VOLKSWAGEN LUPO 3L 1999 (02) PDF Document

When handling the battery in your VOLKSWAGEN LUPO 3L 1999, be aware of the following dangers:

• Corrosive Acid: Battery acid is highly corrosive and can cause severe burns. Ensure suitable neutralizing solutions, like a soap solution, are available.

• Explosive Gas: The gas that forms when charging is explosive. An improperly handled battery may explode. It is prohibited to cause sparks, use naked lights, or smoke near the battery.

• Electric Shock: Always touch the vehicle body before touching the battery to avoid sparks from electrostatic discharge. Avoid short circuits by never laying a tool on the battery.

• Component Damage: Leaking electrolyte can cause skin burns and damage safety-relevant components on the vehicle through corrosion and rusting.

• Improper Jump-Starting: Batteries with a colorless or light yellow “magic eye” must be renewed. Do not check, charge, or jump-start them, as there is a danger of explosion.

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

The safety markings on the battery of your VOLKSWAGEN LUPO 3L 1999 indicate the following precautions:

1. No Flames/Sparks: Fires, sparks, naked flames, and smoking are prohibited. Avoid sparks from electrostatic discharge when working with cables and electrical units. Do not short-circuit the battery.

2. Eye Protection: Always wear eye protection before starting work on the battery.

3. Keep Children Away: Keep children away from battery acid and the battery itself.

4. Proper 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 the household waste system.

6. Explosion Danger: A highly explosive gas is produced when the battery is charged.

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

8. Caustic Acid: Battery acid is very caustic. Wear eye protection and gloves. Do not tilt the battery, as acid can leak from the gas vents.

Performing a visual check on the battery of your VOLKSWAGEN LUPO 3L 1999 establishes the following:

• Check for a Secure Fit: Ensure the battery is securely seated. Vibrations can shorten its life and cause damage. If necessary, tighten the securing bolt to the specified torque.

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

• Check the Terminals: Inspect the battery terminals and wire connections for damage. Damaged terminals can prevent a proper connection. When connecting the clamps, tighten them to the specified torque to prevent malfunctions or wiring damage.

The “magic eye” provides information about the electrolyte level and charge state of the battery in your VOLKSWAGEN LUPO 3L 1999. Before checking, gently tap the magic eye with a screwdriver handle to dissipate any air bubbles that could distort the color.

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

• Green: The battery is sufficiently charged.

• Black: The battery is partly or completely discharged (charge state < 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 (newer models):

• Black: The electrolyte level is OK. The charge state cannot be read from the magic eye and 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 the vehicle.

Note that the magic eye only applies to one cell, so an exact determination of the battery’s condition is only possible through a battery load test.

To perform a battery load test with the VAS 5097 A tester on your VOLKSWAGEN LUPO 3L 1999, follow these steps. The battery must have a temperature of at least 10 °C.

1. Switch off the ignition and all electrical consumers.

2. If the battery has a magic eye, check its color. Do not test if it is colourless or light yellow.

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

4. On the VAS 5097 A, select the low-temperature test current using the selection switch.

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

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

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

8. Use the selection switch to indicate if the tester is connected directly to the battery or to external test points.

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

10. The test result will be printed out. If the unit does not start, the battery needs to be recharged.

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

Important: Perform the test only once, as repeating it 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 for your VOLKSWAGEN LUPO 3L 1999:

To perform a battery test with the VAS 6161 tester on your VOLKSWAGEN LUPO 3L 1999, follow these steps:

1. Switch off the ignition and all electrical consumers.

2. If the battery has a magic eye, check its status. Do not test if it is colourless or light yellow.

3. Switch on the VAS 6161 unit.

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

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

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

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

• Service test: Used for regular service checks.

• Guarantee test: Used for warranty claims.

7. Follow the on-screen prompts, which may include selecting “On battery terminal” or “On jump-start point,” selecting the vehicle type, and scanning a barcode or manually selecting the battery type and manufacturer.

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

9. Start the test. The test is completed after about 10 seconds, and the result is printed.

To check the no-load voltage, you will need a hand multimeter like the V.A.G 1526 B. The battery must not have been charged or discharged within the last 2 days for an accurate reading.

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

2. Compare the measured value to the following conditions:

A battery is considered totally discharged if its no-load voltage is less than 11.60 V (0% charge).

To charge the battery in your VOLKSWAGEN LUPO 3L 1999 using the VAS 5095 A charger, follow these steps. The battery can remain in the vehicle. The battery must have a temperature of at least 10 °C.

1. Switch off the ignition and all electrical consumers.

2. On the base of the charger unit, set the battery type change-over switch to 2.4 V/C (volts/battery cell). This setting applies to all batteries.

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

4. Connect the black terminal clamp (-) of the charger to the negative terminal on the battery.

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

6. The yellow charging current indicators will light up. When only one yellow LED is lit, the battery is approximately 90% charged.

7. When the green “maintaining charge” LED lights up, the battery is fully charged.

8. Switch off the charging unit.

9. Remove the charger terminals from the battery terminals.

A battery in your VOLKSWAGEN LUPO 3L 1999 is designated as “totally discharged” when its no-load voltage is less than 11.6 V.

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

• Sulphation: When a battery is totally discharged, its plates sulphate, meaning they harden. If recharged shortly after discharge, the sulphation can mostly dissipate. If not recharged, the plates continue to harden, reducing the ability to recharge and lowering the battery’s output.

• Charging: To attempt a recharge, check the battery’s no-load voltage. Special charging procedures are required for totally discharged batteries, often involving a gentle charging procedure with a low current, which some advanced chargers can initiate automatically.

• Renewal: Batteries with a colourless or light yellow magic eye are beyond recovery and must be renewed. Do not attempt to charge or jump-start them.

To activate or deactivate the cruise control system (CCS) on your VOLKSWAGEN LUPO 3L 1999, you need to use a vehicle diagnostic tester. The functions are controlled by the engine control unit.

1. Connect the vehicle diagnostic tester to your vehicle.

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

Follow the on-screen instructions to complete the process.

There are several types of hose couplings used in the windscreen washer system of your VOLKSWAGEN LUPO 3L 1999. 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 (Lifting 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.

Gas discharge bulbs operate under dangerous conditions. Observe these safety precautions for your VOLKSWAGEN LUPO 3L 1999:

• Lethal High Voltage: The system uses extremely high voltage (over 28,000 V) to ignite the bulb. It is absolutely necessary to disconnect the battery earth strap before working on any part of the system 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.

• High Pressure: The bulbs are under pressure and can explode if mishandled, causing injury. Always wear protective goggles and gloves when removing and installing them.

• Extreme Heat: The glass of the bulbs can become very hot, posing a burn risk. Only operate the bulbs within the headlight housing.

• UV Radiation and Glare: Avoid looking directly into the beam. The UV radiation is significantly stronger than from halogen bulbs, and the intense light can impair vision for a substantial time.

• General Handling: Do not touch the bulb glass with bare fingers; use clean cloth gloves. Oil from skin can damage the bulb and impair headlight brightness. Never operate the control unit without a bulb fitted.

To replace the illumination bulb in the cigarette lighter of your VOLKSWAGEN LUPO 3L 1999, follow these steps:

Removing:

1. First, remove the cigarette lighter socket from its housing. This requires a special puller (T 40148) to release the locking lugs of the retaining sleeve.

2. Once the socket is removed, press the retaining lugs on the retaining sleeve and remove the sleeve together with the bulb carrier.

3. Unclip the bulb carrier from the retaining sleeve.

4. The bulb carrier consists of two parts. Separate them in areas -A- and -B- to access the bulb.

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

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

Installing:

1. Installation is carried out in the reverse order of removal.

2. Insert the new bulb into the carrier, clip the carrier halves together, attach it to the retaining sleeve, and reinstall the socket assembly.

Note: On some vehicles, illumination is provided by an LED that is permanently attached to the retaining sleeve and cannot be renewed separately. Additionally, some bulb carriers do not allow for separate bulb replacement; in this case, the entire bulb carrier must be replaced.

When performing repairs on the vehicle electrical system of your VOLKSWAGEN LUPO 3L 1999, always observe the following guidelines:

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

• Identify and rectify the cause of any damage (e.g., sharp edges, corrosion) before starting the repair.

• Soldering is not permitted for repairs to vehicle wiring. Use the approved wiring harness repair set (e.g., VAS 1978 B).

• Crimp connectors must never be repaired. If needed, lay a new wire in parallel. After crimping, connectors must be shrink-fitted with a hot air blower to prevent moisture ingress.

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

• For heat-resistant wiring (identifiable by its slightly matt and softer insulation), only use heat-resistant repair wiring.

• If the required wire cross-section is not available in the repair kit, use the next largest size.

• After every repair, perform a function test. It may be necessary to interrogate and erase the fault memory.

• Adhere to special instructions for repairing wiring to airbags, belt tensioners, fibre optic cables, and CAN bus lines.

Repairs to Airbag and Belt Tensioner Wiring:

• Use only specifically designed contacts, connectors, and wiring for these systems. Use the approved wiring harness repair set.

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

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

• The repaired section should not be re-integrated into the main harness and must be marked with yellow insulating tape.

• Wires to triggering units are entwined with a specific spacing (20 mm ± 5). This spacing must be maintained during repair. The wires must have the same length.

• Any untwisted section of wire (e.g., near a connector) must not be longer than 100 mm.

Repairs to CAN bus Wiring:

• An unshielded two-wire line (0.35 mm² or 0.5 mm²) is used.

• The color codes for the CAN bus wiring are as follows:

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

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

• Any untwisted section of wire (e.g., near a connector) must not be longer than 50 mm.

• Mark the area of repair with yellow insulation tape.

To repair an open circuit in a single wire on your VOLKSWAGEN LUPO 3L 1999, follow these steps:

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

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

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

4. Crimp the connector using the correct crimp recess on the crimping pliers. Ensure the wire insulation is not crimped.

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

6. Heat the crimp connector with the hot air blower, working from the middle outwards until it is completely sealed and adhesive escapes from the ends. Be careful not to damage surrounding components.

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

8. Secure the repaired wiring harness with a cable tie if necessary to prevent noise.

Note: If multiple wires are repaired, stagger the crimp connectors so they are not directly adjacent to each other to prevent the harness from becoming too bulky.