VOLKSWAGEN SCIROCCO 2009 (02) PDF Document

To ensure long use of the battery on your VOLKSWAGEN SCIROCCO 2009, 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.

This is a maintenance-free battery with liquid electrolyte (wet battery). No stickers may be removed, and you should not replenish it with distilled water. Only perform a visual check.

WARNING:

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, charging, or slave/jump starting. These batteries must be renewed.

An Absorbent Glass Mat (AGM) battery is a maintenance-free, sealed, lead-acid battery where the electrolyte is contained within a microscopic glass mat. Due to the contained electrolyte, this type of battery may not have a magic eye. AGM batteries are identified by the abbreviation “AGM” on the battery. When replacing an AGM battery, it must always be replaced with another AGM battery.

Handling vehicle batteries can be dangerous. To avoid injury, observe the following warnings:

• Untrained personnel should only work on batteries under supervision.

• Battery acid is highly corrosive. Have a neutralizing solution (e.g., soap solution) available to treat acid burns.

• Leaking electrolyte can cause skin burns and corrosion on the vehicle.

• Gas formed during charging is explosive. Mishandling can lead to a battery explosion.

• Batteries with a colourless or light yellow magic eye must be renewed and not checked, charged, or jump-started due to explosion risk.

• Avoid sparks, grinding, welding, cutting, or naked lights near batteries. Smoking is prohibited. 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 your vehicle’s battery indicate the following precautions:

1. Fires, sparks, naked flames, and smoking are prohibited. Avoid sparks from electrostatic discharge 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. Disposal: 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. 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, as acid can leak from vents.

To prevent damage to the battery clamps and terminals on your VOLKSWAGEN SCIROCCO 2009, 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.

Carry out the procedure in the following sequence:

1. Perform a visual check.

2. Check the colour display of the “3-colour” or “2-colour” magic eye.

WARNING: Batteries where the magic eye is colourless or light yellow must not be checked or charged. Do not slave/jump start the vehicle! These batteries must be renewed due to the danger of explosion.

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

4. Depending on the result of the battery test, perform a current draw test if necessary.

Carry out the procedure in the following sequence:

1. Perform a visual check.

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

3. Depending on the result of the battery test, perform a current draw test.

It is essential to visually inspect the external condition, check the terminals, and ensure proper attachment of the battery before performing extensive tests. This establishes:

• If the battery housing is damaged: Electrolyte can leak out, which can cause serious damage to the vehicle. Treat components affected by leaked battery acid immediately with an acid neutraliser or a soap solution.

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

Caution: The battery will be damaged if not secured correctly. Vibrations can shorten its life and create an explosion danger. Ensure the battery is securely seated and tighten the securing bolt to the specified torque if necessary.

The “3-colour” magic eye provides information on the electrolyte level and charge state. Before checking, lightly tap the magic eye with a screwdriver handle to dissipate air bubbles for a more accurate reading. Three different colour displays are possible:

• Green: Battery is charged sufficiently.

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

• Colourless or light yellow: Battery must be renewed.

WARNING: Batteries with a colourless or light yellow magic eye must not be checked, charged, or used for jump-starting due to the danger of explosion. These batteries must be renewed.

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

For newer batteries, the “green” display has been discontinued. The magic eye now only provides information concerning the electrolyte level. The charge state must be determined with a battery load test. Before checking, lightly tap the magic eye to dissipate any air bubbles.

The possible displays are:

• Black: Electrolyte level is OK.

• Colourless or light yellow: Electrolyte level is too low. The battery must be renewed.

WARNING: Batteries where the magic eye is colourless or light yellow must not be checked, charged, or used for a jump-start. There is a danger of explosion. These batteries must be renewed.

To perform a battery load test using the VAS 5097 A, follow these steps:

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 batteries that have one.

4. 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 to find the DIN value.

5. Select the low-temperature test current on the tester using the selection switch.

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

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

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

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

10. The result will be printed out. If the unit does not start, recharge the battery and test again.

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

Note: The test is completed in about 20 seconds. Perform the test only once, as repeating it can falsify the result. The tester needs approximately 30 minutes to cool down before the next test.

To perform a battery test with the VAS 6161 tester, follow these steps:

1. Switch off the ignition and all electrical consumers.

2. Check the magic eye on batteries equipped with one.

3. Switch on the unit.

4. Connect the red terminal “+” of the tester to the positive terminal of the battery.

5. Connect the black terminal “-” of the tester to the negative terminal of the battery. Ensure the test clamps have a good contact.

6. Select one of the following functions from the menu:

• Maintenance test

• Service test

• Guarantee test

The test is completed after about 10 seconds, and the result is printed out. The tester does not require a cooling phase before the next measurement.

A current draw test is performed to quickly ascertain the state of discharged batteries and determine if they must be replaced or can be fully recharged. This test is required when a battery tester (like VAS 5097A or VAS 6161) indicates results such as “Starting output sufficient/poor/very poor” or “Perform current draw test.”

Test requirements:

• Battery temperature must be at least +10 °C.

• The charger must be capable of at least 30 A (e.g., VAS 5095A, VAS 5900, VAS 5903).

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

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 (A) 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.

The no-load voltage test is used to assess the battery’s condition on stock and stored vehicles to determine if it needs recharging. The battery must not have been charged or discharged within the last 2 days.

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

To charge the battery with the VAS 5095 A charger, 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 base of the charger unit, set the battery type switch to 2.4 V/C (volts/battery cell). This applies to all batteries.

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. For vehicles with a start/stop function and battery monitor control unit, the black clamp must be connected to body earth to avoid system malfunction.

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

The charging current indicators will light up yellow. 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.

7. Once charging is complete, switch off the charging unit.

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

The functions of the cruise control system (CCS) on your VOLKSWAGEN SCIROCCO 2009 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.

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. Follow the instructions for the type on your vehicle:

Type 1 (No securing device):

• To loosen: Pull the two coupling sections apart.

• 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 (Pull-up lock ring):

• To loosen: Pull up the lock ring -1- by approx. 1 mm and pull off the hose connection.

• To secure: Attach the hose connection and press in the clip -1- until it engages.

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

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

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

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

4. Secure the repair joints with cable ties.

To repair a corrugated pipe, you will need a hot air blower (e.g., VAS 5179).

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

2. Select suitable end pieces and the correct sized shrink-fit piping from the electronic parts catalogue (ETKA).

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

4. Push a connector into the heated end.

5. Heat the end of the other piece of corrugated pipe.

6. Push the other connector into the second heated end.

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

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

Note: Repair points must not be subjected to pulling or bending forces.

Working on gas discharge (xenon) headlights involves several risks. Always observe the following safety measures:

• High Voltage: Control units and components conduct lethally high voltage. It is absolutely necessary to disconnect the battery earth strap before working on any parts marked with yellow high-voltage symbols. After disconnecting, switch the dipped beam on and off again to eliminate any residual voltage.

• High Pressure/Temperature: H7 and gas discharge bulbs are under pressure and can explode. The glass can get very hot, causing burns. Always wear protective goggles and gloves.

• UV Radiation/Glare: Avoid looking directly into the beam. The UV rays are stronger than normal halogen bulbs, and the glare can impair vision.

• Operation: The bulbs must only be operated in the headlight housing. Never operate the control unit without a bulb fitted.

• Disposal: Gas discharge bulbs contain mercury and must be disposed of as hazardous waste at an authorised collection point.

Note: Only illuminated sockets (cigarette lighter) can be removed with the puller T 40148. Sockets without illumination usually cannot be removed without being damaged.

Removing:

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

2. Push the puller T 40148 into the socket so that its locking lugs engage in the recesses of the retaining sleeve.

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. Take care not to stretch the wiring.

5. Pull off the socket connector.

6. To release the puller, press the spindle and turn the puller briefly to the left.

Caution: When the puller is mounted, the socket retaining springs are pressed apart. After removing the socket, carefully press the retaining springs back together and check that the cigarette lighter remains in its removal position after a heating phase to prevent it from being ejected.

Installing:

Install in the reverse order of removal.

To connect a vehicle diagnostic tester:

1. Apply the handbrake.

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

3. 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.

4. Switch on the ignition.

5. Switch off all other electrical consumers before beginning diagnosis.

When performing repairs to 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.

• Wiring harness repairs must be carried out using the appropriate wiring harness repair set (e.g., VAS 1978 B). Repairs should be marked with yellow adhesive tape.

• Crimp connectors may never be repaired; if necessary, lay a new wire parallel to the defective one. After crimping, they must be shrink-fitted to prevent moisture ingress.

• Special information must be observed for repairs to airbag, belt tensioner, fibre optic, CAN bus, and aerial wiring.

• Perform a function test after every repair. The fault memory may need to be interrogated and erased.

• If possible, do not loosen any earth wires from the body to avoid corrosion.

• 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 repair wiring.

WARNING: Faulty repairs to the airbag and seat belt tensioning system can cause malfunctions in the passenger protection system and may cause the components to fail.

In addition to the general notes on electrical repairs, follow these specific instructions:

• 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 to avoid excessive resistance.

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

• Mark the area of repair clearly with yellow insulating tape and do not incorporate it back into the main wiring harness.

• Repairs should be no more than 30 cm from the next contact housing.

• The wires to the triggering units 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 the triggering units must have the same length.

• There must not be any section of wiring longer than 100 mm that is not twisted, for example, near the crimp connectors.

An unshielded two-wire line with a cross section of 0.35 mm² or 0.5 mm² is used for CAN bus wiring. The colour codes are as follows:

When performing repairs:

• Both bus wires must be repaired to the same length.

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

• There must not be any untwisted section of wiring longer than 50 mm, for example, near crimp connectors.

• Mark the area of repair with yellow insulation tape.

1. Place the wire to be repaired to one side.

2. If necessary, unbind the wiring harness.

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

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

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

6. After crimping, the connector must be shrink-fitted using a hot air blower to prevent any ingress of moisture. Heat the connector from the middle outwards until it is sealed and adhesive escapes from the ends.

7. If necessary, re-wrap the repair position with yellow insulation tape and attach the harness with a cable tie.

Note: If the wire ends are too short for this repair, use a piece of repair wire with two crimp connectors.

The general procedure for releasing a contact from its housing is as follows:

1. Open or disengage any secondary locking mechanism on the contact housing. These are often a different colour from the housing and can be a toothed element, a flap, or a slide.

2. Identify the correct release tool for the specific contact type (round, flat, special).

3. Insert the appropriate release tool into the release port of the contact housing.

4. Grab the wire of the contact and push it lightly into the housing. This action helps lift the primary locking tabs off the housing edge.

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

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

7. Remove the release tool.

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

1. Disconnect the battery.

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

3. Check the ring terminal 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 and grind off corrosion and dirt with circular movements.

Caution: Do not abrade the tin coating excessively to the point where copper appears, as this can cause faulty repairs.

6. Check the ring terminal and regrind if necessary. Use a deburrer to remove any punching burr.

7. Tighten the ring terminal to the specified torque.

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

9. Reconnect the battery and teach-in any required systems (windows, radio code, etc.).

Note: Do not repair Lambda probe wires, as this can result in malfunctions.

General Procedure:

1. Remove the defective Lambda probe from the vehicle.

2. Place both the old and new Lambda probes next to each other so that the sensor housings 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 and secure the excess with cable ties.

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

5. Install the new Lambda probe in the vehicle.