VOLKSWAGEN TOUAREG 2010 (02) PDF Document

The repair groups for the electrical system are as follows:

Repair Group

27 – Starter, current supply, CCS

90 – Gauges, instruments

92 – Windscreen wash/wipe system

94 – Lights, bulbs, switches – exterior

96 – Lights, bulbs, switches – interior

97 – Wiring

To ensure long use, the battery must be checked, serviced, and maintained according to specifications. 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 descriptions are for maintenance-free batteries. No stickers should be removed, and they should not be replenished with distilled water. Only a visual check is needed.

Battery with magic eye:

This is a maintenance-free battery with liquid electrolyte (wet battery). It is equipped with a magic eye that provides information about the electrolyte level and charge state via a colored display.

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 (AGM). The battery is sealed and fitted with valves. 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. Note that an AGM battery should always be replaced with another AGM battery.

Handling vehicle batteries can be dangerous. These dangers can be avoided by observing the warnings on the battery and in the manuals.

WARNINGS:

• Untrained personnel may only work on batteries when supervised by a qualified technician.

• 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. An improperly handled battery may explode.

• Renew batteries where the magic eye is colorless or light yellow. Do not check, charge, or jump-start them.

• Prohibit sparks, grinding, welding, cutting operations, and naked lights near batteries. Do not smoke. Avoid electrostatic charging by touching the vehicle body before the battery.

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

Safety Markings on Battery:

1. Fires, sparks, naked flames, and smoking are prohibited. Avoid short circuits.

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.

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, 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.

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

Caution: The battery will be damaged if not secured correctly. Vibrations shorten battery life and can cause damage.

• Check that the battery is securely seated. If necessary, tighten the securing bolt to the specified torque.

A visual check establishes:

• If the battery housing is damaged. Leaking electrolyte can cause serious damage to the vehicle. Treat affected components immediately with an acid neutralizer or soap solution.

• Whether the battery terminals are damaged. Damaged terminals prevent proper contact. Tighten battery clamps to the specified torque to avoid malfunctions or wiring damage.

The magic eye provides information concerning the electrolyte level and charge state of the battery. Before checking, lightly tap the magic eye with a screwdriver handle to dissipate any air bubbles that could distort the display.

Note: The magic eye applies only to one cell. An exact determination of the battery condition is only possible through a battery load test.

Three different color displays are possible:

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

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

• **”Colorless or light yellow”**: Battery must be renewed.

WARNING: Batteries where the magic eye is colorless or light yellow must not be checked or charged. Do not jump-start the vehicle. These batteries must be renewed due to explosion risk.

For newer batteries, the “green” color display for charge state 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 with a screwdriver handle to dissipate any air bubbles.

The possible color displays are:

• **”Black”**: Electrolyte level is OK.

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

WARNING: Batteries where the magic eye is colorless or light yellow must not be checked or charged. Do not jump-start the vehicle. These batteries must be renewed due to explosion risk.

The battery does not need to be removed or disconnected for this test. The battery must have a temperature of at least 10 °C.

Procedure:

1. Switch off the ignition and all electrical consumers.

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

3. 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.

4. Select the low-temperature test current on the tester.

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

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

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

8. Select the connection point with the selection switch (1 – directly to battery, 2 – to external test points).

9. Press the start test button. The test program runs automatically, and the result is printed out. The test takes about 20 seconds.

10. If the unit does not start, recharge the battery and test again.

11. Switch off the unit and remove test terminals.

Note: Perform the test only once, as repeating it falsifies the result. The tester needs approx. 30 minutes to cool down before the next test.

The test results are printed out by the tester. The following table explains what measures to take based on the printout:

The battery tester with printer -VAS 6161- works on the principle of dynamic conductance acquisition and does not load the battery. It is not necessary to remove or disconnect the battery.

Performing battery test:

1. Switch off ignition and all electrical consumers.

2. Check magic eye on batteries with magic eye.

3. Switch on the unit.

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

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

6. Select one of the following functions:

• **Maintenance test:** (only in new cars before registration, in stationary and stock maintenance programme)

• **Service test**

• **Guarantee test**

The test is completed after about 10 seconds and the result is printed out. The tester requires no cooling phase before the next measurement.

The actions required depend on the test performed (guarantee/service or maintenance) and the result displayed.

Evaluating battery test results for guarantee and service tests:

Evaluating battery test results for maintenance test:

A current draw test while charging helps to quickly determine the state of discharged batteries. It helps to determine whether the battery must be replaced or can be fully recharged.

Test requirements:

• When charging, 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 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 (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.

• If the charge current is below 10% of the nominal capacity after 5 minutes (e.g., < 5A for a 50Ah battery), the battery must be renewed.

This test is used to assess the battery’s condition on stock and stored vehicles. 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 no-load voltage.

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

The battery must have a temperature of at least 10 °C. Always set the battery type to 2.4 V/C (volts/battery cell) when charging.

Procedure:

1. Switch off the ignition and all electrical consumers.

2. Check the setting for the battery type on the switch, it must be set to 2.4 V/C.

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, 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 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.

6. Switch off the charging unit.

7. Remove the charger terminals from the battery terminals.

For totally discharged batteries, the charger automatically initiates a gentle charging procedure with a low current. The battery voltage must be at least 0.6 V.

The support mode provides the onboard supply with power when the battery is removed or disconnected. This is useful for conserving power when renewing a battery or testing ancillaries without a battery.

Procedure:

1. Switch off ignition and all electrical consumers.

2. Remove the battery.

Caution: When the battery is removed, ensure no contact between the positive terminal clamp and body earth, and no contact between the two battery clamps.

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, the black terminal clamp “-” must be connected to body earth.

5. Check the setting for the 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 “-” from the vehicle.

3. Disconnect the red terminal clamp “+” from the vehicle.

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

The procedure is similar for both chargers. The battery must have a temperature of at least 10 °C.

Procedure:

1. Switch off 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. Set the battery to the respective operating mode (e.g., standard for wet batteries or standard for gel/AGM) using the INFO button.

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

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

6. For vehicles with a start/stop function and battery monitor control unit, the black terminal clamp must be connected to body earth. For other vehicles, connect it to the negative battery terminal.

The charger unit recognizes the required voltage and begins the charging sequence. At approximately 80-85% charge, it switches to “final charge” mode. At 100%, all bars appear on the display, and the charger will switch to maintenance mode after 1-7 hours.

Ending the charging sequence:

1. Press the START / STOP button.

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

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

Note on “Service Charge” / “Refresh Charge” mode: This mode is for sulfated wet batteries and is not permitted on VW vehicles with the battery connected, as voltage peaks can damage onboard electronics. If you need to use this mode, the battery must be disconnected from the vehicle.

The solar panel VAS 6102A supports the onboard supply and prevents spontaneous battery discharging. It has integrated electronics to prevent overcharging. A green LED indicates its function; the brighter the LED, the higher the charging current.

Procedure:

1. Secure the solar panel VAS 6102A on the interior mirror.

2. Place the underside of the panel on the dash panel for support.

Note: Do not let the solar panel lie fully on the dash panel, as this can cause discoloration.

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

4. Connect the solar panel to the diagnostic connection of the vehicle. The connection procedure is the same as for a vehicle diagnostic tester.

5. Check the function of the solar panel. The green LED indicates that it is working.

The functions of the cruise control system are controlled by the engine control unit. You can activate or deactivate the system using a vehicle diagnostic tester.

1. Connect the vehicle diagnostic tester to the 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)

Different hose coupling types are used to connect hoses to pumps and spray jets.

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 by 90° and pull off the hose connection.

• To secure: Push on the hose connection and rotate the lock ring until it engages.

Type 3 (Pull-Up Lock Ring/Clip):

• To loosen: Pull up the lock ring/clip 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 Coupling:

• 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 securing clip has correctly engaged by trying to pull it off without the clip.

Replacement parts are available for repairing both smooth and corrugated washer system pipes.

Repairing 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 (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.

Repairing 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 ETKA.

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

4. Push a connector into the heated pipe end.

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 headlights with gas discharge bulbs involves lethally high voltage and other hazards. Always wear protective goggles and gloves.

WARNINGS on High Voltage:

• It is absolutely necessary to disconnect the battery earth strap before working on parts of the gas discharge headlights 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 there is no voltage in any components. Residual voltage can be dissipated by turning the dipped beams on and then off again after withdrawing the ignition key.

• Ensure the lights cannot be switched on while working.

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

WARNINGS on Pressure, Temperature, and Radiation:

• Bulbs must only be operated in the headlight housing.

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

• Avoid looking directly into the beam; the UV rays are about 2.5 times greater than normal halogen bulbs.

• Avoid looking into the light beam to prevent glare; vision may be impaired.

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

The removal and installation procedure is the same for all illuminated sockets. A special puller (T 40148) is required.

Caution: Only illuminated sockets (cigarette lighter) 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 necessary.

2. Push the puller into the socket so that its locking lugs engage in the recesses of 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 release the puller from the socket, press the spindle on the puller and turn it briefly to the left.

Installing:

Install in the reverse order of removal.

Note: On some vehicles, the illumination is provided by an LED that is permanently attached to the retaining sleeve and cannot be renewed separately. On other versions, the bulb may be replaceable or may require replacement of the entire bulb carrier.

Removing:

1. Remove the cigarette lighter socket first.

2. Press the retaining lugs and remove the retaining sleeve together with the bulb carrier.

3. Unclip the bulb carrier from the retaining sleeve.

4. Separate the bulb carrier into its two parts (A and B).

5. Open part B of the bulb carrier.

6. Remove the light bulb.

Installing:

Installation is carried out in the reverse order of removal.

• Always disconnect the battery earth strap before working on the electrical system.

• Before starting, identify and rectify the cause of damage (e.g., sharp edges, corrosion).

• Soldering is not permitted for repairs to vehicle wiring.

• Use the specified wiring harness repair set (e.g., -VAS 1978 B-).

• Repaired sections should not be integrated back into the main harness and must be marked with yellow adhesive tape.

• Crimp connectors must never be repaired. If needed, lay a new wire parallel to the defective one.

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

• Special instructions must be followed for repairs to airbag, belt tensioner, CAN bus, and fibre optic systems.

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

• For heat-resistant wiring (found mainly in the engine compartment), only use heat-resistant repair wiring.

• Carry out a function test after every repair.

WARNING: Faulty repairs to the airbag and seat belt tensioning system can cause malfunctions in the passenger protection system, leading to failure of the airbag or tensioner.

• 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 for the airbag and belt tensioner system. More repairs increase resistance and can trigger faults.

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

• Mark the repair area clearly with yellow insulating tape.

• Repairs should not be 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 maintained 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, for example, near the crimp connectors.

To release contacts without damage, you must use the correct release tools and follow the proper procedure for primary and secondary locking mechanisms.

1. Secondary Locking Element:

• The secondary locking mechanism is a housing catch that secures all wires in the connector. It is usually a different color from the housing.

• Before releasing individual contacts, this secondary lock must always be opened or removed. This can be done by removing a “toothed element,” opening a “flap,” or detaching a “slide,” depending on the connector type.

2. Primary Locking Element:

• The primary lock fixes an individual crimp contact in the housing.

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

• Gently grab the wire and push the contact lightly into the housing. This action, combined with the release tool, lifts the locking tab(s) of the contact off the housing edge.

• At the same time, push the release tool further into the housing and pull the released contact out by its wire.

• Remove the release tool from the housing.

Note: Never pull contacts out of the housing with force. Always use the correct release tools.

This set allows for optimal cleaning of threaded connections in the high-current circuit (starting and charging).

Note: Do not use penetrating fluid, contact spray, or grease. Grey sanding pads are for light dirt and “soft surfaces,” while red pads are for heavy dirt and “hard surfaces.”

Repairing Ring Terminals:

1. Disconnect the battery.

2. Loosen the cap nut and remove the ring terminal.

3. Check the ring terminal for corrosion and dirt.

4. Select a suitable adapter and sanding pad.

5. Insert the adapter into the ring terminal and grind off corrosion with circular movements. Check visually to avoid abrading the tin coating excessively.

6. If necessary, remove any punching burr with the deburrer.

7. Tighten the ring terminal to the specified torque.

8. Apply a suitable anti-corrosion treatment.

9. Reconnect the battery.

Repairing Threaded Connections:

The procedure is similar. Use the appropriate adapter on the threaded connection itself to grind off corrosion and dirt.

Cleaning Battery Clamp and Terminal:

1. Disconnect the battery.

2. Use the wire brush of a 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.

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

Note: Do not repair Lambda probe wires, as this can result in malfunctions. The wires should not be crimped or cut.

General Procedure (for LSF 4-pin and LSU 6-pin probes):

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. The new uniform probe will have a longer cable. Tie back any excess length (approx. 50 – 250 mm) to match the size of the defective probe and secure it 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 onboard supply system connector with the one supplied with the new probe. On newer vehicles, the coding should match.

5. Install the new Lambda probe in the vehicle.