VOLKSWAGEN GOLF 2004 (13) PDF Document

To ensure long use of the battery in your VOLKSWAGEN GOLF 2004, it must be checked, serviced, and maintained according to the specifications in the manual. Apart from supplying energy for starting the engine, the battery also acts as a buffer and supplies electrical energy to the complete electrical onboard supply of the vehicle.

The instructions provided are for maintenance-free batteries. For these batteries, do not remove any stickers and do not replenish with distilled water. Only a visual check should be performed.

Battery with magic eye:

This is a maintenance-free wet battery with liquid electrolyte. The magic eye provides information on the electrolyte level and the charge state of the battery through a colored display.

WARNING: Batteries where the magic eye is colorless or light yellow must not be checked or charged. Do not slave/jump start the vehicle! There is a danger of explosion. These batteries must be renewed.

Absorbent glass mat (AGM) battery:

This is a maintenance-free battery where the electrolyte is contained within a microscopic glass mat. It is sealed and fitted with valves. Due to the contained electrolyte, this type of battery may not have a magic eye. AGM batteries are identified by the abbreviation “AGM” on the battery.

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

Handling vehicle batteries can be dangerous. Always observe the warnings on the battery and in your vehicle’s manuals.

Key Dangers and Precautions:

• Corrosive Acid: Battery acid is highly corrosive. Take measures to neutralize acid burns, for example, with a soap solution. Leaking electrolyte can cause skin burns and damage to vehicle components.

• Explosive Gas: The gas formed during charging is explosive. An improperly handled battery can explode. It is prohibited to cause sparks, use naked lights, or smoke near batteries. Always touch the vehicle body to discharge static electricity before touching the battery.

• Qualified Personnel: Untrained personnel should only work on batteries under the supervision of a qualified vehicle mechanic or electrician.

• Magic Eye Warning: Batteries with a colorless or light yellow magic eye must be renewed. Do not check, charge, or jump start them due to explosion risk.

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

The safety markings on the battery provide crucial safety information:

1. No Fires/Sparks: Fires, sparks, naked flames, and smoking are prohibited. Avoid sparks from cables, electrical units, and electrostatic discharge. Do not lay tools on the battery to avoid short circuits.

2. Eye Protection: Wear eye protection before working on the battery.

3. Keep Children Away: Keep children away from acid and batteries.

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

5. No Household Waste: Never dispose of old batteries in household waste.

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

7. Follow Instructions: Always follow instructions on the battery and in the vehicle’s manuals.

8. Caustic Acid: 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 GOLF 2004, 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.

The procedure for checking the battery depends on the battery type.

For a battery with a magic eye:

1. Perform a visual check.

2. Check the color display of the “3-colour” or “2-colour” magic eye.

WARNING: Batteries where the magic eye is colorless or light yellow must not be checked or charged. Do not jump start the vehicle. These batteries must be renewed.

3. Perform a battery load test using a suitable battery tester (e.g., VAS 5097 A or VAS 6161).

4. Depending on the test result, you may need to perform a current draw test.

For an absorbent glass mat (AGM) battery:

1. Perform a visual check.

2. Perform a battery load test using a suitable battery tester.

3. Depending on the test result, you may need to perform a current draw test.

Before performing extensive tests, it is essential to visually inspect the external condition, check the terminals, and ensure proper attachment of the battery. This helps establish:

• Housing Integrity: Check if the battery housing is damaged. If electrolyte is leaking, it can cause serious damage to the vehicle. Treat affected components immediately with an acid neutralizer or soap solution.

• Terminal Condition: Check whether the battery terminals are damaged. Damaged terminals can prevent proper contact with the battery clamps. When connecting, tighten clamps to the specified torque. Incorrectly seated clamps can cause wiring to burn and lead to electrical malfunctions.

• Secure Mounting: The battery will be damaged if not secured correctly. Vibrations can shorten its life and may damage the housing or internal plates. Check that the battery is securely seated and, if necessary, tighten the securing bolt to the specified torque.

The magic eye provides information about 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 color.

“3-Colour” Magic Eye (Older batteries):

• Green: Battery is charged sufficiently.

• Black: Battery is partly or completely discharged (charge state < 65%).

• Colourless or light yellow: Battery must be renewed. DO NOT check, charge, or jump start the vehicle due to explosion risk.

“2-Colour” Magic Eye (Newer batteries):

The “green” display has been discontinued. This eye only indicates the electrolyte level.

• Black: Electrolyte level is OK.

• Colourless or light yellow: Electrolyte level is too low. The battery must be renewed. DO NOT check, charge, or jump start the vehicle due to explosion risk.

Note: The magic eye is located in only one cell, so its display applies only to that cell. An exact determination of the overall battery condition is only possible through a battery load test.

Follow these steps to perform a battery load test:

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 from the battery label. If values are shown in IEC or EN/SAE, convert them using the provided table.

5. Select the low-temperature test current on the tester.

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

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

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

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

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

11. The test result will be printed out after about 20 seconds. If the unit does not start, the battery needs to be recharged.

12. Switch off the unit and remove the test terminals.

Important: 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.

If your VOLKSWAGEN GOLF 2004 battery values are shown in IEC or EN/SAE instead of DIN, you can use the following table to convert the figures.

The printout from the battery tester provides an assessment of the battery’s starting capability. Based on the result, different actions are required.

The following tables explain how to interpret the results from guarantee, service, and maintenance tests performed with the VAS 6161 tester.

Evaluating battery test results for guarantee and service tests

Evaluating battery test results for maintenance test

A current draw test while charging helps to quickly determine the state of a discharged battery and decide if it 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 (A) 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 a full charge, let the battery rest for two hours before performing another battery test.

• If the charge current, in amperes, is below 10% of the nominal capacity after 5 minutes of charging, renew the battery.

The no-load voltage test is used to assess the battery’s condition on stock and stored vehicles. The battery must not have been charged or discharged within the last 2 days for an accurate reading.

The VAS 5095 A charges without peaks in amperage or voltage, so the battery can remain in the vehicle.

Charging procedure:

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, check the battery type switch. It must be set 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. 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.

The yellow charging current indicators will light up. When only the LED for “> 90%” is lit, the battery is partially discharged. If the LED lights up green, the charger has switched to “maintaining charge,” and the battery is fully charged.

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

8. Remove the charger terminals from the battery terminals.

The support mode provides power to the onboard supply when the battery is removed or disconnected. This is useful for conserving power when renewing the battery or testing ancillaries without a battery installed.

CAUTION: The terminal polarity protection is not active in this mode. Connect clamps correctly to avoid sparks, short-circuits, and damage to the charger unit.

Procedure:

1. Switch off ignition and all electrical consumers.

2. Remove the battery. When removed, ensure there is no contact between the positive terminal clamp and body earth, or between the positive and negative clamps.

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

4. Connect the black terminal clamp “-” to the negative terminal of the vehicle. For vehicles with a start/stop system, connect the black clamp to body earth.

5. Set the normal/support mode switch on the charger to “support mode”.

6. Check the polarity of the charger unit cables.

7. Switch on the battery charger.

Ending battery support mode:

1. Switch off the battery charger.

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

3. Pull the charger plug out.

Follow these steps to use the VAS 5900 charger:

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

2. Switch off the ignition and all electrical consumers.

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

4. Press INFO to select the operating mode: symbol-1 for standard wet batteries or symbol-2 for gel/AGM batteries.

5. Set the battery capacity (Ah) using the “Up” or “Down” buttons.

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

7. Connect the black terminal clamp “-” to the negative battery terminal. For vehicles with a start/stop system, connect the black clamp to body earth.

The charger will recognize the battery voltage and begin the charging sequence. At approx. 80-85% charge, it switches to “final charge” mode. When fully charged (100%), all bars will appear on the display, and it will switch to maintenance mode.

Ending charging sequence:

1. Press START / STOP.

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

3. Unplug the charger.

Troubleshooting:

• Displayed voltage not nominal: Press “Up” or “Down” until charging starts.

• Displayed voltage not nominal (charging already started): Press START / STOP twice, then press “Up” or “Down” to restart the sequence.

• Charger doesn’t detect battery (voltage < 2 V): The display remains unchanged. You will need to use the mode for totally discharged batteries.

The “service charge (SERV)” mode is only used on sulphated wet batteries where the magic eye is black or green. It charges the battery at a voltage of > 14.4 V to help reduce the sulphated layer.

CAUTION: This operating mode is not permitted on VW vehicles with the battery connected, as the voltage peaks can damage the onboard electronics. The battery must be disconnected from the vehicle’s onboard supply before using this mode.

The procedure is the same as a standard charge, but you must select the “Service charge for wet batteries” or “Service charge for gel/absorbent glass mat batteries” option in the display after connecting the charger plug.

After charging, always check the color of the magic eye before using the battery.

The solar panel -VAS 6102A- supports the onboard supply and prevents spontaneous battery discharging in your VOLKSWAGEN GOLF 2004. It achieves a maximum voltage of 14.3 V and a charging current of up to 255 mA.

Procedure:

1. Secure the solar panel (-1-) on the interior mirror.

2. Place the underside of the panel (-2-) on the dash panel for support. Note: Do not allow the panel to lie fully on the dash panel, as this could cause discoloration.

3. Pull the attachment string tight so the panel is positioned close to the windscreen.

4. Connect the solar panel to the diagnostic connection in the vehicle.

5. Check the function of the solar panel. A green LED on the frame will indicate its function; the brighter the LED, the higher the charging current.

A battery is designated as “totally discharged” when its no-load voltage is less than 11.6 V.

Consequences:

• Freezing: Totally discharged batteries freeze prematurely because the electrolyte is comprised almost entirely of water. Frozen batteries should no longer be used.

• Sulphation: The entire plate surfaces of the battery harden (sulphate). If recharged shortly after losing its charge, the sulphation can mostly dissipate. However, if not recharged, the plates continue to harden, reducing the ability to recharge and lowering the battery’s output.

Note: Totally discharged batteries in vehicles before registration must be exchanged prior to delivery, as preliminary damage cannot be excluded.

The functions of the cruise control system are controlled by the engine control unit. To activate or deactivate it using a vehicle diagnostic tester, follow these steps:

1. Connect the vehicle diagnostic tester to the vehicle.

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 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)

Your VOLKSWAGEN GOLF 2004 may use several types of hose couplings for the washer system. 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 back 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.

Type 4 (Headlight Washer System Push Lock Ring):

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

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

A smooth pipe with a diameter of 5×1 mm or 6×1 mm can be repaired using a special EPDM hose.

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

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

3. Cut the EPDM hose so that the ends (-1- and -3-) of the smooth pipe can each be pushed about 10 mm into the EPDM hose.

4. Secure the repair joints with cable ties (-1-).

Repairing a corrugated pipe requires a hot air blower and specific replacement parts. Note that repair points must not be subjected to pulling or bending forces.

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

2. Select suitable end pieces (-2- and -3-) and the correct sized shrink-fit piping from the electronic parts catalogue (ETKA).

3. Heat the end of the corrugated pipe (-1-).

4. Push connector (-2-) into the corrugated pipe (-arrow A-).

5. Heat the end of the other corrugated pipe section (-4-).

6. Push connector (-3-) into that corrugated pipe section (-arrow B-).

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

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

You can identify the brand of the jointless wiper blades on your VOLKSWAGEN GOLF 2004 by inspecting the wiper arm fastening.

• Bosch wiper blades have a distinct fastening mechanism, as shown by items -1 and 2- in the manual’s diagram.

• Federal Mogul wiper blades have a different fastening design, as shown by item -1- in the corresponding diagram.

When renewing wiper rubbers or the entire wiper blades, the same make must be used.

Working on gas discharge headlights involves lethally high voltages. Always observe the following safety precautions:

• Disconnect Power: 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.

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

• Prevent Accidental Power-On: Switch off the ignition, remove the key, and ensure the lights cannot be switched on while working.

• Operate in Housing Only: Due to the high ignition voltage (above 28,000 V) and high temperatures, the gas discharge bulb must only be operated in the headlight housing.

• Use Protective Gear: Always wear protective goggles and gloves when removing and installing gas discharge bulbs.

• Avoid Contact: The glass of the bulbs can be very hot, posing a danger of burns. Also, avoid contact with burst bulbs.

• Avoid Looking at the Beam: Do not look directly into the beam. The UV rays are about 2.5 times greater than normal halogen bulbs, and the intense light can cause glare and impair vision.

CAUTION: Only illuminated sockets (cigarette lighter) can be removed with the puller T 40148. Sockets without illumination usually cannot be removed without being damaged, as the puller does not release their locking lugs.

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 (-1-) engage in the recesses (-2-) inside the socket.

3. Pull the grip (-3-) of 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 (-1-) in direction of arrow B, then turn the puller handle (-2-) briefly to the left (arrow A).

Installing:

Install in the reverse order of removal.

After removing the socket: The retaining springs inside the socket may have been spread apart by the puller. Carefully press them back together and test that the cigarette lighter remains in its removal position after its heating phase without being ejected from the vehicle interior.

WARNING: During testing, there is a risk of serious injury. If the diagnostic system is in an airbag’s deployment area, a triggered airbag could cause injury. Work with a second person who can operate the system from a back seat.

Connection Procedure:

1. Apply the handbrake.

2. For automatic gearboxes, move the selector lever to “P” or “N”. For manual gearboxes, move the gear lever to neutral.

3. Pull out the trim piece (-1-) in the direction of the arrow to access the diagnostic interface.

4. With the ignition switched off, connect the vehicle diagnostic tester to the diagnostic interface (-arrow-) in the vehicle using the appropriate diagnostic cable.

5. Switch on the ignition.

6. Switch off all electrical consumers before starting diagnosis.

When using special pliers (VAS 1978/1 with insert VAS 1978/2) for wiring repairs, it is crucial to use the correct color-coded crimp recess for the wire’s cross-section. The insulation on the wires must not be crimped.

When performing electrical repairs, always follow these guidelines:

• Always disconnect the battery earth strap before working on the electrical system.

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

• Soldering is not permitted for repairs to vehicle wiring.

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

• Crimp connectors may never be repaired. After crimping, they must be shrink-fitted using a hot air blower to prevent moisture ingress.

• There are supplementary instructions for specific systems like airbags, CAN bus lines, and fibre optic cables that must be followed.

• Perform a function test after every repair. It may be necessary to interrogate and erase the fault memory.

• Do not loosen earth wires from the body if possible, to avoid corrosion risk.

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

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

WARNING: Faulty repairs to the airbag and seat belt tensioning system can cause malfunctions in the passenger protection system and may lead to component failure. Only use contacts, connectors, and wiring specifically designed for this purpose.

• Use only the wiring harness repair set -VAS 1978 B- (and previous versions).

• A maximum of two positions may be repaired in the wiring. More repairs increase resistance and can trigger faults.

• Crimp connectors must always be shrink-fitted to prevent corrosion.

• The repaired area should not be incorporated back into the main harness and must be marked with yellow insulating tape.

• Repairs should not be more than 30 cm from the next contact housing.

• The wires to the triggering units (airbags) are entwined. This standard twine spacing (A = 20 mm ± 5) must be maintained on the repair lengths.

• Wires to the triggering units must have the same length after repair.

• There must not be any section of wiring longer than 100 mm (B) where the wires are not twisted (e.g., near crimp connectors).

CAN bus wiring is an unshielded, twisted two-wire line.

• Wire Colors:

• Powertrain CAN, high wire: Orange/black

• Convenience CAN, high wire: Orange/green

• Infotainment CAN, high: Orange/violet

• CAN low wire, (all): Orange/brown

• Repair Procedure:

• Both bus wires must have the same length after repair.

• When twisting the wires (-1- and -2-) together, the length of each complete twist must be A = 20 mm.

• There must not be any untwisted section of wiring longer than B = 50 mm (e.g., near crimp connectors).

• Mark the area of repair with yellow insulation tape to make it easy to identify.

This procedure is for when the wire ends are long enough to be joined with a single crimp connector after the damaged section is removed.

1. If necessary, unbind the wiring harness.

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

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

4. Push the crimp connector over both stripped wire ends.

5. Crimp the connector using crimping pliers, ensuring the correct crimp recess is used and the wire insulation is not crimped.

6. After crimping, the connector must be shrink-fitted to prevent moisture ingress. Place the shrink element for the hot air blower on the blower nozzle.

7. Heat the crimp connector along a straight line, working from the middle outwards, until it is completely sealed and adhesive escapes from the ends.

CAUTION: When shrink-fitting, do not damage any other wiring, plastic parts, or insulating material with the hot air.

8. If necessary, re-wrap the repair position with yellow insulation tape and secure the harness with a cable tie to prevent noise.

This method is used when the original wire ends are too short to be joined directly after the damaged section is removed.

1. Unbind the wiring harness if necessary.

2. Place a new yellow repair wire next to the damaged harness and cut it to the required length.

3. Cut the damaged section out of the vehicle’s original wire.

4. Strip the wire ends of the vehicle’s wire and the repair wire by 6 – 7 mm.

5. Use two crimp connectors. For the first connection, push a connector onto one end of the vehicle’s wire and one end of the repair wire, then crimp them together.

6. Repeat this procedure for the other end of the repair wire and the other end of the vehicle’s wire.

7. After crimping, both connectors must be shrink-fitted using a hot air blower. Heat each connector from the middle outwards until fully sealed.

Note: If several wires are repaired, position the crimp connectors so they are offset slightly from each other to prevent the harness from becoming too thick.

A secondary locking mechanism is a housing catch that secures all the wires in a contact housing at once. It is often a different color from the rest of the housing for easy identification. This lock must be opened or removed before individual crimp contacts can be released.

There are several types:

• Example 1: The catch is disengaged by removing a “toothed element” in the direction of the arrow.

• Example 2: The catch is disengaged by opening a “flap” in the direction of the arrow.

• Example 3: The catch is disengaged by detaching a “slide” in the direction of the arrow.

To release a contact (primary locking element), you must first disengage any secondary locking mechanism. Then, use the appropriate release tool for the specific contact type.

General Procedure:

1. Insert the correct release tool into the release port of the contact housing.

2. Grab the wire and gently push the contact further into the housing. This action helps lift the locking tabs off the housing edge so the release tool can disengage them.

3. At the same time, push the release tool into the housing to disengage the lock, and then pull the released contact and wire out from the back of the housing.

4. Remove the release tool.

This general principle applies to various connector types, including:

• Round connector systems

• Flat connectors with one or two locking tabs

• Asymmetrical connectors

• Faston contacts

• GT 150/280 contacts

Always use the correct release tool to avoid damaging the contact or housing. Never pull contacts out by force.

WARNING: Always observe safety regulations and wear appropriate protective gear when working on the battery.

1. Disconnect the battery.

2. Check the battery clamp and terminal for corrosion or dirt.

3. Clean the inside of the battery clamp using the wire brush of a battery terminal cleaner (e.g., VAG 1331) with circular movements.

4. Clean the battery terminal post using the underside of the battery terminal cleaner with circular movements.

5. Reconnect the battery and tighten the battery terminals to the specified torque. Optimum contact is ensured when components are tightened to the specified torque after cleaning.

CAUTION: Missing anti-corrosion treatment can result in damage to the onboard supply.

• All threaded connections must be tightened to the specified torque.

• Use protection wax for cold areas and cavity sealing agent for warm areas.

• Always use the hose supplied with the anti-corrosive agent tin. The sealing agent will reach the necessary points through capillary action.

Application:

• For a ring terminal on a post, hold the injector below the ring terminal and spray the pin all around.

• For a ring terminal on a flat surface, hold the injector above the ring terminal and spray the pin and wiring eye all around.

Note: Do not repair Lambda probe wires, as this can result in 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.

3. Tie back any excess length in the uniform probe’s cable (approx. 50 – 250 mm) to match the length of the defective probe and secure the excess with cable ties (-1-).

4. Check that the connector housing of the new Lambda probe is compatible with the onboard supply side connector. 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.

In addition to the part number, the protective tube at the tip of the sensor can be used for identification:

• Type D1: Has 6 openings at 3.5 mm each. Only used on 4-pin LSF Lambda probes.

• Type D2: Has 6 openings at 2 mm each. Used on both 4-pin LSF Lambda probes and 6-pin LSU Lambda probes.

• Type D4: Has 12 openings at 1.4 mm each. Used on both 4-pin LSF Lambda probes and 6-pin LSU Lambda probes.