VOLKSWAGEN TIGUAN 2008 (02) PDF Document

To ensure long use of the battery on your VOLKSWAGEN TIGUAN 2008, the battery must be checked, serviced, and maintained according to the specifications in the manual. Apart from supplying energy for starting the engine, the battery has other tasks: it acts as a buffer and supplies electrical energy to the complete electrical onboard supply of the vehicle.

The PDF describes two main types of maintenance-free batteries for your VOLKSWAGEN TIGUAN 2008:

Battery with magic eye: This is a maintenance-free wet battery with liquid electrolyte. It is equipped with a “magic eye” that provides information on the electrolyte level and charge state via a colored display. For these batteries, no stickers should be removed, and they should not be replenished with distilled water. Only a visual check is performed.

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

Absorbent glass mat (AGM) battery: This is a maintenance-free 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 and may not have a magic eye. When replacing an AGM battery, it must be replaced with another AGM battery.

When handling the battery on your VOLKSWAGEN TIGUAN 2008, observe the following warnings:

• Untrained personnel (e.g., apprentices, trainees) may only work on batteries when supervised by a qualified vehicle mechanic or electrician.

• Acid is highly corrosive. Handle batteries correctly to avoid acid burns. Have a neutralizing solution, like soap solution, available.

• Leaking electrolyte can cause skin burns and corrosion on the vehicle, potentially damaging safety-relevant components.

• The gas formed during charging is explosive. An improperly handled battery may explode in extreme cases.

• Batteries with a colorless or light yellow magic eye must be renewed. They must not be checked, charged, or used for jump-starting due to an explosion risk.

• It is prohibited to cause sparks (through grinding, welding, cutting), use naked lights, or smoke in the vicinity of batteries. Avoid sparks from electrostatic charging by touching the vehicle body before touching the battery.

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

The safety markings on the battery of your VOLKSWAGEN TIGUAN 2008 indicate the following precautions:

1. Fires, sparks, naked flames, and smoking are prohibited. Avoid sparks and electrostatic discharge when working with cables and electrical units. Do not lay tools on the battery to avoid short circuits.

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 center according to legislation.

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

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

7. Always follow instructions on the battery, in the “Electrical System, General Information” manual, and in the owner’s manual.

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

To prevent damage to the battery clamps and terminals on your VOLKSWAGEN TIGUAN 2008, 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.

The procedure for checking the battery on your VOLKSWAGEN TIGUAN 2008 depends on the battery type:

For a battery with a magic eye:

1. Perform a visual check.

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

WARNING: Batteries where the magic eye is colorless or light yellow must not be checked or charged and must be renewed due to the danger of explosion.

3. Perform a battery load test using a battery tester like the VAS 5097 A or VAS 6161.

4. Depending on the test result, you may need to perform a current draw test.

For an Absorbent Glass Mat (AGM) battery:

1. Perform a visual check.

2. Perform a battery load test using a battery tester like the VAS 5097 A or VAS 6161.

3. Depending on the test result, you may need to perform a current draw test.

A visual inspection is essential before performing extensive tests on the battery of your VOLKSWAGEN TIGUAN 2008. This check establishes:

• If the battery housing is damaged: A damaged housing can leak electrolyte (battery acid), which can cause serious damage to the vehicle. If acid has leaked, treat the affected components immediately with an acid neutralizer or soap solution.

• If the battery terminals are damaged: Damaged terminals can prevent proper contact with the battery clamps, leading to potential malfunctions or even wiring fires. Ensure the battery clamps are correctly seated and tightened to the specified torque.

Also, always check that the battery is securely seated and the securing bolt is tightened to the specified torque. Vibrations from an unsecured battery can shorten its life and cause damage.

The “magic eye” on certain batteries for your VOLKSWAGEN TIGUAN 2008 provides information about the electrolyte level and charge state. Before checking, gently tap the magic eye with a screwdriver handle to dissipate any air bubbles that could distort the color.

There are two types of magic eye displays:

3-Colour Display (on older batteries):

• Green: Battery is sufficiently charged.

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

• Colourless or light yellow: Battery must be renewed.

2-Colour Display (on newer batteries):

• Black: Electrolyte level is OK.

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

WARNING: For both types, if the magic eye is colourless or light yellow, the battery must not be checked or charged. Do not attempt to jump-start the vehicle. These batteries must be renewed due to a high risk of explosion.

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

The actions required depend on the type of test performed and the results from the VAS 6161 tester on your VOLKSWAGEN TIGUAN 2008.

Evaluating battery test results for guarantee and service tests:

Evaluating battery test results for maintenance test:

A current draw test helps to determine if a discharged battery can be recharged or needs to be replaced. Follow these requirements for your VOLKSWAGEN TIGUAN 2008:

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).

• The battery’s current draw must be measured with a current pick-up clamp.

Procedure:

1. Connect the battery to a suitable battery charger.

2. Start the charging sequence.

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

Test Result Interpretation:

• If the current draw (in Amperes) is higher than 10% of the nominal capacity (in Ah): For example, > 6.1 A for a 61 Ah battery. In this case, fully charge the battery and test it again after allowing it to rest for two hours.

• If the charge current is below 10% of the nominal capacity after 5 minutes: For example, < 5.0 A for a 50 Ah battery. In this case, 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.

Using a hand multimeter (e.g., V.A.G 1526 B), check the battery no-load voltage and take the following action:

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

The functions of the cruise control system (CCS) on your VOLKSWAGEN TIGUAN 2008 are controlled by the engine control unit. You can activate or deactivate the system using a vehicle diagnostic tester by following these steps:

1. Connect the vehicle diagnostic tester to your vehicle.

2. Select “Guided fault finding” mode in the vehicle diagnostic 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)

Your VOLKSWAGEN TIGUAN 2008 uses several types of hose couplings for the 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 while pushing on the hose connection. Check that it has engaged correctly by trying to pull it off without depressing the clip.

The repair method depends on whether the pipe is smooth or corrugated.

Repairing a Smooth Pipe:

1. Cut the damaged section squarely out of the smooth pipe.

2. Select the appropriate size 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 be pushed about 10 mm into each side of the repair hose.

4. Secure the repair joints with cable ties.

Repairing a Corrugated Pipe:

1. Cut the damaged section squarely out of the corrugated pipe.

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

3. Heat one end of the corrugated pipe and push a connector into it.

4. Heat the other end of the corrugated pipe and push the other connector into it.

5. Cut a piece of heat-shrink hose so that it will cover the ends of the corrugated pipe by about 20 mm on each side of the repair.

6. Push the heat-shrink hose over the corrugated pipe, join the connectors, and secure the repair joint by heating the heat-shrink hose.

Gas discharge (xenon) bulbs operate under high voltage, pressure, and temperature. It is critical to follow these safety precautions when working on the headlights of your VOLKSWAGEN TIGUAN 2008:

High Voltage Danger:

• It is absolutely necessary to disconnect the battery earth strap before working on any parts marked with yellow high voltage symbols.

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

• Ensure the ignition is off, all electrical consumers are off, and the ignition key is removed.

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

Physical Dangers:

• H7 and gas discharge bulbs are under pressure and can explode while being changed, causing injury. Always wear protective goggles and gloves.

• The bulbs may only be operated inside the headlight housing to protect against contact with very hot surfaces and explosion.

• The glass of the bulbs can become very hot, creating a burn hazard.

• 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.

Repair Notes:

• Before changing a bulb, switch off all electrical consumers, turn off the ignition, and remove the key.

• Do not touch the bulb glass with bare fingers; use clean cloth gloves. Oils from skin can vaporize and damage the headlight reflector.

• Always replace a bulb with one of the same type. The designation is on the base of the bulb.

• Ensure connectors are properly engaged and seated tightly during installation.

Disposal Regulations:

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

• These bulbs contain metallic mercury (Hg) and traces of thallium. Never destroy them.

• These components must be recycled in accordance with national law.

• Dispose of bulbs only in containers intended for this purpose at an authorized collection point.

Note: On some vehicles, the illumination is provided by a permanently attached LED and cannot be renewed separately. This procedure applies only to sockets with a replaceable light bulb.

Removing:

1. Remove the cigarette lighter socket from its housing, typically using a special puller tool (T 40148).

2. 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. Separate the two parts of the bulb carrier to access the bulb.

5. Open the carrier and remove the light bulb.

Installing:

Installation is carried out in the reverse order of removal.

When carrying out repairs to the vehicle electrical system of your VOLKSWAGEN TIGUAN 2008, observe the following general notes:

• 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.

• Use only the approved wiring harness repair set (e.g., VAS 1978 B) and its components.

• Wiring harness repairs should be marked with yellow adhesive tape to indicate a previous repair.

• Crimp connectors may never be repaired. If a connection is faulty, lay a new wire parallel to the defective one.

• After crimping, connectors must be shrink-fitted using a hot air blower to prevent moisture ingress.

• Observe special supplementary information for repairing airbag systems, fibre optic cables, CAN bus lines, and aerial cables.

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

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

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

Faulty repairs to the airbag and seat belt tensioning system can cause malfunctions in the passenger protection system. In addition to the general wiring repair guidelines, you must observe these specific rules:

• Only use contacts, connectors, and wiring specifically designed for this purpose, as listed in the Electronic Parts Catalogue (ETKA).

• A maximum of two repairs may be performed in the wiring to the airbag and belt tensioner system. More repairs can increase resistance and trigger faults.

• Crimp connectors used in these repairs must always be shrink-fitted to prevent corrosion.

• The repaired section should not be incorporated back into the main wiring harness. It should be clearly marked with yellow insulating tape.

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

• The wires to the triggering units (airbags) 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 unit must have the same length.

• There must not be any section of untwisted wiring longer than 100 mm.

CAN bus wiring on your VOLKSWAGEN TIGUAN 2008 is an unshielded two-wire line. For proper repairs, follow these guidelines:

• Use the correct wire cross-section (0.35 mm² or 0.5 mm²) and color code for the specific CAN system you are repairing:

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

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

• There must not be any section of wiring longer than 50 mm where the wires are not twisted (e.g., near crimp connectors).

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

Aerial wires must not be repaired in the traditional sense; they must be replaced using a specific set of genuine parts. The total length of an aerial wire can be divided into sections by components like an aerial diversity control unit or amplifier. Only the defective section needs to be replaced.

The repair requires three components: an adapter cable for the source (e.g., radio), a connecting wire of the correct length, and an adapter cable for the destination (e.g., aerial).

1. Disconnect the defective aerial wire from the units at both ends.

2. Measure the total length of the section to be replaced.

3. To determine the length of the new connecting wire required, subtract 60 cm (for the two 30 cm adapter cables) from the total measured length.

4. Obtain the two required adapter cables and the connecting wire of the calculated length.

5. Cut the connectors off the old, defective aerial wire. The remainder of the old wire stays in the vehicle.

6. Connect the new adapter cables to the equipment in the vehicle (e.g., radio and aerial).

7. Route the new connecting wire along the original factory routing.

8. Connect the connecting wire to the two adapter cables.

9. Perform a functional test.

Note: Do not kink or excessively bend aerial wires. The bending radius must not be below 50 mm.

The procedure depends on whether the remaining wire ends are long enough for a single connector.

Repair with one crimp connector (if wire ends are long enough):

1. Cut out the damaged piece of wiring.

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

3. Push the single crimp connector over both stripped wire ends.

4. Crimp the connector using the correct recess on the crimping pliers. The insulation must not be crimped.

5. Using a hot air blower, shrink-fit the connector, working from the middle outwards, until it is sealed and adhesive escapes from the ends.

Repair with two crimp connectors and a new wire section (if wire ends are too short):

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

2. Cut a length of new, yellow repair wire to bridge the gap.

3. Strip the ends of the original wires and the new repair wire by 6-7 mm.

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

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

6. Crimp and shrink-fit both connectors as described above.

Note: When repairing multiple adjacent wires, position the crimp connectors so they are offset slightly from each other to prevent the wiring harness from becoming too thick.

Releasing contacts requires the correct release tool to avoid damaging the contact or the housing.

General Procedure:

1. Disengage Secondary Lock: If the connector has a secondary locking mechanism (often a different colored piece like a flap, slide, or toothed element), it must be opened, removed, or disengaged first.

2. Insert Release Tool: Insert the appropriate release tool for the specific contact type into the release port of the contact housing.

3. Push the Contact: Grab the wire and gently push the contact further into the housing. This action, combined with the release tool, lifts the primary locking tab(s) away from the housing edge.

4. Release and Pull: While pushing the contact, push the release tool in the direction of the contact housing. This will disengage the lock. You can then pull the contact and wire out from the back of the housing.

5. Remove Tool: Once the contact is out, the release tool can be removed from the housing.

This general process applies to various connector types, including round connectors, flat connectors (with one or two locking tabs), and special connectors (like Faston or GT 150/280).

Properly cleaning and protecting electrical connections like ring terminals, threaded studs, and battery terminals is crucial for the electrical system of your VOLKSWAGEN TIGUAN 2008.

Cleaning Ring Terminals and Threaded Connections:

1. Disconnect the battery.

2. Loosen the nut and remove the ring terminal from the threaded connection (stud).

3. Check both surfaces for corrosion and dirt.

4. Use a suitable adapter and sanding pad from a contact surface cleaning set (e.g., VAS 6410) to grind off corrosion and dirt with circular movements. Take care not to abrade excessively through the tin coating to the copper underneath.

5. If necessary, remove any punching burrs from the ring terminal with a deburrer.

6. Reassemble the connection and tighten to the specified torque.

Cleaning Battery Clamps and Terminals:

1. Disconnect the battery.

2. Use a battery terminal cleaner tool (e.g., VAG 1331). Clean the inside of the battery clamp and the outside of the battery terminal with the wire brushes on the tool, using circular movements.

3. Reconnect the battery and tighten the terminals to the specified torque.

Applying Anti-Corrosion Treatment:

1. After cleaning and tightening, apply an anti-corrosion treatment. Use protection wax for cold areas or cavity sealing agent for warm areas.

2. Using the supplied hose/injector, hold it below the ring terminal and spray the pin all around. Then, hold it above the ring terminal and spray the pin and wiring eye all around. The agent will spread through capillary action.

The procedure is similar for 4-pin LSF and 6-pin LSU probes. Do not repair, cut, or crimp Lambda probe wires, as this will cause malfunctions.

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 (approx. 50 – 250 mm) to match the length of the old probe. Secure the excess cable with cable ties.

4. Check that the connector housing of the new probe is compatible with the onboard supply side connector. On newer vehicles, the coding should match. On older vehicles, it may be necessary to replace the onboard supply system connector with the one supplied with the new probe.

5. If necessary, replace any attachment parts, cable ties, or marking rings to match the new probe to the defective probe’s setup.

6. Install the new Lambda probe in the vehicle.