VOLKSWAGEN BORA VARIANT 1999 (02) PDF Document

The Repair Groups for the electrical system of a VOLKSWAGEN BORA VARIANT 1999 are as follows:

Repair Group

27 – Starter, current supply, CCS

90 – Gauges, instruments

92 – Windscreen wash/wipe system

94 – Lights, bulbs, switches – exterior

96 – Lights, bulbs, switches – interior

97 – Wiring

To ensure long use of the battery in your VOLKSWAGEN BORA VARIANT 1999, it must be checked, serviced, and maintained according to the specifications in the 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 electrical onboard supply of the vehicle.

When handling batteries for your VOLKSWAGEN BORA VARIANT 1999, observe the following warnings:

• Untrained personnel (e.g., apprentices, trainees) may only work on batteries when supervised by a vehicle mechanic/foreman or vehicle electrician/foreman.

• Acid is highly corrosive. There is a considerable danger of acid burns if personnel do not handle batteries correctly. Ensure suitable measures, like a soap solution, are available to neutralize acid burns.

• If electrolyte leaks from a battery, it may cause skin burns or acid corrosion and 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.

• Batteries with a colourless or light yellow magic eye must be renewed. They must not be checked, charged, or used for a slave/jump start due to the danger of explosion.

• It is prohibited to cause sparks (through grinding, welding, cutting, naked lights) in the vicinity of batteries. Smoking is also prohibited. Avoid sparks from electrostatic charging by touching the vehicle body before touching the battery.

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

The safety markings on a VOLKSWAGEN BORA VARIANT 1999 battery indicate the following precautions:

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

2. Wear eye protection before working on the battery.

3. Keep children away from acid and batteries.

4. Disposal: Old batteries are hazardous waste and must be disposed of through a suitable collection centre according to legislation.

5. Never dispose of old batteries in household waste.

6. Danger of explosion: A highly explosive gas is produced when batteries are charged.

7. Always follow instructions on the battery and in the owner’s manual.

8. Battery acid is very caustic. Wear eye protection and gloves. Do not tilt the battery, as acid can leak from gas vents.

To prevent damage to the battery clamps and terminals on your VOLKSWAGEN BORA VARIANT 1999, observe the following:

• The battery clamps should only be fitted by hand and without using force.

• Battery terminals should not be coated with grease.

• The battery clamps should be fitted so that the battery terminal is either flush with the clamp or protruding from it.

• Once the battery clamps have been tightened to the specified torque, the threaded connections should not be tightened any further.

It is essential to visually inspect the external condition, check the terminals, and ensure proper attachment of the battery on your VOLKSWAGEN BORA VARIANT 1999 before performing extensive tests. This check establishes:

• If 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 components affected by leaked battery acid immediately with an acid neutraliser or a soap solution.

• If the battery terminals are damaged: The necessary contact on the battery clamps cannot be guaranteed. When connecting the battery clamps, tighten them to the specified torque. If not correctly seated and tightened, the wiring may burn, causing malfunctions in the electrical system.

Caution:

• The battery will be damaged if it is not secured correctly.

• Vibrations shorten the life of the battery, and there is a danger of explosion. The cell plates may be damaged, and the clamping bracket may damage the battery housing.

• Check that the battery is securely seated. If necessary, tighten the securing bolt to the specified torque.

The “3-colour” magic eye on the battery of your VOLKSWAGEN BORA VARIANT 1999 provides information on the electrolyte level and charge state. Before checking, lightly tap the magic eye with a screwdriver handle to dissipate any air bubbles that could distort the display.

The possible colour displays are:

• »Green«: The battery is charged sufficiently.

• »Black«: The battery is partly discharged (charge state < 65%) or completely discharged.

• »Colourless or light yellow«: The battery must be renewed. Do not check, charge, or slave/jump start a battery with this display due to the danger of explosion.

Note: The display applies only to the one cell where the magic eye is located. An exact determination of the battery condition is only possible through a battery load test.

To perform a battery load test on your VOLKSWAGEN BORA VARIANT 1999 with the VAS 5097 A tester, follow these steps:

1. Ensure the battery has a temperature of at least 10 °C.

2. Switch off the ignition and all electrical consumers.

3. Check the magic eye on batteries equipped with one.

4. Check the low-temperature test current in amperes (A) according to DIN from the indications on the battery. If values are shown in IEC or EN/SAE, convert them using the provided table.

5. Select the low-temperature test current and measuring range (80 – 379 A or 380 – 499 A) on the tester.

6. Connect the red terminal “+” of the tester to the positive battery terminal and the black terminal “-” to the negative terminal. Ensure a good contact.

7. Select the point of connection (directly to battery or to external test points) with the selection switch.

8. Press the start test button. The green LED will light up, and the test program will run automatically.

9. The test result will be printed out. If the unit does not start (no LED, no printout), recharge the battery and test again.

10. After the test (approx. 20 seconds), switch off the unit and remove the test terminals.

Note: Perform the test only once, as repeating it can falsify the result. The tester requires approximately 30 minutes to cool down before the next test.

Use the following table to assess the printout from the VAS 5097 A battery tester for your VOLKSWAGEN BORA VARIANT 1999 and determine the necessary measures:

To perform a battery test with the VAS 6161 tester on your VOLKSWAGEN BORA VARIANT 1999, follow these steps:

1. Switch off the ignition and all electrical consumers.

2. Check the magic eye on batteries equipped with one. Do not test batteries with a colorless or light yellow magic eye.

3. Switch on the VAS 6161 unit.

4. Connect the red terminal “+” of the tester to the positive battery terminal.

5. Connect the black terminal “-” of the tester to the negative battery terminal. Ensure a good contact.

6. Select one of the following functions on the tester:

• Maintenance test: (only in new cars before registration, in stationary and stock maintenance programme)

• Service test

• Guarantee test

7. Follow the on-screen prompts for the selected test, which may include scanning the vehicle identification number, selecting the test point (battery terminal or jump-start point), selecting battery type, and measuring temperature.

8. Start the test. The test is completed after about 10 seconds, and the result is printed out.

The following tables provide the measures to be taken based on the test results from the VAS 6161 tester for your VOLKSWAGEN BORA VARIANT 1999.

Evaluating battery test results for guarantee and service tests:

Evaluating battery test results for maintenance test:

A current draw test helps to quickly ascertain the state of a discharged battery in your VOLKSWAGEN BORA VARIANT 1999. It determines whether the battery must be replaced or can be fully recharged.

Test requirements:

• When charging, the battery temperature must be at least +10 °C.

• The charger must be capable of outputting a charge current of at least 30 A (e.g., VAS 5095A, VAS 5900, VAS 5903).

• The battery’s current draw must be measured with a current pick-up clamp.

Procedure:

1. Connect the battery to the battery charger and start the charging sequence.

2. Measure the charging current of the battery after 5 minutes.

Test result:

• If the current draw (in Amperes) is higher than 10% of the nominal capacity (e.g., > 6.1 A for a 61 Ah battery), fully charge the battery and test again.

• After a full charge, allow the battery to rest for two hours and then perform a battery test.

• If the charge current lies below 10% of the nominal capacity after 5 minutes of charging, the battery must be renewed.

The no-load voltage test is used to assess the battery’s condition on stock and stored vehicles as part of prescribed maintenance. A hand multimeter like the V.A.G 1526 B is required.

Test conditions:

The battery must not have been charged or discharged within the last 2 days.

Procedure:

Check the battery no-load voltage with the hand multimeter.

Results:

A no-load voltage of 11.60 V indicates a 0% charge, meaning the battery is discharged and has no capacity.

To charge the battery of your VOLKSWAGEN BORA VARIANT 1999 with the VAS 5095 A charger, follow these steps:

1. Ensure the battery temperature is at least 10 °C.

2. Switch off the ignition and all electrical consumers.

3. On the base of the charger unit, set the battery type switch to 2.4 V/C (volts/battery cell).

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

5. Connect the black terminal clamp “-” of the charger to the negative terminal on the battery. For vehicles with a start/stop function and battery monitor control unit, connect the black terminal clamp to body earth to avoid system malfunctions.

6. Switch on the battery charger using the ON/OFF switch.

7. Monitor the charging current indicators. When both yellow LEDs (indicators 2 and 3) are lit, the battery is charging. When only LED 3 is lit yellow, the battery is approximately 90% charged.

8. When the LED (indicator 4) lights up green, the charger has switched to “maintaining charge,” and the battery is fully charged.

9. Switch off the charging unit.

10. Remove the charger unit terminals from the battery terminals.

The functions of the cruise control system (CCS) on your VOLKSWAGEN BORA VARIANT 1999 are controlled by the engine control unit. To activate or deactivate the system, you need to use a vehicle diagnostic tester.

1. Connect the vehicle diagnostic tester to the vehicle.

2. Select the “Guided fault finding” mode on the tester.

3. Using the “GoTo” button, select “Functions/component” and navigate through the following menu options in succession:

• Drive

• Engine code

• 01 – On Board Diagnostic capable systems

• Engine management/diesel direct injection and glow plug system

• Functions

• Activating and deactivating cruise control system (CCS)

Follow the on-screen instructions on the diagnostic tester to complete the activation or deactivation process.

Different hose coupling types are used on the VOLKSWAGEN BORA VARIANT 1999. Follow these instructions based on the type you are working with:

Type 1 (No securing device):

• To loosen: Pull the two coupling sections apart.

• To secure: Push the two coupling sections together until you hear and feel them engage.

Type 2 (Rotate lock ring):

• To loosen: Rotate the lock ring -1- through 90° and pull off the hose connection.

• To secure: Push on the hose connection and rotate the lock ring -1- until it engages.

Type 3 (Pull up lock ring):

• To loosen: Pull up the lock ring -1- by approx. 1 mm and pull off the hose connection.

• To secure: Attach the hose connection and press in the clip -1- until it engages.

Headlight Washer System Type:

• To loosen: Push the lock ring -1- and pull off the hose connection.

• To secure: Push and hold the lock ring and push on the hose connection. Check that the securing clip has correctly engaged by trying to pull it off without the clip.

To repair a smooth pipe (5×1 mm or 6×1 mm diameter) on the washer system of your VOLKSWAGEN BORA VARIANT 1999, follow these steps:

1. Cut the damaged section out of the smooth pipe at right angles.

2. Select the appropriate EPDM hose and cable ties from the electronic parts catalogue (ETKA).

3. Cut a piece of the EPDM hose so that the ends of the smooth pipe can each be pushed about 10 mm into it.

4. Secure both repair joints with cable ties.

To repair a corrugated washer pipe on your VOLKSWAGEN BORA VARIANT 1999, you will need a hot air blower (e.g., VAS 5179) and the correct replacement parts from the electronic parts catalogue (ETKA).

Note: Repair points must not be subjected to pulling or bending forces. If the damaged section is longer than 20 mm, a new piece of corrugated pipe must be used.

Procedure:

1. Cut the damaged section out of the corrugated pipe at right angles.

2. Select suitable end pieces and the correct sized heat-shrink piping from the parts catalogue.

3. Heat one end of the corrugated pipe.

4. Push a connector into the heated end.

5. Heat the other end of the corrugated pipe.

6. Push the other connector into that end.

7. Cut the heat-shrink hose so that the ends of the corrugated pipe are each covered by about 20 mm of the hose.

8. Push the heat-shrink hose over the corrugated pipe, join the connectors, and secure the repair joints by applying heat with the hot air blower.

Working on gas discharge (xenon) headlights on your VOLKSWAGEN BORA VARIANT 1999 is dangerous due to extremely high voltage. Always follow these safety procedures:

High Voltage Danger:

• It is absolutely necessary to disconnect the battery earth strap before working on any parts of the gas discharge headlights (marked with yellow high voltage symbols).

• After disconnecting the battery, switch the dipped beam on and off again to eliminate any possible residual voltage.

• Never operate the gas discharge lamp control unit without a gas discharge lamp installed.

• The gas discharge bulb must only be operated inside the headlight housing due to the high ignition voltage (above 28,000 V).

• Control units, connectors, and components conduct lethally high voltage. Operating them is only permitted with the bulb fully fitted.

Pressure, Temperature, and Radiation Risks:

• The bulbs can only be operated in the headlight housing to protect against very hot surfaces, UV radiation, and explosion.

• The glass of the bulbs can be very hot, posing a burn risk.

• Avoid looking directly into the beam, as the UV rays are much stronger than from halogen bulbs.

• H7 and gas discharge bulbs are under pressure and can explode while being changed, causing injury. Always wear protective goggles and gloves.

• Avoid contact with burst bulbs.

When repairing or replacing gas discharge bulbs on your VOLKSWAGEN BORA VARIANT 1999, follow these specific procedures.

Repair Notes:

• Before changing a bulb, switch off the ignition and all electrical consumers and remove the ignition key.

• Do not touch the new bulb glass with bare fingers; use clean cloth gloves. Oils from fingerprints can vaporize and damage the reflector.

• Always replace a bulb with one of the same type. The designation is on the bulb’s base or glass.

• Ensure connectors are properly engaged and seated tightly during installation.

Disposal Regulations:

• Gas discharge bulbs must be disposed of as hazardous waste. Never dispose of them as conventional waste.

• These bulbs contain metallic mercury (Hg) and traces of thallium. Never destroy them.

• These components must be recycled in accordance with national law.

• Dispose of them only in containers intended for this purpose at an authorized collection point.

To remove and install an illuminated cigarette lighter socket on your VOLKSWAGEN BORA VARIANT 1999, you will need the special puller tool T 40148.

Caution: Only illuminated sockets can be removed with this puller. Sockets without illumination usually cannot be removed without being damaged.

Removing:

1. If present, remove the cigarette lighter or dummy plug from the socket.

2. Push the puller (T 40148) into the socket so that its locking lugs engage in the recesses inside the socket.

3. Pull the grip on the tool to release the locking lugs of the retaining sleeve.

4. Pull the socket out of the retaining sleeve using the puller. Take care not to stretch the wiring.

5. Pull off the socket connector.

6. To remove the puller from the socket, press the spindle on the tool and turn the puller briefly to the left to release its locking lugs.

Installing:

Installation is carried out in the reverse order of removal. After removing the socket, carefully press the retaining springs in the housing together and check that the cigarette lighter stays in place after its heating phase.

To replace the illumination bulb in the cigarette lighter of your VOLKSWAGEN BORA VARIANT 1999, first, the socket must be removed.

Note: On some vehicles, illumination is provided by a permanently attached LED that cannot be renewed separately. On others, the bulb may be part of a bulb carrier that must be replaced as a whole unit.

Removing:

1. Remove the cigarette lighter socket from the dashboard.

2. Press the retaining lugs on the side of the retaining sleeve and remove the sleeve together with the bulb carrier.

3. Unclip the bulb carrier from the retaining sleeve.

4. To access the bulb, separate the bulb carrier at points -A- and -B-.

5. Open part -B- of the bulb carrier.

6. Remove the light bulb in the direction of the arrow.

Installing:

Installation is carried out in the reverse order of removal.

When performing repairs on the electrical system of your VOLKSWAGEN BORA VARIANT 1999, it is crucial to follow these guidelines:

• Always observe the latest notes in the respective workshop manual and any country-specific regulations.

• Always disconnect the battery earth strap before working on the electrical system to ensure a safe working environment.

• Before starting a repair, identify and rectify the cause of the damage (e.g., sharp edges, corrosion, defective components).

• Soldering is not permitted for repairs to vehicle wiring.

• Use the appropriate wiring harness repair set for all wiring and connector repairs.

• Wiring harness repairs should be marked with yellow adhesive tape to indicate a previous repair.

• Crimp connectors may never be repaired. If needed, lay new wiring parallel to the defective section. After crimping, connectors must be shrink-fitted to prevent moisture ingress.

• After every repair, carry out a function test. It may be necessary to interrogate and erase the fault memory.

• If possible, do not loosen any earth wires from the body to avoid the danger of corrosion.

• Screened wires must not be repaired; they must be replaced completely if damaged.

• For heat-resistant wiring (identifiable by its slightly matt and softer insulation), only use heat-resistant wiring for repairs.

To repair a damaged wire with a single crimp connector on your VOLKSWAGEN BORA VARIANT 1999, follow these steps:

1. If necessary, unbind the wiring harness using a folding knife.

2. Cut out the damaged piece of wiring using wire strippers (e.g., VAS 1978/3).

3. Strip the insulation from both ends of the wire by 6 – 7 mm.

4. Push a crimp connector onto both stripped wire ends and crimp it on using the correct recess in the crimping pliers. The insulation on the wires must not be crimped.

5. Place the shrink element for the hot air blower over the hot air blower nozzle.

6. Heat up the crimp connector using the hot air blower, working from the middle outwards along a straight line until it is completely sealed and adhesive escapes from the ends. Be careful not to damage any other wiring or plastic parts.

7. If the repair position was previously wrapped, re-wrap it with yellow insulation tape.

8. Attach the repaired wiring harness with a cable tie if necessary to prevent it from generating noise.

Note: If several wires are repaired, ensure the crimp connectors are offset slightly and not directly adjacent to each other to prevent the harness from becoming too thick.

To renew a Lambda probe (LSF 4-pin or LSU 6-pin) on your VOLKSWAGEN BORA VARIANT 1999, follow this general procedure:

Important: Do not repair, crimp, or cut Lambda probe wires, as this will lead to malfunctions.

1. Remove the defective Lambda probe from the vehicle.

2. Place the new uniform probe and the old defective probe next to each other, aligning the sensor housings so they are at the same height.

3. Tie back any excess length in the new uniform probe’s cable (approx. 50 – 250 mm) to match the length of the old probe’s cable. Secure the excess with cable ties.

4. Check that the connector housing of the new Lambda probe is compatible with the connector on the vehicle’s onboard supply side. On older vehicles, it may be necessary to replace the onboard supply system connector with the new one provided with the probe.

5. Install the new Lambda probe in the vehicle.