charger terminal clamps correctly to battery terminals. When charging, always set the battery charger to the correct type of battery. Do not press the START / STOP button when charger unit cables are connected incorrectly, as the charger unit may be damaged. Batteries with a voltage of less than 2 Volt will not be recognized automatically by battery charger -VAS 5900-.

The procedure for charging in support mode:

Switch off the ignition and all electrical consumers.

Connect the charger unit plug to the power supply. The last selected operating mode will appear on the display.

Set the battery to the respective operating mode with INFO. In the display, symbol -1- for “service charge for wet batteries” or symbol -2- for “service charge for gel/absorbent glass mat batteries” will appear.

Set the battery capacity (Ah) of the battery for charging using the respective button “Up” ↑ or “Down” ↓ .

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

Connect the black terminal clamp “-” to the negative terminal on the battery.

Press START / STOP for approximately 5 seconds. The menu ““charging totally discharged batteries/support mode” will be activated.

Press the respective button “Up” ↑ or “Down” ↓ to set the respective battery voltage (6 V, 12 V or 24 V).

Confirm the selected battery voltage with START / STOP. Then the enquiry for “is charger cable terminal polarity correct” follows.

Check the polarity of the charger unit cables.

Confirm the polarity of the charger unit cables with START / STOP. The charger will start the charging sequence for the totally discharged battery.

Ending battery charging sequence:

Press START / STOP .

Disconnect the black terminal clamp “-” of the charger unit from the negative terminal on the battery.

Disconnect the red terminal clamp “+” of the charger unit from the negative terminal on the battery.

Pull the charger unit plug out of the power supply socket.

When the battery is fully charged, the battery charger -VAS 5900- switches to maintenance mode. Proceed as for charging the battery. At a charge condition of 100 %, all bars appear in the display.

Note that when a battery is being charged in the buffer mode and a consumer draws current from the battery, the battery charger -VAS 5900- automatically compensates the charge. The maintenance mode can be continued for an unlimited period, and the battery is always ready for use. Observe battery manufacturer’s maintenance instructions!

The procedure for disconnecting the battery:

Switch off the ignition and all electrical consumers.

Release the catch and take the cover off the battery box.

First unscrew the battery earth clamp -1- from the battery negative terminal.

Then unscrew the battery positive clamp -2- from the battery positive terminal.

Note that by disconnecting the battery earth wire (open circuit), safety is ensured when carrying out work on the electrical system. The battery positive wire need only be disconnected for removal of the battery.

When connecting the battery, observe the instructions on connecting battery terminals.

Fit the battery positive clamp -2- to the positive terminal of the battery and tighten the securing bolt to the specified torque setting.

Fit the battery earth clamp -1- to the negative terminal of the battery and tighten the securing bolt to the specified torque setting.

Carry out the procedures as detailed in the table:

Note that after connecting the battery and switching the ignition on, the ESP and TCS warning lamp -K155- lights up permanently. The warning lamp goes out automatically if a distance of 15 to 20 km/h is driven straight ahead, which activates the steering angle sender -G85- again.

If necessary, the table can be printed out.

The torque settings for battery threaded connections are:

To check the starter -B-, connect the vehicle diagnosis, testing and information system -VAS 5051A-.

Select “guided fault finding” in Vehicle Diagnosis, Testing and Information System -VAS 5051A- .

Using the “Go to” key, select “Function/component selection” and the following menu items one after the other:

Body

Electrical System

27 – Starter, current supply

Electrical components

B – Starter

Note that disconnecting and connecting the battery must be as described in the Workshop Manual.

The torque settings for starter threaded connections are:

The required special tools and workshop equipment are:

Torque wrench -V.A.G 1331-

Torque wrench -V.A.G 1332-

Spring-type clip pliers -VAS 5024-

The removal steps are:

Disconnect the battery.

Release spring-type clip -1- using spring type clip pliers -VAS 5024- and remove securing bolt -2-.

Release hose -3- and pull it off the air filter housing.

Pull the air filter housing on the right side upwards off the rubber mounting -arrow-.

Remove the air filter housing from the vehicle.

Push down the protective cap in -direction of arrow- from the solenoid switch.

Unscrew the positive wire -1- and disconnect the connector from terminal 50 -2-.

Remove noise insulation.

Unscrew the securing nut -1- from the lower starter securing bolt.

Remove wiring retainer -2-.

Remove the lower securing bolt of the starter -arrow-.

Unscrew the securing nut -1- from the upper starter securing bolt.

Remove wiring retainer -2-.

Remove the upper securing bolt of the starter -arrow-.

Unscrew the earth wire securing nut -1- and place the earth wire -2- to one side.

Remove the starter from the vehicle upwards.

For installation, carry out the procedure in the reverse order, tightening threaded connections to specified torque settings.

The required special tools and workshop equipment are:

Torque wrench -V.A.G 1331-

Torque wrench -V.A.G 1332-

Spring-type clip pliers -VAS 5024-

The removal steps are:

Disconnect the battery.

Push down the protective cap in -direction of arrow- from the solenoid switch.

Unscrew the positive wire -1- and disconnect the connector from terminal 50 -2-.

Remove noise insulation.

Unscrew the securing nut -1- from the lower starter securing bolt.

Remove wiring retainer -2-.

Remove the lower securing bolt of the starter -arrow-.

Unscrew the securing nut -1- from the upper starter securing bolt.

Remove wiring retainer -2-.

Remove the upper securing bolt of the starter -arrow-.

Unscrew the earth wire securing nut -1- and place the earth wire -2- to one side.

Remove the starter from the vehicle upwards.

For installation, carry out the procedure in the reverse order, tightening threaded connections to specified torque settings.

The removal steps are:

Disconnect the battery.

Disconnect the connector -arrow-.

Unclip the vacuum hose from its mounting -arrow-.

Loosen the spring-type clip -arrow- from hose -1- using spring type clip pliers -VAS 5024- .

Pull hose -1- off the air filter housing.

Open the retainer -arrow- on the front side of the air filter housing and take hose -1- off.

Unscrew the air filter housing securing bolt -arrow-.

Pull the air filter housing on the right side upwards off the rubber mounting -arrow-.

Separate the connector -arrow- on the rear of the air filter housing.

Remove the air filter housing from the vehicle.

Push down the protective cap in -direction of arrow- from the solenoid switch.

Unscrew the positive wire -1- and disconnect the connector from terminal 50 -2-.

Remove noise insulation.

Unscrew the securing nut -1- from the lower starter securing bolt.

Remove wiring retainer -2-.

Remove the lower securing bolt of the starter -arrow-.

Remove the starter from the vehicle downwards.

For installation, carry out the procedure in the reverse order, tightening threaded connections to specified torque settings.

The required special tools and workshop equipment are:

Torque wrench -V.A.G 1331-

Torque wrench -V.A.G 1332-

Spring-type clip pliers -VAS 5024-

The removal steps are:

Disconnect the battery.

Unbolt the securing bolts -arrow-.

Disconnect the connector -arrow-.

Loosen the spring-type clips -1- using spring type clip pliers -VAS 5024- .

Pull the engine cover off upwards -arrows-.

Push down the protective cap in -direction of arrow- from the solenoid switch.

Unscrew the positive wire -1- and disconnect the connector from terminal 50 -2-.

Remove the upper securing bolt of the starter -arrow-.

Remove the lower securing bolt of the starter -arrow-.

Remove the starter from the vehicle upwards.

For installation, carry out the procedure in the reverse order, tightening threaded connections to specified torque settings.

The removal steps are:

Disconnect the battery.

Push down the protective cap in -direction of arrow- from the solenoid switch.

Unscrew the positive wire -1- and disconnect the connector from terminal 50 -2-.

Unscrew the earth wire from the starter securing bolt -arrow-.

Unscrew the starter securing bolt -arrow-.

Remove noise insulation.

Unscrew the securing nut -1- from the lower starter securing bolt.

Remove wiring retainer -2-.

Unscrew the starter securing bolt -arrow-.

Remove the starter from the vehicle downwards.

For installation, carry out the procedure in the reverse order, tightening threaded connections to specified torque settings.

The removal steps are:

Disconnect the battery.

Unbolt the securing bolts -arrow-.

Disconnect the connector -arrow-.

Loosen the spring-type clips -1- using spring type clip pliers -VAS 5024 A- .

Pull the engine cover off upwards -arrows-.

Push down the protective cap in -direction of arrow- from the solenoid switch.

Unscrew the positive wire -1- and disconnect the connector from terminal 50 -2-.

Unscrew the earth wire from the starter securing bolt -arrow-.

Unscrew the starter securing bolt -arrow-.

Remove noise insulation.

Unscrew the securing nut -1- from the lower starter securing bolt.

Remove wiring retainer -2-.

Unscrew the starter securing bolt -arrow-.

Remove the starter from the vehicle downwards.

For installation, carry out the procedure in the reverse order, tightening threaded connections to specified torque settings.

The removal steps are:

Disconnect the battery.

Pull the engine cover off upwards -arrows-.

Separate connector -1-, release spring-type clip -2- with spring type clip pliers -VAS 5024- and pull off vacuum hose -3-.

Pull the air filter housing upwards out of the brackets and remove.

Push down the protective cap in -direction of arrow- from the solenoid switch.

Unscrew the positive wire -1- and disconnect the connector from terminal 50 -2-.

Unclip hose -1- from hose retainer -2-.

Remove the upper securing bolt of the starter -arrow-.

Remove the lower securing bolt of the starter -arrow-.

Remove the starter from the vehicle upwards.

For installation, carry out the procedure in the reverse order, tightening threaded connections to specified torque settings.

The general torque settings for all alternator threaded connections are:

To check the ribbed belt (poly V-belt):

Crank the engine at the vibration damper/belt pulley using a socket.

Check the fit of the ribbed belt (poly V-belt).

Inspect for:

Sub-surface cracks (cracks, core ruptures, cross sectional breaks)

Layer separation (top layer, draw strands)

Chassis breakout

Fraying of cord strands

Flank wear (material wear, frayed flanks, flank brittleness (glassy flanks), surface cracks)

Traces of oil and grease

Caution: It is essential to renew the poly V-belt if faults are found to avoid possible break-downs or operating problems.

The assembly overview for the alternator on the 1.6 l injection engine includes:

1 – Hexagon head collared bolt (M8x108, 23 Nm)

2 – Hexagon head collared bolts (M8x50, 23 Nm)

3 – Bracket

4 – Hexagon head collared nut (M8)

5 – Hexagon head collared bolts (M8x45, 52 Nm)

6 – Protective cap

7 – Hexagon head collared nut (M8)

8 – Cross-head screw (M5x21, 4.5 Nm)

9 – Hexagon nut, flat (M8)

10 – Plain washer (M5)

11 – Phillips screws (M4x19, 2 Nm)

12 – Cross-head screw (M4x13, 2 Nm)

13 – Voltage regulator (Removing and installing voltage regulator, page 142)

14 – Alternator (Removing and installing alternator, page 105)

15 – Poly V-belt (Checking, page 98)

16 – Hexagon head collared bolts (M8x90, 23 Nm)

17 – Hexagon head collared bolts (M8x50, 25 Nm)

18 – Tensioning element

19 – Bracket (For tensioning element and air conditioner compressor)

20 – Hexagon head collared bolt (M10x50, 20 Nm + 1/4 turn (90°) further)

21 – Spacer sleeve

For the 1.6 l injection engine with an air conditioning system, the ribbed belt routing components are:

1 – Ribbed belt (poly V-belt) pulley – Coolant pump

2 – Tensioning roller

3 – Ribbed belt (poly V-belt) pulley – Alternator

4 – Tensioning roller

5 – Ribbed belt (poly V-belt) pulley – Air conditioner compressor

6 – Poly V-belt

7 – Ribbed belt (poly V-belt) pulley – Crankshaft

The assembly overview for the alternator on the 2.0 l FSI engine includes:

1 – Hexagon head collared bolts (M8x90, 23 Nm)

2 – Hexagon head collared bolts (M8x50, 23 Nm)

3 – Transport bracket

4 – Tensioning element for poly V-belt

5 – Compact bracket (For alternator and air conditioner compressor, Tightening sequence)

6 – Hexagon head collared bolts (M10x45, 52 Nm)

7 – Protective cap

8 – Hexagon head collared nut (M8)

9 – Cross-head screw (M5x21, 4.5 Nm)

10 – Hexagon nut, flat (M8)

11 – Plain washer (M5)

12 – Phillips screws (M4x19, 2 Nm)

13 – Cross-head screw (M4x13, 2 Nm)

14 – Voltage regulator (Removing and installing voltage regulator, page 142)

15 – Alternator (Removing and installing alternator, page 109)

16 – Poly V-belt (Checking, page 98)

For the 2.0 l FSI engine without air conditioning system, the ribbed belt routing components are:

1 – Tensioning roller

2 – Ribbed belt pulley – Alternator

3 – Poly V-belt

4 – Ribbed belt pulley – Crankshaft

For the 2.0 l FSI engine with air conditioning system, the ribbed belt routing components are:

1 – Tensioning roller

2 – Ribbed belt pulley – Alternator

3 – Ribbed belt pulley – Air conditioner compressor

4 – Poly V-belt

5 – Ribbed belt pulley – Crankshaft

The torque settings for alternator threaded connections on the 1.9 l TDI engine are:

For the 1.9 l TDI engine without air conditioning system, the ribbed belt routing components are:

1 – Tensioning roller

2 – Ribbed belt pulley – Alternator

3 – Poly V-belt

4 – Ribbed belt pulley – Crankshaft

For the 1.9 l TDI engine with air conditioning system, the ribbed belt routing components are:

1 – Tensioning roller

2 – Ribbed belt pulley – Alternator

3 – Ribbed belt pulley – Air conditioner compressor

4 – Poly V-belt

5 – Ribbed belt pulley – Crankshaft

The assembly overview for the alternator on the 2.0 l TDI engine includes:

1 – Hexagon head collared bolts (M8x45, 20 Nm)

2 – Tensioning element for poly V-belt

3 – Hexagon head collared bolts (M8x90, 20 Nm)

4 – Compact bracket (For alternator and air conditioner compressor, Tightening sequence)

5 – Hexagon head collared bolts (M10x65, 40 Nm)

6 – Hexagon head collared bolts (M10x45, 40 Nm)

7 – Phillips screws (M4x20, 2 Nm)

8 – Protective cap for alternator

9 – Voltage regulator (Removing and installing voltage regulator, page 142)

10 – Alternator (Removing and installing alternator, page 133)

11 – Poly V-belt (Checking, page 98)

The removal steps are:

Disconnect the battery.

Pull the engine cover off upwards -arrows-.

Unbolt securing bolts -arrow-.

Disconnect the connector -arrow-.

Loosen the spring-type clips -1- using spring type clip pliers -VAS 5024 A- .

Pull the hose -1- off the air filter housing.

Open the retainer -arrow- on the front side of the air filter housing and take hose -1- off.

Unscrew the air filter housing securing bolt -arrow-.

Pull the air filter housing on the right side upwards off the rubber mounting -arrow-.

Separate the connector -arrow- on the rear of the air filter housing.

Remove the air filter housing from the vehicle.

Push down the protective cap in -direction of arrow- from the solenoid switch.

Unscrew the positive wire -1- and disconnect the connector from terminal 50 -2-.

Unscrew the earth wire from the starter securing bolt -arrow-.

Unscrew the starter securing bolt -arrow-.

Remove noise insulation.

Unscrew the securing nut -1- from the lower starter securing bolt.

Remove wiring retainer -2-.

Unscrew the starter securing bolt -arrow-.

Remove the starter from the vehicle downwards.

For installation, carry out the procedure in the reverse order, tightening threaded connections to specified torque settings.

The torque settings for the alternator threaded connections for the 1.6 l injection engine and 2.0 l FSI engine are:

Caution: In order to avoid damage to the cylinder block and compact bracket, you must respect the tightening sequence for the compact bracket.

The tightening sequence for the compact bracket to the cylinder block is:

Before tightening to the specified torque setting, screw in all bolts by hand. Tighten securing bolts of the compact bracket in the following sequence:

A – Hexagon head collared bolt, M10x45, 52 Nm, locating hole

B – Hexagon head collared bolt, M10x45, 52 Nm

C – Hexagon head collared bolt, M10x45, 52 Nm

D – Hexagon head collared bolt, M10x45, 52 Nm

E – Hexagon head collared bolt, M10x45, 52 Nm

F – Hexagon head collared bolt, M10x45, 52 Nm

The torque settings for the alternator threaded connections for the 2.0 l FSI turbo engine are:

Caution: In order to avoid damage to the cylinder block and compact bracket, you must respect the tightening sequence for the compact bracket.

The tightening sequence for the compact bracket to the cylinder block is:

Before tightening to the specified torque setting, screw in all bolts by hand. Tighten securing bolts of the compact bracket in the following sequence:

A – Cylinder collar screw, M10x45, 40 Nm, locating hole

B – Cylinder collar screw, M10x45, 40 Nm

C – Cylinder collar screw, M10x45, 40 Nm

D – Cylinder collar screw, M10x45, 40 Nm

E – Cylinder collar screw, M10x45, 40 Nm

F – Cylinder collar screw, M10x45, 40 Nm

The torque settings for the alternator threaded connections for the 2.5 l injection engine are:

Note that for the compact bracket, no tightening torque must be observed.

The torque settings for exterior lights, bulbs, and switches are:

The torque settings for cables in the electronics box in the left side of the engine compartment are:

The torque settings for the trailer detector control unit -J345- are: