VOLKSWAGEN CC 2010 (01) PDF Document

The repair groups for the electrical system of a VOLKSWAGEN CC 2010 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

There are two main types of maintenance-free batteries used in the VOLKSWAGEN CC 2010:

Battery with magic eye:

This is a maintenance-free wet battery with liquid electrolyte. It is equipped with a “magic eye” that provides information about the electrolyte level and the charge state through a colored display. You should not remove any stickers or replenish it with distilled water; only perform a visual check.

WARNING: Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not jump-start the vehicle. These batteries must be renewed due to the danger of explosion.

Absorbent glass mat (AGM) battery:

This is a maintenance-free lead-acid battery where the electrolyte is contained within a microscopic glass mat. It is sealed, fitted with valves, and does not have a magic eye. AGM batteries are identified by the abbreviation “AGM” on the battery. If you need to replace an AGM battery, it must be replaced with another AGM battery.

When handling the vehicle battery for your VOLKSWAGEN CC 2010, observe the following safety warnings:

♦ Untrained personnel should only work on batteries when supervised by a qualified mechanic or electrician.

♦ Battery acid is highly corrosive. Take measures to neutralize acid burns, for example, by having a soap solution available.

♦ Leaking electrolyte can cause skin burns and corrosion on the vehicle.

♦ Gas formed during charging is explosive. An incorrectly handled battery may explode.

♦ Batteries with a colorless or light yellow magic eye must be renewed. Do not check, charge, or jump-start them.

♦ It is prohibited to cause sparks, use naked lights, or smoke near batteries. Avoid electrostatic discharge by touching the vehicle body before touching the battery.

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

The safety markings on your VOLKSWAGEN CC 2010’s battery indicate the following precautions:

1. Fires, sparks, naked flames, and smoking are prohibited. Avoid sparks and short circuits. Never lay a tool on a battery.

2. Wear eye protection before working on the battery.

3. Keep children away from acid and batteries.

4. Old batteries are hazardous waste and must be disposed of at a suitable collection center 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 caustic. Wear eye protection and gloves. Do not tilt the battery, as acid can leak from vents.

To prevent damage to the battery clamps and terminals on your VOLKSWAGEN CC 2010, observe the following:

♦ Fit the battery clamps by hand only, without using force.

♦ Do not coat battery terminals with grease.

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

♦ Once the clamps are tightened to the specified torque, do not tighten them any further.

A visual inspection is essential to check the external condition, terminals, and proper attachment of the battery before performing extensive tests. This check establishes:

♦ If the battery housing is damaged: Leaking electrolyte can cause serious damage to the vehicle. Treat any affected components immediately with an acid neutralizer or soap solution.

♦ Whether the battery terminals are damaged: Damaged terminals can prevent proper contact with the battery clamps. When connecting, tighten the clamps to the specified torque. Incorrectly seated or tightened clamps can cause wiring to burn and lead to electrical system malfunctions.

CAUTION:

♦ The battery will be damaged if not secured correctly.

♦ Vibrations shorten battery life and can damage cell plates and the battery housing, creating an explosion risk.

♦ Always check that the battery is securely seated and, if necessary, tighten the securing bolt to the specified torque.

Before checking, lightly tap the magic eye with a screwdriver handle to dissipate any air bubbles that could distort the color. The ‘3-colour’ display indicates the following:

♦ Green: The battery is sufficiently charged.

♦ 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 jump-start a battery in this state, as there is a danger of explosion.

Note: The magic eye only reflects the condition of one cell. A full battery condition assessment requires a battery load test.

For newer batteries, the ‘green’ display has been discontinued. Before checking, lightly tap the magic eye with a screwdriver handle to dissipate any air bubbles. The ‘2-colour’ display provides information about the electrolyte level:

♦ Black: The electrolyte level is OK.

♦ Colourless or light yellow: The electrolyte level is too low. The battery must be renewed. Do not check, charge, or jump-start a battery in this state, as there is a danger of explosion.

Note: The charge state can no longer be read from the magic eye; a battery load test is required for this.

To perform a battery load test 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 that have one.

4. Check the low-temperature test current in amperes (A) according to DIN on the battery. If the values are in IEC or EN/SAE, use the conversion table.

5. On the tester, select the low-temperature test current using the selection switch.

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

7. Connect the red terminal clamp (+) of the tester to the positive terminal of the battery.

8. Connect the black terminal clamp (-) of the tester to the negative terminal of the battery. Ensure a good contact.

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

10. Press the start test button. The test will run automatically for about 20 seconds, and the result will be printed out.

11. If the unit does not start (no LED, no print out), recharge the battery and test again.

12. After the test, switch off the unit and remove the test terminals.

Note: Perform the test only once. Repeating the test immediately will falsify the result. The tester requires approximately 30 minutes to cool down before the next test.

Based on the printout from the VAS 5097 A battery tester, take the following measures:

To perform a battery test with the VAS 6161 tester, follow these steps:

1. Switch off the ignition and all electrical consumers.

2. Check the magic eye on batteries that have one.

3. Switch on the VAS 6161 unit.

4. Connect the red terminal clamp (+) to the positive terminal of the battery.

5. Connect the black terminal clamp (-) to the negative terminal of the battery. Ensure a good contact.

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

♦ Maintenance test: For new cars before registration or in stationary/stock maintenance.

♦ Service test: For regular service checks.

♦ Guarantee test: For warranty claims.

7. Follow the on-screen prompts, which may include scanning a vehicle identification number or barcode, selecting battery type, and measuring temperature.

8. Hold the temperature sensor about 5 cm above a battery terminal until the temperature stabilizes.

9. Start the test. The test completes in about 10 seconds, and the result is printed out.

The following tables explain the measures to be taken based on the results from the VAS 6161 tester.

Evaluating battery test results for guarantee and service tests:

Evaluating battery test results for maintenance test:

A current draw test helps determine if a discharged battery must be replaced or can be fully recharged. This test should be performed when indicated by a battery tester like the VAS 5097A or VAS 6161.

Test requirements:

♦ Battery temperature must be at least +10 °C.

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

♦ A current pick-up clamp is needed to measure the current draw.

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 is higher than 10% of the nominal capacity (e.g., > 6.1 A for a 61 Ah battery), fully charge the battery and test it again after allowing it to rest for two hours.

♦ If the charge current is below 10% of the nominal capacity after 5 minutes, the battery must be renewed.

This test is used to assess the battery’s condition on stock and stored vehicles as part of prescribed maintenance.

Test conditions:

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

Procedure:

Check the battery no-load voltage with a hand multimeter (e.g., V.A.G 1526 B).

Assessment:

A no-load voltage of 11.60 V corresponds to a 0% charge, indicating the battery is heavily discharged.

To charge the battery using 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, set the battery type switch to 2.4 V/C (volts/battery cell). This applies to all batteries.

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.

Note: For vehicles with a start/stop function and battery monitor control unit (J367), the black terminal clamp must be connected to body earth, not the negative battery terminal, to avoid system malfunction.

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

7. The charging current indicators will light up yellow. When only the indicator for “> 90%” is lit, the battery is almost fully charged. When the “Maintaining charge” indicator lights up green, the battery is fully charged.

8. Once charging is complete, switch off the charging unit.

9. Remove the charger terminals from the battery terminals.

The procedure is similar for both the VAS 5900 and VAS 5903 chargers:

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

2. Switch off the ignition and all electrical consumers.

3. Connect the charger plug to the battery charger. The last selected battery type will appear on the display.

4. Press the INFO button to set the battery to the respective operating mode (e.g., “standard charge for wet batteries” or “standard charge for gel/AGM batteries”).

5. Set the battery capacity (Ah) using the “Up” (↑) and “Down” (↓) buttons.

6. Connect the red terminal clamp (+) to the positive terminal on the battery.

7. Connect the black terminal clamp (-) to the negative terminal.

Note: For vehicles with a start/stop function and battery monitor control unit (J367), the black terminal clamp must be connected to body earth to avoid system malfunction.

8. The charger will recognize the battery voltage and begin the charging sequence automatically. Bars on the display indicate the charge level.

9. At 100% charge, all bars will appear in the display, and the charger will switch to maintenance mode after 1-7 hours.

To end the charging sequence:

1. Press the START / STOP button.

2. Disconnect the black terminal clamp, then the red terminal clamp.

3. Unplug the charger.

If you encounter issues while charging the battery of your VOLKSWAGEN CC 2010 with a VAS 5900 or VAS 5903 charger, try the following:

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

Press the “Up” (↑) or “Down” (↓) button until the charging sequence starts.

2. Displayed battery voltage is not as per nominal voltage, but charging has already started:

Press the START / STOP button twice. Then, press the “Up” (↑) or “Down” (↓) button until the charging sequence starts again.

3. Battery charger does not detect a battery (when battery voltage is less than 2 V):

The display remains unchanged. The charger will not recognize a totally discharged battery. A special procedure is required for charging totally discharged batteries.

The functions of the cruise control system (CCS) on your VOLKSWAGEN CC 2010 are controlled by the engine control unit. To activate or deactivate the system, you can use the vehicle diagnostic tester:

1. Connect the vehicle diagnostic tester.

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

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

♦ 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)

Different hose coupling types are used for the washer systems. Here is how to handle them:

Type 1 (Simple Push-Fit):

♦ To loosen: Pull the two coupling sections apart (no securing device).

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

Type 2 (Rotating 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/Clip):

♦ To loosen: Pull up the lock ring/clip -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 (Push Lock Ring):

♦ 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 clip has engaged correctly by trying to pull it off without the clip being depressed.

To repair a smooth pipe (5×1 mm or 6×1 mm diameter) on your VOLKSWAGEN CC 2010, 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 the EPDM hose so that the ends of the smooth pipe can each be pushed about 10 mm into the EPDM hose.

4. Secure the repair joints with cable ties.

To repair a corrugated washer hose on your VOLKSWAGEN CC 2010, you will need a hot air blower and the correct replacement parts.

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

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

3. Heat the end of one piece of the corrugated pipe.

4. Push a connector into that heated end.

5. Heat the end of the other piece of corrugated pipe.

6. Push the other connector into that heated end.

7. Cut a piece of 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 heating the heat-shrink hose until it is sealed.

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.

Gas discharge (xenon) headlights operate at extremely high voltages. Observe the following safety precautions:

♦ High Voltage: Control units, connectors, and bulb holders conduct lethally high voltage. It is absolutely necessary to disconnect the battery earth strap before working on any parts marked with yellow high voltage symbols.

♦ Residual Voltage: After disconnecting the battery, switch the dipped beam on and off again to eliminate any possible residual voltage.

♦ Pressure: H7 and gas discharge bulbs are under pressure and can explode if changed improperly, causing injury. Always wear protective goggles and gloves.

♦ Temperature & Radiation: Bulbs become very hot. Operate them only within the headlight housing. Avoid looking directly into the beam due to high UV radiation and potential for glare.

♦ Bulb Handling: Do not touch the bulb glass with bare fingers; use clean cloth gloves. Oil from fingerprints can damage the reflector.

♦ Disposal: Gas discharge bulbs contain mercury and must be disposed of as hazardous waste at an authorized collection point.

Caution: Only illuminated sockets (cigarette lighters) can be removed with the puller T 40148. Using excessive force or attempting to remove non-illuminated sockets can damage the retaining sleeve. Sockets without illumination usually cannot be removed without being damaged.

Removing:

1. Remove the cigarette lighter or dummy plug from the socket if present.

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 puller 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 release the puller from the socket, press the spindle on the puller and turn the puller briefly to the left.

Installing:

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

Note: On some vehicles, illumination is provided by a permanent LED that cannot be renewed separately. On others, the bulb may be integrated into the bulb carrier, requiring replacement of the entire carrier.

Removing:

1. Remove the cigarette lighter socket.

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

3. Unclip the bulb carrier from the retaining sleeve.

4. Separate the two parts of the bulb carrier to access the bulb.

5. Remove the light bulb from the carrier.

Installing:

Installation is carried out in the reverse order of removal.

To connect a vehicle diagnostic tester to your VOLKSWAGEN CC 2010, follow these steps:

1. Apply the handbrake.

2. For vehicles with an automatic gearbox, move the selector lever to “P” or “N”. For vehicles with a manual gearbox, move the gearstick to the neutral position.

3. Switch off all electrical consumers.

4. With the ignition switched off, connect the vehicle diagnostic tester