VOLKSWAGEN POLO 1995 (02) PDF Document

When handling batteries on your VOLKSWAGEN POLO 1995, observe the following safety regulations and markings:

Dangers and Precautions:

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

• Battery acid is highly corrosive. Take measures to neutralize acid burns, for example, with a soap solution. Leaking electrolyte can cause skin burns and corrosion on the vehicle.

• The gas formed during charging is explosive. An incorrectly handled battery may explode.

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

• Prohibit sparks, grinding, welding, cutting, naked lights, and smoking near batteries. Avoid electrostatic discharge by touching the vehicle body before 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 short circuits; never lay a tool on a battery.

2. Wear eye protection.

3. Keep children away from acid and batteries.

4. Dispose of old batteries as hazardous waste through a suitable collection center, following local legislation.

5. Never dispose of old batteries in household waste.

6. Danger of explosion. A highly explosive gas is produced when batteries are charged.

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

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 POLO 1995, follow these steps:

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

• Do not coat the battery terminals with grease.

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

• Once the battery clamps are tightened to the specified torque, do not tighten the threaded connections any further.

It is essential to visually inspect the external condition, terminals, and attachment of the battery on your VOLKSWAGEN POLO 1995 before performing extensive tests. This check establishes the following:

• Check for a damaged battery 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 a soap solution.

• Check for damaged battery terminals: If terminals are damaged, proper contact with the clamps cannot be guaranteed. When connecting, tighten the clamps to the specified torque. Incorrectly seated or tightened clamps can cause the wiring to burn and lead to electrical system malfunctions.

• Check if the battery is secured correctly: The battery will be damaged if not secured. Vibrations can shorten its life, pose an explosion risk, damage cell plates, and the clamping bracket may damage the housing. Ensure the battery is securely seated and tighten the securing bolt to the specified torque if necessary.

The “magic eye” on your VOLKSWAGEN POLO 1995’s battery 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 one cell it is located in.

For batteries with a “3-colour” display:

• 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 a battery in this state due to a high risk of explosion.

For newer batteries with a “2-colour” display:

• Black: The electrolyte level is OK.

• Colourless or light yellow: The electrolyte level is too low. The battery must be renewed. Do not check, charge, or jump-start a battery in this state due to a high risk of explosion.

Based on the printout from the battery tester, take the following actions for your VOLKSWAGEN POLO 1995:

When assessing the battery of your VOLKSWAGEN POLO 1995 using the VAS 6161 tester, follow this guide for both guarantee/service tests and maintenance tests.

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 on your VOLKSWAGEN POLO 1995.

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).

• Measure the current draw with a current pick-up clamp.

Procedure:

1. Connect the battery to the battery charger and start the charging sequence.

2. 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), fully charge the battery and test it again. After charging, let the battery rest for two hours before performing a new battery test.

• If the charge current is below 10% of the nominal capacity after 5 minutes of charging, the battery must be renewed.

This test is used to assess the battery condition on stock and stored vehicles.

Test Conditions:

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

Procedure:

Use a hand multimeter (e.g., V.A.G 1526 B) to check the battery no-load voltage.

Assessment:

A no-load voltage of 11.60 V corresponds to a 0% charge, meaning the battery is discharged and has no capacity.

To charge the battery of your VOLKSWAGEN POLO 1995 with a charger like the VAS 5095 A, follow these steps:

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

2. Switch off the ignition and all electrical consumers.

3. On the charger, check the setting for 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 on the battery.

6. Switch on the battery charger.

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

8. When the indicator LED lights up green, the charger has switched to “maintaining charge” and the battery is fully charged.

9. Switch off the charging unit.

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

The support mode provides power to the onboard supply of your VOLKSWAGEN POLO 1995 when the battery is removed or disconnected. This is useful for power conservation when renewing the battery or for testing ancillaries without a battery installed.

Procedure:

1. Switch off the ignition and all electrical consumers.

2. Remove the battery.

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

4. Connect the black terminal clamp (-) to the negative terminal of the vehicle.

5. On the charger, check that the normal/support mode switch is set to support mode.

6. Check the polarity of the charger unit cables.

7. Switch on the battery charger. The charger will start in support mode.

Ending Battery Support Mode:

1. Switch off the battery charger.

2. Disconnect the black terminal clamp (-) from the negative terminal of the vehicle.

3. Disconnect the red terminal clamp (+) from the positive terminal of the vehicle.

4. Pull the charger plug out of the battery charger.

The cruise control system (CCS) functions on your VOLKSWAGEN POLO 1995 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.

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)

Follow the on-screen instructions to complete the process.

Your VOLKSWAGEN POLO 1995 may use 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 (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 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 by approx. 1 mm and pull off the hose connection.

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

Type 4 (Headlight Washer System – Push Lock Ring):

• To loosen: Push the lock ring and pull off the hose connection.

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

Smooth pipes with a diameter of 5×1 mm or 6×1 mm can be repaired using a special EPDM hose.

1. Cut the damaged section at a right angle out of the smooth pipe that needs to be repaired.

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

3. Cut the EPDM hose to a length that allows the ends of the smooth pipe to each be pushed about 10 mm into the EPDM hose.

4. Secure the repair joints with cable ties.

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

Before Starting Work:

1. It is absolutely necessary to disconnect the battery earth strap before working on any parts of the gas discharge headlight system (marked with yellow high voltage symbols).

2. After disconnecting the battery, switch the dipped beam on and off again. This will dissipate any possible residual voltage.

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

During Operation and Handling:

• The gas discharge lamp control unit must never be operated without a gas discharge lamp fitted.

• The bulb must only be operated inside the headlight housing due to high ignition voltage (above 28,000 V), high temperatures, and to protect against UV radiation and potential explosion.

• The glass of the bulbs can be very hot, posing 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 for a substantial time.

• H7 and gas discharge bulbs are under pressure and can explode while being changed, causing injury.

• Do not touch the bulb glass with bare fingers. Use clean cloth gloves. Oils from fingerprints can vaporize and settle on the reflector, impairing brightness.

Disposal:

• Gas discharge bulbs must be disposed of as hazardous waste; never dispose of them as conventional waste.

• They contain metallic mercury (Hg) and traces of thallium; never destroy these bulbs.

• Dispose of them only in containers intended for this purpose at an authorized collection point, in accordance with national law.

Only illuminated sockets (cigarette lighters) can be removed without damage using the puller T 40148. Sockets without illumination may be damaged during removal.

Required Tool: Puller -T 40148-

Removing:

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. If necessary for clearance, use the thrust piece 40148/1 with the knurled nut.

6. Pull off the socket connector.

7. To remove the puller from the socket, press the spindle on the puller to release its locking lugs, then turn the puller briefly to the left and remove it.

Installing:

Installation is carried out in the reverse order of removal. After removing the socket, carefully press the socket’s retaining springs back together to ensure the cigarette lighter will remain in place after the heating phase.

Note that on some vehicles, illumination is provided by a non-replaceable LED. On others, the bulb may be integrated with the bulb carrier, requiring replacement of the entire carrier. This procedure applies only if the bulb is replaceable.

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

5. Open part B of the bulb carrier.

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

7. Install the new bulb and reassemble all components in the reverse order of removal.

To connect a vehicle diagnostic tester to your VOLKSWAGEN POLO 1995, follow these steps:

1. Apply the handbrake.

2. For vehicles with an automatic gearbox, move the selector lever to position “P” or “N”.

3. For vehicles with a manual gearbox, move the gearstick to the neutral position.

4. Switch off all electrical consumers.

5. With the ignition switched off, connect the vehicle diagnostic tester using the appropriate diagnostic cable (e.g., VAS 5051/6A) to the diagnostic interface in the vehicle.

6. Switch on the ignition.

When performing repairs on the vehicle electrical system of your VOLKSWAGEN POLO 1995, always observe the following 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, defective components).

• 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 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 heat-resistant wiring may be used for repairs.

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

• Observe special supplementary information for repairs to airbag/belt tensioner systems, CAN bus lines, and fibre optic cables.

When repairing the unshielded two-wire CAN bus line on your VOLKSWAGEN POLO 1995, you must follow these rules to ensure proper function:

• Both bus wires must have the same length when repaired.

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

• There must not be any section of wiring longer than 50 mm (B) that is not twisted, for example, in the vicinity of crimp connectors.

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

The colour codes for the CAN bus wiring are as follows:

There are two methods for repairing an open circuit, depending on the available length of the wire.

Repair with One Crimp Connector (if wire ends are long enough):

1. Unbind the wiring harness if necessary.

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

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 recess in the crimping pliers.

5. After crimping, shrink-fit the connector using a hot air blower, working from the middle outwards until it is completely sealed.

Repair with Two Crimp Connectors and an Interlinked Wire (if wire ends are too short):

1. Cut a length of new yellow repair wire.

2. Cut out the damaged section of the original wire.

3. Strip 6-7 mm of insulation from all four wire ends (two on the vehicle harness, two on the new repair wire).

4. Use one crimp connector to join one end of the vehicle wire to one end of the repair wire.

5. Use a second crimp connector to join the other end of the vehicle wire to the other end of the repair wire.

6. Shrink-fit both connectors using a hot air blower.

Important Notes for all repairs:

• Ensure the correct crimp recess is used for the wire size.

• The wire insulation must not be crimped.

• When repairing multiple wires, offset the crimp connectors so they are not directly adjacent to each other to avoid making the harness too thick.

• Re-wrap the repair area with yellow insulation tape.

To release contacts from housings without damage, you must use the correct release tools from a set like VAS 1978/35.

General Procedure:

1. Disengage Secondary Lock: First, open or remove any secondary locking mechanism on the contact housing. This is often a different colored piece, such as a toothed element, a flap, or a slide, that secures all wires in the connector.

2. Disengage Primary Lock: The primary lock is what holds an individual contact in place.

• Insert the correct release tool for the specific contact type into the release port of the contact housing.

• Gently grab the wire and push the contact slightly *into* the housing. This action helps lift the locking tabs off the housing edge.

• While pushing the contact in, simultaneously push the release tool further into the housing to disengage the locking tabs.

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

3. Remove Tool: Once the contact is out, the release tool can be pulled out of the housing.

Never pull contacts out of the housing with force, as this will damage the contact and the housing.

The contact surface cleaning set is used to remove dirt and corrosion from high-current connections like battery terminals and threaded ground points.

Important Notes:

• Do not use penetrating fluid, contact spray, or grease, as this can cause incorrect torque and breakage.

• Grey sanding pads are for light dirt and soft surfaces; red pads are for heavy dirt and hard surfaces.

• When cleaning, do not abrade the tin coating so excessively that the underlying copper is exposed, as this can cause faulty repairs.

Cleaning a Ring Terminal:

1. Disconnect the battery.

2. Loosen the nut and remove the ring terminal.

3. Select a suitable adapter and sanding pad.

4. Insert the adapter into the ring terminal and grind off corrosion with circular movements.

5. If necessary, use a deburrer to remove any punching burr.

Cleaning a Threaded Connection (e.g., Ground Stud):

1. Disconnect the battery and remove the ring terminal.

2. Select a suitable adapter and sanding pad for the threaded connection.

3. Set the adapter on the threaded connection and grind off corrosion with circular movements.

Cleaning Battery Clamps and Terminals:

1. Disconnect the battery.

2. Use the wire brush of the battery terminal cleaner (e.g., VAG 1331) to clean the inside of the battery clamp and the outside of the battery terminal with circular movements.

After Cleaning:

1. Reassemble the connection and tighten to the specified torque to ensure optimum contact.

2. Apply a suitable anti-corrosion treatment.

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

Do not attempt to repair Lambda probe wires, as this can result in malfunctions. The entire probe must be replaced with a uniform probe that is adapted to fit.

Procedure for LSF (4-pin) and LSU (6-pin) 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 (typically 50-250 mm) to match the length of the old probe. Secure the excess cable with cable ties.

4. If necessary, replace any attachment parts, cable ties, or marking rings from the old probe onto the new one to ensure it matches the original installation.

5. Check that the connector housing of the new Lambda probe is compatible with the connector on the vehicle’s onboard supply side. On older vehicles, it may be necessary to replace the vehicle-side connector with the one supplied with the new probe.

6. Install the new Lambda probe in the vehicle.