VOLKSWAGEN GOLF PLUS 2009 (03) PDF Document

When handling the battery of your VOLKSWAGEN GOLF PLUS 2009, observe the following safety regulations and warnings to avoid injury or damage:

Dangers and Warnings:

• Only trained personnel should work on batteries. If you are an apprentice or trainee, you must be supervised by a vehicle mechanic or electrician.

• Battery acid is highly corrosive. Handle batteries carefully to avoid acid burns. Have a neutralizing solution, like soap solution, available.

• Leaking electrolyte can cause skin burns and corrosion on the vehicle, potentially damaging safety-relevant components.

• Gas formed during charging is explosive. Mishandling can lead to a battery explosion.

• Batteries with a colorless or light yellow magic eye must be renewed. Do not check, charge, or jump-start them due to the danger of explosion.

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

• Only work on batteries in well-ventilated rooms.

Safety Markings on Battery:

1. Fires, sparks, naked flames, and smoking are prohibited. Avoid short circuits; never lay tools on a battery.

2. Always wear eye protection.

3. Keep children away from acid and batteries.

4. Dispose of old batteries as hazardous waste at a suitable collection center according to legislation.

5. Never dispose of old batteries in household waste.

6. Be aware of the explosion danger. A highly explosive gas is produced when batteries are charged.

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

8. 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 GOLF PLUS 2009, follow these guidelines:

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

• Do not coat battery terminals with grease.

• Fit the battery clamps so that the battery terminal is either flush with the clamp or protruding from it.

• After tightening the battery clamps to the specified torque, do not tighten the threaded connections any further.

A visual inspection is essential to check the external condition, terminals, and proper attachment of the battery in your VOLKSWAGEN GOLF PLUS 2009. This helps establish the following:

• Check for Secure Mounting: Ensure the battery is securely seated. If necessary, tighten the securing bolt to the specified torque. An unsecured battery can be damaged by vibrations, shortening its life and posing an explosion risk.

• Inspect the Battery Housing: Look for any damage to the housing. If the housing is damaged, electrolyte can leak out, causing serious damage to the vehicle. Treat any components affected by leaked battery acid immediately with an acid neutralizer or soap solution.

• Check Battery Terminals: Inspect the battery terminals and wire connections for damage. Damaged terminals can prevent proper contact. When connecting the clamps, tighten them to the specified torque to prevent poor connections that could cause the wiring to burn and lead to electrical malfunctions.

The “3-colour” magic eye on certain batteries 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 display. Note that the display applies only to the single cell it is located in. For an exact determination of the battery’s condition, a full battery load test is required.

The possible colour displays are:

• 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 with this display, as there is a danger of explosion.

On newer batteries for your VOLKSWAGEN GOLF PLUS 2009, the green display for charge state has been discontinued. The magic eye on these batteries only indicates the electrolyte level. Before checking, tap the magic eye lightly to dissipate air bubbles.

The possible colour displays are:

• Black: The electrolyte level is OK. The charge state cannot be read from the magic eye; a battery load test is required.

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

To perform a battery load test with the VAS 5097 A on your VOLKSWAGEN GOLF PLUS 2009, 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. If the battery has a magic eye, check its colour. Do not test batteries with a colourless or light yellow magic eye.

4. Check the low-temperature test current in amperes (A) according to DIN from the indications on the battery. If 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 using the selection switch: “1” for directly on the battery or “2” for external test points in the engine compartment.

10. Press the start test button. The green LED will light up, and the test will run automatically for about 20 seconds.

11. The test result will be printed out. If the unit does not start (no LED, no printout), the battery needs to be recharged.

12. 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.

After performing a load test with the VAS 5097 A, use the following table to assess the printout and determine the necessary actions for your VOLKSWAGEN GOLF PLUS 2009’s battery:

To test the battery of your VOLKSWAGEN GOLF PLUS 2009 with the VAS 6161 tester, follow these steps. The test takes about 10 seconds and does not require a cooling phase between measurements.

1. Switch off the ignition and all electrical consumers.

2. If applicable, check the magic eye on the battery.

3. Switch on the VAS 6161 unit.

4. Connect the red terminal (+) to the positive terminal and the black terminal (-) to the negative terminal. Ensure a good contact.

5. Select one of the following functions from the menu:

• Maintenance test: Used for new cars before registration or during stock maintenance.

• Service test: Used for regular service checks.

• Guarantee test: Used for warranty claims.

For a Service Test:

1. Select “Service test” in the menu.

2. Select “On battery terminal” or “On jump-start point”.

3. Select the vehicle type.

4. Measure the temperature by holding the sensor about 5 cm above a battery terminal until the reading stabilizes.

5. Select the battery type (“Normal”, “AGM”, etc.) and the rating norm (“CCA”, “DIN”, “EN”, etc.).

6. Start the test.

7. Print out the test log if necessary.

The following tables outline the recommended measures based on the test results from the VAS 6161 battery tester for guarantee, service, and maintenance tests on your VOLKSWAGEN GOLF PLUS 2009.

Evaluating Battery Test Results for Guarantee and Service Tests

Evaluating Battery Test Results for Maintenance Test

A current draw test helps to quickly determine the state of a discharged battery in your VOLKSWAGEN GOLF PLUS 2009. It ascertains whether the battery must be replaced or can be fully recharged. This test is required when indicated by a battery tester like the VAS 6161 or after certain results from the VAS 5097A.

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 a suitable battery charger.

2. Start the charging sequence.

3. After 5 minutes, measure the charging current being drawn by the battery.

Test Result:

• If the current draw is higher than 10% of the battery’s nominal capacity (e.g., > 6.1 A for a 61 Ah battery), the battery is likely serviceable. Fully charge the battery, let it rest for two hours, and then perform a standard battery test again.

• If the charge current is below 10% of the nominal capacity after 5 minutes (e.g., < 5A for a 50Ah battery), the battery should be renewed.

Checking the no-load voltage is used to assess the battery’s condition on stock and stored vehicles as part of prescribed maintenance. This test determines if the battery requires recharging.

Test Conditions:

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

• You will need a hand multimeter (e.g., V.A.G 1526 B).

Procedure:

1. Use the hand multimeter to check the battery’s no-load voltage.

2. Compare the measured value to the following:

• No-load voltage ≥ 12.5 V: The no-load voltage is OK.

• No-load voltage < 12.5 V: The battery needs charging.

A no-load voltage of 11.60 V corresponds to a 0% charge state, indicating the battery is heavily discharged and may have no capacity left.

The functions of the Cruise Control System (CCS) on your VOLKSWAGEN GOLF PLUS 2009 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’s diagnostic port.

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

3. Using the “GoTo” button, select “Functions/component”.

4. 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 provided by the diagnostic tester to complete the activation or deactivation process.

Your VOLKSWAGEN GOLF PLUS 2009 uses several types of hose couplings for the windscreen, rear window, and headlight washer systems. Here is how to handle them:

Type 1 (Simple Push-Fit):

• To loosen: Pull the two coupling sections apart. There is 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 the hose connection on and rotate the lock ring -1- until it engages.

Type 3 (Clip Lock Ring):

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

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

Type 4 (Headlight Washer System):

• 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 securing clip has correctly engaged by trying to pull it off without the clip.

You can repair both smooth and corrugated washer hoses on your VOLKSWAGEN GOLF PLUS 2009 using the appropriate replacement parts.

Repairing Smooth Pipe:

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

2. Select the appropriate size EPDM hose and cable ties from the electronic parts catalogue.

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

4. Secure both repair joints with cable ties.

Repairing Corrugated Pipe:

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

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

3. Cut a piece of heat-shrink hose so it will cover the repair joint by about 20 mm on each side.

4. Slide the heat-shrink hose over one end of the corrugated pipe.

5. Heat the ends of the corrugated pipe and push the connector end pieces into them.

6. Join the connectors, slide the heat-shrink hose over the joint, and heat it with a hot air blower to secure the repair.

Gas discharge bulbs operate with lethally high voltage and require special safety precautions. Always wear protective goggles and gloves.

High Voltage Precautions:

• Before working on any parts of the gas discharge headlights (marked with yellow high voltage symbols), you must disconnect the battery earth strap.

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

• Ensure there is no voltage in any components before proceeding. Residual voltage can be dissipated by turning the dipped beams on and then off again after withdrawing the ignition key.

• Ensure the lights cannot be switched on while you are working.

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

Pressure, Temperature, and Radiation Notes:

• The bulbs must only be operated inside the headlight housing to protect against contact with very hot bulbs, UV radiation, and potential explosion.

• Gas discharge bulbs are under pressure and can explode if changed improperly, causing injury.

• The glass can get very hot, creating a burn risk.

• Avoid looking directly into the beam due to high UV radiation and the danger of glare, which can impair vision.

Repair and Disposal:

• Do not touch the bulb glass with bare fingers; use clean cloth gloves to prevent oil from impairing brightness.

• Gas discharge bulbs contain mercury (Hg) and must be disposed of as hazardous waste at an authorized collection point, not in conventional waste.

To remove and install an illuminated cigarette lighter socket in your VOLKSWAGEN GOLF PLUS 2009, you will need the special puller tool T 40148. Sockets without illumination usually cannot be removed without being damaged.

Removing the Socket:

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

2. Push the puller (T 40148) into the socket until 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 that holds the socket.

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 from the back of the socket.

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 the Socket:

Installation is carried out in the reverse order of removal. Ensure the socket is fully engaged and the connector is securely attached.

To replace the illumination bulb (L28) for the cigarette lighter, you must first remove the socket. Note that on some vehicles, illumination is provided by a non-replaceable LED.

1. Remove the cigarette lighter socket from its housing.

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. Separate the two parts of the bulb carrier (in areas A and B) and open part B of the carrier.

5. Remove the old light bulb.

Installing the new bulb:

Installation is performed in the reverse order of removal. Insert the new bulb, reassemble the bulb carrier, clip it back onto the retaining sleeve, and reinstall the socket assembly.

To connect a vehicle diagnostic tester to your VOLKSWAGEN GOLF PLUS 2009, follow this procedure:

1. Apply the handbrake.

2. If your vehicle has an automatic gearbox, move the selector lever to position “P” or “N”. For a manual gearbox, move the gearstick to the neutral position.

3. Switch off the ignition.

4. Connect the vehicle diagnostic tester using the appropriate diagnostic cable (e.g., VAS 5051/6A) to the diagnostic interface located in the driver’s side footwell.

5. Switch on the ignition.

6. Switch off all electrical consumers (radio, lights, A/C) to ensure an accurate diagnosis.

When performing repairs on the vehicle electrical system of your VOLKSWAGEN GOLF PLUS 2009, adhere to the following notes:

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

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

• Soldering is not permitted for repairs to vehicle wiring.

• Use the specified wiring harness repair set (e.g., VAS 1978 B) for all wiring and connector repairs.

• Crimp connectors must never be repaired. If a connection is faulty, lay a new wire parallel to the defective one.

• After crimping, connectors must be shrink-fitted using a hot air blower to prevent moisture ingress.

• Observe supplementary information for specific systems like airbags, CAN bus lines, and fibre optic cables.

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

• Do not use screened wires for repairs; if damaged, they must be replaced completely.

• For heat-resistant wiring (found mainly in the engine compartment), use only heat-resistant repair wiring.

Faulty repairs to the airbag and seat belt tensioning system can cause malfunctions in the passenger protection system. In addition to the general repair guidelines, you must observe the following specific instructions:

• Only use wires, contacts, and connectors specifically designed for this purpose, available from the electronic parts catalogue.

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

• Always shrink-fit the crimp connectors to prevent corrosion.

• Do not incorporate the repaired wiring back into the vehicle’s main wiring harness. Mark the area of repair clearly with yellow insulating tape.

• Repairs should be no more than 30 cm from the next contact housing.

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

• During repairs, the wires to the triggering units must have the same length.

• There must not be any untwisted section of wiring longer than 100 mm.

There is no provision for fibre optic cable repairs. In the event of damage, the entire fibre optic wiring harness must be replaced. When handling or replacing these cables, observe the following precautions:

• Avoid sharp bends in the fibre optic cable; the bend radius should be no tighter than 25 mm.

• Do not route fibre optic cables over sharp edges.

• The end pieces (lenses) must not be made dirty or touched with bare hands.

• Do not expose fibre optic cables to heat.

• Entwining two fibre optic cables or a fibre optic cable with a copper wire is not permissible.

CAN bus wiring consists of an unshielded two-wire line. When performing repairs, follow these guidelines:

• Use repair wiring with the correct cross section (0.35 mm² or 0.5 mm²) and colour code. The colour codes are:

• Powertrain CAN, high wire: Orange/black

• Convenience CAN, high wire: Orange/green

• Infotainment CAN, high wire: Orange/violet

• CAN low wire (all): Orange/brown

• When repairing, both bus wires must have the same length.

• When twisting the two wires together, the length of each complete twist must be 20 mm.

• There must not be any section of wiring longer than 50 mm that is not twisted, for example, near the crimp connectors.

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

You can repair an open circuit with one repair position (if the wire ends are long enough) or two repair positions (by adding a new piece of wire).

Repair with One Repair Position (Single Crimp Connector):

1. Unbind the wiring harness if necessary.

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

3. Strip 6-7 mm of insulation from both wire ends.

4. Push a single crimp connector onto both stripped wire ends.

5. Crimp the connector using the correct recess on the crimping pliers. The insulation on the wires must not be crimped.

6. Using a hot air blower, shrink-fit the crimp connector, working from the middle outwards, until it is sealed and adhesive escapes from the ends.

7. If the repair was in a wrapped section, re-wrap it with yellow insulation tape.

Repair with Two Repair Positions (Interlinked Wire):

1. Cut out the damaged section of wire.

2. Cut a new piece of yellow repair wire to the required length.

3. Strip the insulation from all four wire ends (two on the vehicle harness, two on the repair wire).

4. Use two crimp connectors to join the repair wire in between the ends of the vehicle’s own wire.

5. Crimp and shrink-fit both connectors as described above.

Note: When repairing multiple wires, position the crimp connectors so they are offset slightly from each other to prevent the harness from becoming too bulky.

To release contacts from housings, you must first disengage the secondary locking mechanism, then the primary one.

1. Disengaging the Secondary Locking Element:

The secondary lock is a housing catch that secures all wires at once. It is usually a different colour from the rest of the housing. Depending on the type, it can be disengaged by:

• Removing a “toothed element”.

• Opening a “flap”.

• Detaching a “slide”.

A small screwdriver can be used as an aid.

2. Disengaging the Primary Locking Element:

The primary lock fixes an individual crimp contact in the housing. Use the appropriate release tool from the release tool set (e.g., VAS 1978/35) for the specific contact type.

• General Procedure:

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

2. Gently push the contact wire further into the housing. This helps lift the locking tabs off the housing edge.

3. While pushing the wire, push the release tool in the direction of the contact housing to disengage the tabs.

4. Pull the released contact and wire out from the back of the housing.

5. Remove the release tool.

Always use the correct release tool. Never pull contacts out of the housing with force, as this will damage them.

The contact surface cleaning set VAS 6410 is used to clean ring terminals and threaded connections in the high-current circuit (starting and charging) to ensure optimal contact.

Repairing Ring Terminals:

1. Disconnect the battery.

2. Loosen the cap nut and remove the ring terminal from the threaded connection.

3. Check the ring terminal for corrosion and dirt.

4. Select a suitable adapter and sanding pad (grey for light dirt, red for heavy dirt).

5. Insert the adapter into the ring terminal and grind off corrosion with circular movements. Check your progress frequently to avoid abrading the tin coating excessively.

6. If necessary, remove any punching burr with the deburrer tool.

7. Tighten the ring terminal back to the specified torque.

8. Apply a suitable anti-corrosion treatment.

9. Reconnect the battery.

Cleaning Battery Clamps and Terminals:

1. Disconnect the battery.

2. Use the wire brush tool (VAG 1331) to clean the inside of the battery clamp and the outside of the battery terminal post with circular movements.

3. Reconnect the battery and tighten the terminals to the specified torque.

Note: Do not use penetrating fluid, contact spray, or grease, as this can cause incorrect torque readings and potential breakage.

Lambda probe wires should not be repaired. If a probe is defective, it must be renewed using a uniform replacement probe. The procedure is similar for 4-pin (LSF) and 6-pin (LSU) probes.

Procedure:

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. Adjust the length of the new probe’s cable to match the old one. Tie back any excess length (approx. 50 – 250 mm) and secure it with cable ties.

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 connector housing on the vehicle side with the one supplied with the new probe.

5. If necessary, transfer any attachment parts, cable ties, or marking rings from the old probe to the new one.

6. Install the new Lambda probe in the vehicle.