VOLKSWAGEN GOLF VARIANT 2010 (15) PDF Document

Batteries can be dangerous and specific hazards must be avoided. When handling a battery on a VOLKSWAGEN GOLF VARIANT 2010, observe the following safety markings:

1. Fire, sparks, naked light and smoking are prohibited. Avoid sparks and electrostatic discharge when working with cables. Avoid short circuits; do not place tools on the battery.

2. Wear eye protection before commencing work.

3. Keep children away from acid and batteries.

4. Old batteries are hazardous waste and must be disposed of through a suitable collection centre in accordance with legislation.

5. Never dispose of old batteries in the household waste system.

6. Charging creates a highly explosive oxyhydrogen gas mixture, creating a risk of explosion.

7. Follow all instructions provided in the owner manual.

8. Electrolyte acid is highly corrosive, so protective gloves and eye protection must be worn. The battery must not be tilted to prevent acid leakage from vents.

Additionally, untrained personnel, such as apprentices or trainees, must only work on batteries when supervised by a qualified vehicle mechanic or electrician.

To prevent damage to the battery terminal clamps and terminals on a VOLKSWAGEN GOLF VARIANT 2010, the following must be observed:

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

Battery terminals should not be coated with grease.

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

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

It is essential to first check the external condition of the battery and verify that the terminals of the VOLKSWAGEN GOLF VARIANT 2010 battery are seated securely. Points for the visual check include:

Damage to the battery housing: If the housing is damaged, electrolyte can leak out, which can cause serious vehicle damage. Affected areas should be treated immediately with an acid neutraliser or soap solution.

Damage to battery terminals: If terminals are damaged, contact at the terminal clamps cannot be guaranteed. Ensure clamps are tightened to the specified torque. Incorrect seating or tightening can cause wiring to burn and result in electrical system malfunctions.

Security of battery: Ensure the battery is securely seated and, if necessary, tighten the securing bolt to the specified torque. Lack of security can cause damage due to vibration and potential cell plate damage.

For a 3-colour display (up to 03/08), the following applies:

Green: Battery is charged sufficiently.

Black: Battery is partly discharged (less than 65%) or completely discharged.

Colourless/light yellow: Battery must be renewed. Do not test or charge batteries with this colour; replace them immediately.

For a 2-colour display (from 04/08 onwards):

Black: Electrolyte level OK.

Colourless/light yellow: Electrolyte level too low. Battery must be renewed.

Note: Air bubbles can form below the magic eye, especially after recharging, which can falsify the reading. Tap the magic eye lightly with the handle of a screwdriver to dissipate air bubbles before checking.

The no-load voltage test is used to assess the condition of a battery on stock or stored vehicles. The battery must not have been charged or discharged within the last 2 days. Use a hand multimeter to check the voltage.

Test results for a VOLKSWAGEN GOLF VARIANT 2010:

At 11.60 V, the battery is considered discharged, with no capacity, and is heavily discharged.

If a smooth pipe with a diameter of 5×1 mm or 6×1 mm needs repair, 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 as specified in the electronic parts catalogue.

3. Cut the EPDM hose to size so that the pipe ends can be inserted approximately 10 mm into the EPDM hose.

4. Secure the repair joints with cable ties.

To repair a corrugated pipe, use a hot air blower. The following steps should be taken:

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

2. Select the appropriate connectors and heat-shrink hose from the electronic parts catalogue.

3. Heat the end of the corrugated pipe with the hot air blower.

4. Push the connector into the corrugated pipe.

5. Repeat the heating and connector insertion for the other end of the corrugated pipe.

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

7. Push the heat-shrink hose over the corrugated pipe, join the connectors, and secure the repair joints with the heat-shrink hose.

Gas discharge bulbs conduct lethally high voltage. Follow these safety instructions for a VOLKSWAGEN GOLF VARIANT 2010:

Disconnect the battery before working on parts marked with yellow high-voltage symbols, then switch the dipped beam on and off again to eliminate residual voltage.

Never operate the gas discharge lamp control unit without a gas discharge lamp fitted.

Gas discharge bulbs must only be operated in the headlight housing to protect against heat, UV radiation, and explosion.

The glass envelope of the bulb can be very hot; do not touch with bare fingers, use a clean cloth glove.

H7 bulbs and gas discharge bulbs are under pressure and can explode. Always wear safety goggles and gloves when removing or installing them.

Gas discharge bulbs contain mercury and traces of thallium; dispose of them as hazardous waste.

Removal requires the use of puller T40148 and thrust piece 40148/1. Ensure you do not exert excessive force, as the retaining sleeve may be damaged.

1. Remove the cigarette lighter or dummy from the socket.

2. Push puller T40148 into the socket so that the locking lugs engage in the recesses.

3. Pull the grip in the direction of the arrow to release the locking lugs of the retaining sleeve.

4. Pull the socket out of the retaining sleeve using the puller.

5. Disconnect the connector from the socket.

Note: Take care not to stretch the wiring when pulling out the socket.

Follow these steps to repair an open circuit:

1. Unbind the wiring harness if necessary using a folding knife.

2. Cut out the damaged piece of wiring using wire strippers.

3. Strip the wire ends of insulation by 6 to 7 mm.

4. Push a crimp connector onto both stripped wire ends and crimp using the appropriate crimping pliers.

5. Place the shrink element for the hot air blower onto the blower.

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