VOLKSWAGEN POLO 2010 (02) PDF Document

To ensure long use of the battery in your VOLKSWAGEN POLO 2010, it must be checked, serviced, and maintained according to the specifications in the manual. Apart from supplying energy for starting the engine, the battery also acts as a buffer and supplies electrical energy to the complete electrical onboard supply of the vehicle.

The batteries are maintenance-free. Do not remove any stickers or replenish with distilled water. Only a visual check is necessary.

Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle. There is a danger of explosion when checking and charging or slave/jump starting. These batteries must be renewed.

An AGM battery is a maintenance-free battery with a contained electrolyte and no magic eye. It is a lead-acid battery where the electrolyte is contained within a microscopic glass mat. The battery is sealed and fitted with valves. AGM batteries are identified by the abbreviation “AGM” on the battery. If you need to replace an AGM battery, it must be replaced with another absorbent glass mat battery.

When handling the vehicle battery for your VOLKSWAGEN POLO 2010, observe the following warnings:

• Untrained personnel may only work on batteries when supervised by a qualified vehicle mechanic or electrician.

• 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.

• Gas formed during charging is explosive. A battery may explode if not handled correctly.

• It is prohibited to cause sparks, use naked lights, or smoke near batteries. Always touch the vehicle body to discharge static electricity before touching the battery.

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

The safety markings on the battery of your VOLKSWAGEN POLO 2010 indicate the following precautions:

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

2. Wear eye protection before working on the battery.

3. Keep children away from acid and batteries.

4. Old batteries are hazardous waste and must be disposed of at a suitable collection center.

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 owner’s manual.

8. Battery acid is caustic; wear eye protection and gloves. Do not tilt the battery.

To prevent damage to the battery clamps and terminals on your VOLKSWAGEN POLO 2010, observe the following:

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

• Battery terminals should not be coated with grease.

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

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

A visual inspection is essential to check the external condition, terminals, and proper attachment of the battery before performing extensive tests. This establishes:

• **If the battery housing is damaged:** Electrolyte can leak out, potentially causing serious damage to the vehicle. Treat any components affected by leaked battery acid immediately with an acid neutralizer or a soap solution.

• **If the battery terminals are damaged:** Proper contact cannot be guaranteed if terminals are damaged. When connecting, tighten clamps to the specified torque. If not correctly seated and tightened, the wiring may burn, causing malfunctions.

Always check that the battery is securely seated and, if necessary, tighten the securing bolt to the specified torque. Vibrations can shorten the battery’s life and damage the housing or cell plates.

The magic eye provides information on 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. The three possible colours indicate:

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

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

• **Colourless or light yellow:** Battery must be renewed. Do not check, charge, or jump start a battery with this display due to explosion risk.

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

For newer batteries, the “green” display has been discontinued. This magic eye provides information concerning the electrolyte level only. Before checking, lightly tap the magic eye to dissipate air bubbles. The two possible colours indicate:

• **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 a battery with this display due to explosion risk.

The charge state of the battery can no longer be read from this type of magic eye; a battery load test must be performed.

To perform a battery load test with the VAS 5097 A tester:

1. Ensure the battery has a temperature of at least 10 °C.

2. Switch off the ignition and all electrical consumers.

3. Check the magic eye on the battery, if applicable.

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, convert them using the provided table.

5. Select the low-temperature test current and measuring range (e.g., 380 – 499 A) on the tester.

6. Connect the red terminal “+” of the tester to the positive terminal and the black terminal “-” to the negative terminal. Ensure a good contact.

7. Select the connection point (directly to battery or external test points) with the selection switch.

8. Press the start test button. The green LED will light up, and the test will run automatically.

9. After about 20 seconds, the test result will be printed out. If the unit does not start, recharge the battery and test again.

10. 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.

Based on the printout from the battery tester, take the following measures:

To perform a battery test with the VAS 6161 tester:

1. Switch off the ignition and all electrical consumers.

2. Check the magic eye on batteries that have one.

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 in stock maintenance programs.

• **Service test:** For regular service checks.

• **Guarantee test:** For warranty-related claims.

6. Follow the on-screen prompts for the selected test, which may include scanning the VIN, selecting the test point (battery terminal or jump-start point), selecting battery type, and measuring temperature.

7. Start the test. The result will be completed in about 10 seconds and printed out.

The following tables explain the measures to take based on the test results from the VAS 6161 tester.

Evaluating battery test results for guarantee and service tests:

Evaluating battery test results for maintenance test:

A current draw test helps determine if a discharged battery must be replaced or can be fully recharged. Ensure the correct charging mode is set on the charger to avoid falsifying the test.

Test requirements:

• 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 the battery charger and start the charging sequence.

2. Measure the charging current of the battery after 5 minutes.

Test result:

• If the current draw 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 a two-hour rest period.

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

This test is used to assess the battery condition on stock and stored vehicles as part of prescribed maintenance. The battery must not have been charged or discharged within the last 2 days for an accurate reading.

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

A no-load voltage of 11.60 V indicates a 0% charge, and the battery is considered totally discharged.

The VAS 5095 A charger can remain in the vehicle while charging. The battery must have a temperature of at least 10 °C.

1. Switch off the ignition and all electrical consumers.

2. Check the setting on the battery type switch on the base of the charger. It must be set to 2.4 V/C (volts/battery cell).

3. Connect the red terminal clamp “+” of the charger to the positive terminal on the battery.

4. For vehicles with a start/stop function and battery monitor control unit (J367), the black terminal clamp “-” must be connected to body earth. For other vehicles, connect it to the negative battery terminal.

5. Switch on the battery charger.

The yellow charging current indicators will light up. When only one yellow LED is lit, the battery is approximately 90% charged. When the green LED lights up, the charger has switched to “maintaining charge,” and the battery is fully charged.

6. Switch off the charging unit.

7. Remove the charger terminals from the battery terminals.

The charger will automatically recognize a totally discharged battery and initiate a gentle charging procedure with a low current.

Support mode provides the onboard supply with power 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.

1. Switch off the ignition and all electrical consumers.

2. Remove the battery.

3. Connect the red terminal clamp “+” to the positive terminal of the vehicle.

4. For vehicles with a start/stop function and battery monitor control unit (J367), the black terminal clamp must be connected to body earth.

5. Check the setting for battery type on the normal/support mode switch; it must be switched 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.

To end battery support mode:

1. Switch off the battery charger.

2. Disconnect the black terminal clamp, then the red terminal clamp.

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

The procedure is similar for both VAS 5900 and VAS 5903 chargers. Ensure the battery has a temperature of at least 10 °C.

1. Switch off the ignition and all electrical consumers.

2. Connect the charger plug to the battery charger. The last selected battery type will appear on the display.

3. Press the INFO button to set the battery to the respective operating mode (e.g., standard charge for wet batteries or for gel/AGM batteries).

4. Set the battery capacity (Ah) using the “Up” and “Down” arrow buttons.

5. Connect the red terminal clamp “+” to the positive terminal on the battery.

6. For vehicles with a start/stop function, connect the black terminal clamp “-” to body earth. Otherwise, connect it to the negative terminal.

7. The charger unit recognizes the required voltage and initiates the charging sequence automatically.

At approximately 80-85% charge, the charger switches to “final charge” mode. At 100% charge, all bars appear in the display. The charger will switch to maintenance mode after 1-7 hours.

To end charging:

1. Press START / STOP.

2. Disconnect the black clamp, then the red clamp.

3. Unplug the charger.

If you encounter issues while charging:

• **Displayed battery voltage is not as per nominal voltage:** Press the “Up” or “Down” button until the charging sequence starts.

• **Displayed voltage is incorrect after charging has started:** Press START / STOP twice, then press “Up” or “Down” until the charging sequence starts again.

• **Charger does not detect a battery (voltage is less than 2 V):** The display remains unchanged. The battery is likely totally discharged and requires a special charging procedure.

The VAS 5906 charger is designed for charging during vehicle presentation and starts automatically without requiring settings.

1. Place the charger in the engine compartment or under the vehicle.

2. Connect the mains cable to the charger and plug it into a mains socket. The “ready” light will turn on.

3. Switch off the ignition.

4. Connect the red charging cable to the positive terminal “+” on the battery.

5. For vehicles with a start/stop function, connect the black charging cable to the negative terminal “-” on the battery to a body earth point. For others, connect to the negative terminal.

Charging will start after about 2 seconds. The number of LEDs lit indicates the charge condition. Once all lights are lit, the battery is fully charged, and the charger switches to trickle charging.

To terminate charging:

1. Press the start/stop button.

2. Disconnect the black charging cable.

3. Disconnect the red charging cable.

The solar panel VAS 6102A supports the onboard supply and prevents spontaneous battery discharging.

1. Secure the solar panel on the interior mirror.

2. Place the underside of the panel on the dash panel for support. Do not let the panel lie fully on the dash panel, as this can cause discoloration.

3. Pull the attachment string tight so the panel is positioned close to the windscreen.

4. Connect the solar panel to the diagnostic connection of the vehicle.

5. Check the function of the solar panel. A green LED indicates its function; the brighter the LED, the higher the charging current.

A battery is designated “totally discharged” when the no-load voltage is less than 11.6 V.

Key points and risks:

• Totally discharged batteries freeze prematurely. Frozen batteries should no longer be used.

• In this state, the electrolyte is comprised almost entirely of water, as the acid content is very low.

• The battery plates sulphate, meaning they harden. If recharged shortly after discharge, the sulphation will mostly dissipate.

• If not recharged, the plates continue to harden, reducing the ability to recharge and lowering the battery’s output.

The functions of the cruise control system are controlled by the engine control unit. To activate or deactivate the system, you must use a vehicle diagnostic tester.

1. Connect the vehicle diagnostic tester.

2. Select “Guided fault finding” mode.

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)

There are several types of hose couplings used on the windscreen, rear window, and headlight washer systems.

• **Type 1 (No securing device):** To loosen, pull the two coupling sections apart. To secure, push them together until they engage.

• **Type 2 (Rotating lock ring):** To loosen, rotate the lock ring 90° and pull off the hose connection. To secure, push on the 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.

• **Headlight Washer System Type:** To loosen, push the lock ring 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.

Repairing a smooth pipe:

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

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 right angles.

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

3. Heat the end of one piece of corrugated pipe.

4. Push a connector into the heated pipe.

5. Repeat for the other piece of corrugated pipe and the other connector.

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 using a hot air blower.

Working on gas discharge headlights involves significant risks due to high voltage, pressure, and temperature. Always wear protective goggles and gloves.

High Voltage Danger:

• It is absolutely necessary to disconnect the battery earth strap before working on these headlights.

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

• Control units for these light systems conduct lethally high voltage. Never operate the control unit without a bulb fitted.

Pressure, Temperature, and Radiation Risks:

• Bulbs must only be operated in the headlight housing.

• The glass of the bulbs can be very hot, causing burns.

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

• Avoid looking directly into the beam due to high UV radiation and the danger of glare.

Disposal:

• Gas discharge bulbs must be disposed of as hazardous waste. They contain metallic mercury (Hg) and traces of thallium. Never destroy these bulbs and dispose of them only at an authorized collection point.

Only illuminated sockets (cigarette lighters) can be removed with the puller T 40148. Sockets without illumination usually cannot be removed without being damaged, as the puller cannot release their locking lugs.

Removing:

1. Remove the cigarette lighter or dummy plug from the socket if present.

2. Push the puller (T 40148) 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 remove the puller from the socket, press the spindle on the puller and turn it briefly to the left to release the locking lugs.

Installing:

Install in the reverse order of removal.

Note: On some vehicles, illumination is provided by an LED that is permanently attached and cannot be renewed separately. On others, the bulb carrier must be replaced with the bulb. Check your specific version.

Removing:

1. Remove the socket from the vehicle.

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 to access the bulb.

5. Remove the light bulb.

Installing:

Installation is carried out in the reverse order of removal.

When performing repairs on the vehicle electrical system, always observe the following:

• 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).

• Soldering is not permitted for repairs to vehicle wiring.

• Use the appropriate wiring harness repair set for all repairs.

• Crimp connectors may never be repaired. If needed, 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; they must be replaced completely.

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

• Carry out a function test after every repair.

Faulty repairs to the airbag and seat belt tensioning system can cause malfunctions and system failure. In addition to the general repair notes, follow these rules:

• Only use contacts, connectors, and wiring designed specifically for this purpose.

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

• Crimp connectors must always be shrink-fitted.

• Do not incorporate the repaired section back into the vehicle’s wiring harness; instead, mark the area of repair clearly with yellow insulating tape.

• Repairs should not be more than 30 cm from the next contact housing.

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

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

• There must not be any section of wiring longer than 100 mm that is not twisted.

The CAN bus uses an unshielded two-wire line. The color codes are as follows:

When performing repairs:

• 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.

• Mark the area of repair with yellow insulation tape.

To release and dismantle contacts without damage, always use the correct release tools. Never pull contacts out by force.

1. **Secondary Locking:** First, open or disengage any secondary locking mechanism. This is often a different colored piece on the housing, such as a toothed element, a flap, or a slide. It must be moved or removed to allow the primary locks to be released.

2. **Primary Locking:** The primary lock is what holds an individual crimp contact in the housing. The procedure varies by connector type:

• **Round/Flat Connectors:** Insert the appropriate release tool into the release port of the contact housing. Gently push the contact by its wire further into the housing; this helps lift the locking tabs. At the same time, push the release tool in the direction of the contact housing and pull the released contact out from the back.

• **Special Connectors (e.g., GT 150/280):** Insert the release tool under the locking tab in the contact housing and push it to the limit stop. The contact will be ejected.

Damaged contact housings must always be replaced.

Use the contact surface cleaning set (VAS 6410) for these repairs. Do not use penetrating fluid, contact spray, or grease, as this can affect torque settings.

1. Disconnect the battery.

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

3. Check the ring terminal and connection 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 (or onto the threaded connection) and grind off corrosion and dirt with circular movements. Be careful not to abrade the tin coating excessively, to avoid exposing the copper underneath.

6. Check the surface and regrind if necessary. If needed, remove any punching burr from the ring terminal with a deburrer.

7. Tighten the ring terminal to the specified torque.

8. Apply a suitable anti-corrosion treatment.

9. Reconnect the battery and teach-in any systems as required (e.g., electric windows, radio code).

Do not repair Lambda probe wires, as this can result in malfunctions. The procedure differs slightly for 4-pin (LSF) and 6-pin (LSU) probes.

1. Remove the defective Lambda probe.

2. Place both the new uniform probe and the old defective probe next to each other so that the sensor housings are at the same height.

3. Tie back any excess length in the new probe’s cable (approx. 50-250 mm) to match the length of the defective probe’s cable. Secure the excess with cable ties.

4. Check that the connector housing of the new probe is compatible with the onboard supply side. For older vehicles, it may be necessary to replace the onboard supply system connector with the one provided with the new probe.

5. Install the new Lambda probe in the vehicle.