VOLKSWAGEN GOLF VARIANT 1998 (02) PDF Document

When handling the battery on your VOLKSWAGEN GOLF VARIANT 1998, observe the following safety regulations and warnings to prevent injury and damage:

Dangers and Warnings:

• Only trained personnel should work on batteries. Apprentices or trainees must be supervised by a vehicle mechanic or electrician.

• Battery acid is highly corrosive. There is a considerable danger of 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.

• Never check, charge, or jump-start batteries where the “magic eye” indicator is colourless or light yellow. These batteries must be renewed due to an explosion risk.

• Prohibit sparks, grinding, welding, cutting operations, and naked lights near batteries. Smoking is also prohibited. To avoid electrostatic sparks, always touch the vehicle body before touching the battery.

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

Safety Markings on the Battery:

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

2. Always wear eye protection when working on a battery.

3. Keep children away from acid and batteries.

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

5. Never dispose of old batteries in household waste.

6. An 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 GOLF VARIANT 1998, follow these steps for connection:

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

• Do not coat the battery terminals with grease.

• Ensure the battery clamps are fitted so that the battery terminal is either flush with the clamp or protruding slightly from it.

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

A visual inspection is essential before performing more extensive tests on your VOLKSWAGEN GOLF VARIANT 1998’s battery. This check helps establish the following:

Caution:

• An improperly secured battery can be damaged. Vibrations can shorten its life, create an explosion risk, and damage cell plates or the housing.

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

Inspection Points:

• **Check for Housing Damage:** If the battery housing is damaged, electrolyte can leak, causing serious damage to the vehicle. Treat any components affected by battery acid immediately with an acid neutraliser or a soap solution.

• **Check Battery Terminals:** Inspect the terminals (wire connections) for damage. Damaged terminals can prevent proper contact. When connecting, tighten the battery clamps to the torque specified in the workshop manual. Incorrectly seated clamps can cause the wiring to burn and lead to electrical system malfunctions.

The “magic eye” indicator provides information about the electrolyte level and charge state of the battery. Note that the display applies only to the single cell it is located in. For an exact determination of the battery’s condition, a load test is required.

Before checking:

• Lightly and carefully tap the magic eye with a screwdriver handle. This helps dissipate any air bubbles that could distort the colour display.

For batteries with a “3-colour” magic eye:

• **Green:** Battery is sufficiently charged.

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

• **Colourless or Light Yellow:** The battery must be renewed. Do not check, charge, or jump-start the vehicle, as there is a danger of explosion.

For batteries with a “2-colour” magic eye:

• **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 the risk of explosion.

The checking procedure depends on the type of battery installed in your VOLKSWAGEN GOLF VARIANT 1998.

For a Battery with a Magic Eye:

1. Perform a visual check of the battery’s external condition.

2. Check the colour display of the “3-colour” or “2-colour” magic eye. WARNING: If the magic eye is colourless or light yellow, the battery must be renewed. Do not check, charge, or jump-start it.

3. Perform a battery load test using a 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 of the battery’s external condition.

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

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

After performing a battery load test using a tester like the VAS 5097 A, use the following table to assess the printout and determine the next steps:

When using a battery tester like the VAS 6161, the results from guarantee, service, and maintenance tests require different actions.

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 and whether it must be replaced or can be fully recharged. This test must be performed when indicated by a battery tester (e.g., VAS 5097A or VAS 6161).

Test Requirements:

• 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).

• Use a current pick-up clamp 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 of the battery.

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):** The battery can likely be recharged. Fully charge the battery and then perform a battery test after allowing it to rest for two hours.

• **If the charge current is below 10% of the nominal capacity after 5 minutes:** The battery should be renewed.

To safely charge the battery, follow this general procedure. WARNING: Batteries where the magic eye is colourless or light yellow must not be charged; they must be renewed due to an explosion risk.

Prerequisites:

• The battery must have a temperature of at least 10 °C.

Charging Procedure:

1. Switch off the ignition and all electrical consumers.

2. Connect the red terminal clamp (+) of the charger unit to the positive terminal on the battery.

3. Connect the black terminal clamp (-) of the battery charger 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, not the negative terminal, to avoid system malfunctions.

4. Switch on the battery charger and begin the charging sequence according to the charger’s instructions.

5. Once the battery is fully charged (indicated by the charger, e.g., a green light), switch off the charging unit.

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

Charging a Totally Discharged Battery:

• Use a charger that automatically recognizes totally discharged batteries and initiates a gentle charging procedure with a low current. The battery voltage must be at least 0.6 V for charging to begin.

The cruise control system (CCS) functions are controlled by the engine control unit. To activate or deactivate the system, a vehicle diagnostic tester is required.

1. Connect the vehicle diagnostic tester to your VOLKSWAGEN GOLF VARIANT 1998.

2. Select “Guided fault finding” mode in the vehicle diagnostic 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 types of couplings are used for the windscreen, rear window, and headlight washer systems.

Type 1: Simple Push-Fit (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: 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 approximately 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.

You can repair both smooth and corrugated washer hoses using available replacement parts.

Repairing a Smooth Pipe (5×1 mm or 6×1 mm diameter):

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

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

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

4. Secure the repair joints with cable ties.

Repairing a 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 parts catalogue.

3. Use a hot air blower to heat one end of the corrugated pipe, then push a connector into it.

4. Repeat for the other end of the pipe with the other connector.

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

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

Gas discharge bulb systems operate with lethally high voltage and require strict safety measures.

High Voltage and Current Warnings:

• **Disconnect the Battery:** 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).

• **Dissipate Residual Voltage:** After disconnecting the battery, switch the dipped beam on and off again to eliminate any possible residual voltage. Ensure the lights cannot be switched on while working.

• **Operate in Housing Only:** Due to the high ignition voltage (over 28,000 V) and high temperatures, the gas discharge bulb and its control unit must only be operated inside the complete headlight housing with the bulb fitted.

Pressure, Temperature, and Radiation Warnings:

• The bulbs can get very hot, creating a danger of burns.

• Avoid looking directly into the beam. The UV rays are about 2.5 times greater than normal halogen bulbs, and the glare can impair vision.

• H7 and gas discharge bulbs are under pressure and can explode if changed improperly, causing injury. Avoid contact with burst bulbs.

• **Always wear protective goggles and gloves** when removing and installing gas discharge bulbs.

Disposal:

• Gas discharge bulbs must be disposed of as hazardous waste. They contain metallic mercury (Hg) and traces of thallium. Never destroy them or dispose of them as conventional waste.

The procedure is the same for all illuminated sockets. Caution: Only illuminated sockets (cigarette lighters) can be removed with the puller T 40148. Sockets without illumination usually cannot be removed without being damaged.

Required Tool: Puller -T 40148-

Removing the Socket:

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

2. Push the puller 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. Be careful not to stretch the wiring.

5. Pull off the socket connector.

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

Caution After Removal: When the puller is used, the socket’s retaining springs are pressed apart. After removing the socket, carefully press these retaining springs back together. Check that the cigarette lighter remains in its removal position after a heating phase and is not ejected from the socket.

Installing the Socket:

Install in the reverse order of removal.

Note: On some vehicles, illumination is provided by an LED that is permanently attached to the retaining sleeve and cannot be renewed separately. On others, the bulb carrier may need to be replaced with the bulb.

Removing the Bulb:

1. Remove the cigarette lighter socket from the vehicle.

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

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

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

Installing the Bulb:

Installation is carried out in the reverse order of removal.

To connect a diagnostic tester to your VOLKSWAGEN GOLF VARIANT 1998 (Model Year 1998 – 2003), follow these steps:

1. Apply the handbrake.

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

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

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

5. Switch on the ignition.

6. Switch off all electrical consumers.

When performing repairs on the vehicle electrical system, adhere to the following guidelines for safety and quality:

• 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, defective components).

• Soldering is not permitted for repairs to vehicle wiring.

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

• Crimp connectors must not be repaired; if necessary, lay a new wire parallel to the defective one. After crimping, connectors must be shrink-fitted to prevent moisture ingress.

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

• For heat-resistant wiring (found mainly in the engine compartment, identifiable by its matt and soft insulation), only use heat-resistant repair wiring.

• 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.

Faulty repairs to the airbag and seat belt tensioning system can cause malfunctions in the passenger protection system. Follow these special instructions carefully:

• Only use contacts, connectors, and wiring specifically designed for this purpose, available from the Electronic Parts Catalogue (ETKA).

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

• To avoid corrosion, crimp connectors must always be shrink-fitted.

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

• 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 adhered to on repair lengths.

• During repairs, both wires to a triggering unit must have the same length.

• There must not be any untwisted section of wiring longer than 100 mm (e.g., near crimp connectors).

CAN bus wiring is an unshielded two-wire line with a specific twist that must be maintained during repairs.

Wire Colour Codes:

Repair Guidelines:

• When repairs are performed, both bus wires must have the same length.

• When twisting the 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 (e.g., near crimp connectors).

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

This procedure is for repairing an open circuit in a single wire.

Repair with One Position (Single Crimp Connector):

1. Unbind the wiring harness if necessary.

2. Cut out the damaged piece of wiring.

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

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

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

Repair with Two Positions (Using a Piece of Repair Wire): This method is used if the vehicle’s own wiring is too short after cutting.

1. Cut a yellow repair wire to the required length.

2. Cut out the damaged section of the vehicle’s wire.

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

4. Use two separate crimp connectors to join the repair wire to the vehicle’s wire.

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

Note for Multiple Repairs: Ensure that where several wires are repaired, the crimp connectors are not directly adjacent to each other. Stagger them slightly to prevent the wiring harness from becoming too thick.

To release individual crimp contacts without damage, you must first disengage the secondary locking mechanism, then the primary lock.

1. **Disengage the Secondary Locking Element:**

• The secondary locking mechanism secures all wires in the housing at once and is often a different colour. It must be opened or removed before individual contacts can be released.

• This can be a toothed element that is removed, a flap that is opened, or a slide that is detached. Use an appropriate tool or a small screwdriver.

2. **Disengage the Primary Locking Element (Individual Contact):**

• Select the appropriate release tool for the specific contact housing type (e.g., round, flat, Faston).

• Insert the release tool into the release port of the contact housing.

• Gently grab the wire of the contact and push it lightly into the housing. This action helps lift the locking tabs off the housing edge.

• At the same time, push the release tool further into the housing to disengage the contact’s locking tabs.

• Pull the released contact and its wire out of the back of the contact housing.

• Remove the release tool.

Important: Always use the correct release tools. Never pull contacts out of the housing by force, as this will damage the contact or housing.

Properly cleaning contact surfaces is crucial for high-current connections like starting and charging circuits. Use a contact surface cleaning set (e.g., VAS 6410) for this.

Prohibited Materials: Do not use penetrating fluid, contact spray, or grease. These can cause incorrect torque readings and potential breakage.

Repairing Ring Terminals:

1. Disconnect the battery.

2. Loosen the cap nut and remove the ring terminal.

3. Check the ring terminal for corrosion and dirt.

4. Select a suitable adapter and sanding pad. Use grey pads for light dirt (“soft surfaces”) and red pads for heavy dirt (“hard surfaces”).

5. Insert the adapter into the ring terminal and grind off corrosion with circular movements. Caution: Do not abrade the tin coating excessively to the point that copper is exposed, as this can cause faulty repairs.

6. If necessary, use a deburrer to remove any punching burrs.

Cleaning Threaded Connections:

1. Follow the same steps to remove the ring terminal.

2. Select the appropriate adapter and sanding pad for the threaded connection (stud).

3. Set the adapter on the threaded connection and clean it with circular movements.

Final Steps:

1. Tighten the ring terminal to the specified torque to ensure optimum contact.

2. Apply a suitable anti-corrosion treatment to the connection.

3. Reconnect the battery and, if necessary, teach-in windows and recode control units.

Lambda probe wires should not be repaired, as this can result in malfunctions. The entire probe must be renewed.

General Procedure (applies to both 4-pin LSF and 6-pin LSU probes):

1. Remove the defective Lambda probe from the vehicle.

2. Place the old probe and the new uniform 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 defective probe. Secure the excess cable with cable ties.

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

5. If necessary (usually on older vehicles), replace the onboard supply system connector with the new connector housing supplied with the uniform probe.

6. Install the new Lambda probe in the vehicle.