Test Sequence
Battery, Checking, Vehicles with Battery Monitoring Control Module J367 or Energy Management Control Module J644 and Data Bus On Board Diagnostic Interface J533
Caution
It is not possible to check the battery using "Guided Fault Finding" through MY 2010 during the following procedure, even if the vehicle has a Battery Monitoring Control Module -J367-:
Battery test. Refer to → Chapter "Checking the Battery - Vehicles without a Battery Monitoring Control Module -J367- or Energy Management Control Module -J644-".
WARNING
Risk of injury. Follow all warning messages and safety precautions. Refer to → Chapter "Warnings and Safety Precautions".
Perform Tests in the Following Sequence:
1. Visual inspection. Refer to → Chapter "Visual Inspection".
2. Check the visual indicator color display (if equipped). Refer to → Chapter "Visual Indicator Color Display, Checking".
WARNING
Do not check or charge a Battery -A- when the visual indicator has "no color or is bright yellow". Jump starting must not be used!
There is a risk of explosion during testing, charging or jump starting.
These Batteries -A- must be replaced.
3. Battery Test with Vehicle Diagnostic Tester refer to → Chapter "Battery Test with Vehicle Diagnostic Tester".
Checking the Battery - Vehicles without a Battery Monitoring Control Module -J367- or Energy Management Control Module -J644-
Caution
It is not possible to check the battery using "Guided Fault Finding" through MY 2010 during the following procedure, even if the vehicle has a Battery Monitoring Control Module -J367-:
WARNING
Risk of injury. Follow all warning messages and safety precautions. Refer to → Chapter "Warnings and Safety Precautions".
Perform the Tests in the Following Sequence:
1. Visual inspection. Refer to → Chapter "Visual Inspection".
2. Check the visual indicator color display (if equipped). Refer to → Chapter "Visual Indicator Color Display, Checking".
WARNING
Do not check or charge a Battery -A- when the visual indicator has "no color or is bright yellow". Jump starting must not be used!
There is a risk of explosion during testing, charging or jump starting.
These Batteries -A- must be replaced.
Note
The Battery Tester with Printer -VAS5097A- will no longer be used for warranty testing. Only the Battery Tester -VAS6161- is still being used.
3. Battery test with:
4. Depending on the result of the battery load test, "perform current draw test". Refer to → Chapter "Current Draw Test".
Visual Inspection
WARNING
Risk of injury. Follow all warning messages and safety precautions. Refer to → Chapter "Warnings and Safety Precautions".
Before any extensive measurements are taken, visually inspect the exterior of the battery, the connections, and the secure installation of the Battery -A-.
Caution
Visual Indicator Color Display, Checking
3-Color Visual Indicator, Checking, through 03/2008
WARNING
Risk of injury. Follow all warning messages and safety precautions. Refer to → Chapter "Warnings and Safety Precautions".
Visual Indicator General Information:
The visual indicator provides information concerning the electrolyte level and the Battery -A- charge level.
To obtain an accurate reading, gently tap the charge indicator with a screwdriver handle or rock vehicle slightly. By doing this, the air bubbles that occur normally during battery charging (even during vehicle operation) that adversely affect charge indicator reading will be displaced. Thereby, the color indicator of the visual indicator is more accurate.
Note
There Are Three Possible Color Indications
WARNING
Do not check or charge a Battery -A- when the visual indicator has "no color or is bright yellow". Jump starting must not be used!
There is a risk of explosion during testing, charging or jump starting.
These Batteries -A- must be replaced.
2-Color Visual Indicator, Checking, from 04/2008
WARNING
Risk of injury. Follow all warning messages and safety precautions. Refer to → Chapter "Warnings and Safety Precautions".
Visual Indicator General Information
The "green" visual indicator for the charge level indicator is no longer used for these Batteries -A-. Only "black" or "no color or bright yellow" are used.
The visual indicator shows the Battery -A- electrolyte level.
It is no longer possible to read the Battery -A- charge level using the visual indicator. It is necessary to perform a battery test. Refer to → Chapter "Battery Load Test".
To obtain an accurate reading, gently tap the charge indicator with a screwdriver handle or rock vehicle slightly. By doing this, the air bubbles that occur normally during battery charging (even during vehicle operation) that adversely affect charge indicator reading will be displaced. Thereby, the color indicator of the visual indicator is more accurate.
Note
Two Visual Indicators Are Possible
WARNING
Do not check or charge a Battery -A- when the visual indicator has "no color or is bright yellow". Jump starting must not be used!
There is a risk of explosion during testing, charging or jump starting.
These Batteries -A- must be replaced.
Battery Test with Vehicle Diagnostic Tester
The Battery -A- can also be checked using the Vehicle Diagnostic Tester when it is installed and without being connected to a battery charger.
Special tools and workshop equipment required
Test Prerequisites
Procedure
Vehicle Diagnostic Tester is attached.
- Select the Diagnostic mode and start the diagnostics.
- Select the tab Test Plan.
- Select Select Individual Tests and choose the following sequence.
The Vehicle Diagnostic Tester continues with the battery test from here on.
Battery Tester -VAS6161-
General Description:
WARNING
Risk of injury. Follow all warning messages and safety precautions. Refer to → Chapter "Warnings and Safety Precautions".
It is not necessary to disconnect or remove the Battery -A- when using the Battery Tester -VAS6161-.
The Battery Tester -VAS6161- does not load the Battery -A-. It is working according to the principle of dynamic conductivity.
The Battery Tester -VAS6161- stores all battery types.
The data can be stored on an SD memory card.
The Battery Tester -VAS6161- can be updated via an interface or a SD card, so that all battery data from Volkswagen is always current.
The integrated infrared sensor (measuring the battery temperature) increases the quality of the measurements.
As an option, there is a scanner available, which can be used to read the bar code on the Battery -A-.
Note
Observe the Battery Tester -VAS6161- Operating Instructions.
Battery Tester -VAS6161- Device Description
Battery Tester -VAS6161-
1 - Internal printer
2 - Operating lever for the paper tray
3 - Paper slot
4 - Main menu display
5 - Display with on/off-button
6 - Connection for the battery tester cable
7 - Slot for the SD memory card
8 - Infrared temperature sensor
9 - PC file transmitter
Battery Test, Performing using Battery Tester -VAS6161-
Special tools and workshop equipment required
WARNING
Risk of injury. Follow all warning messages and safety precautions. Refer to → Chapter "Warnings and Safety Precautions".
Procedure
WARNING
Do not check or charge a Battery -A- when the visual indicator has "no color or is bright yellow". Jump starting must not be used!
There is a risk of explosion during testing, charging or jump starting.
These Batteries -A- must be replaced.
Note
The Battery -A- temperature must be at least 10 ºC (50 ºF).
- Turn off the ignition and all electrical consumers and remove the ignition key.
- Check the visual indicator on Batteries -A- with visual indicator. Refer to → Chapter "Battery, Checking, Vehicles with Battery Monitoring Control Module J367 or Energy Management Control Module J644 and Data Bus On Board Diagnostic Interface J533".
- Switch on the Battery Tester -VAS6161-. Refer to → Chapter "Battery Tester -VAS6161- Device Description".
- Connect the red terminal (+) to the positive terminal of the Battery -A-.
- Connect the black terminal (-) to the negative terminal for the Battery -A-.
Note
Make sure the test terminals make good contact!
- Select one of the following:
Note
- Switch off the Battery Tester -VAS6161-. Refer to → Chapter "Battery Tester -VAS6161- Device Description".
- Remove the test terminals.
Maintenance Test, Performing
WARNING
Do not check or charge a Battery -A- when the visual indicator has "no color or is bright yellow". Jump starting must not be used!
There is a risk of explosion during testing, charging or jump starting.
These Batteries -A- must be replaced.
Procedure
- Select "Maintenance Test".
- Connect the scanner.
Note
If there is no scanner, manually enter the VIN on the printed test results.
- Scan the VIN.
- Select "at the battery pole" or "at the battery jump start terminal".
- Section vehicle model.
- Scan the barcode or manually select the "type and manufacturer" in the menu.
- Determine the temperature above the Battery -A-. Hold the infrared sensor approximately 5 cm above the battery pole until the temperature is stable.
- Start the test.
- Print out the test notes.
Service Test, Performing
WARNING
Do not check or charge a Battery -A- when the visual indicator has "no color or is bright yellow". Jump starting must not be used!
There is a risk of explosion during testing, charging or jump starting.
These Batteries -A- must be replaced.
Procedure
- Select "Service Test".
- Select "at the battery pole" or "at the battery jump start terminal".
- Section vehicle model.
- Determine the temperature above the Battery -A-. Hold the infrared sensor approximately 5 cm above the battery pole until the temperature is stable.
- Select battery type (Normal, AGM, 2*6 V or Gel).
- Select Norm (CCA, JIS, DIN, SAE, IEC or EN).
- Start the test.
- Print out the test notes.
Warranty Test, Performing
WARNING
Do not check or charge a Battery -A- when the visual indicator has "no color or is bright yellow". Jump starting must not be used!
There is a risk of explosion during testing, charging or jump starting.
These Batteries -A- must be replaced.
Procedure
- Select "Warranty Test".
- Select "inside the vehicle" or "outside of the vehicle".
- Select "at the battery pole" or "at the battery jump start terminal".
- Section vehicle model.
- Determine the temperature above the Battery -A-. Hold the infrared sensor approximately 5 cm above the battery pole until the temperature is stable.
- Select battery type (Normal, AGM, 2*6 V or Gel).
- Select battery capacity.
- Start the test.
- Print out the test notes.
Explanation of Test Results
1 - Type of test
2 - Test result
3 - Measured voltage
4 - Battery -A- measured cold start value
5 - Battery -A- cold start value set on the Battery Tester -VAS6161-
6 - Temperature measured above the Battery -A-
7 - Battery -A- component location
8 - Battery terminal clamp position set on the Battery Tester -VAS6161-
9 - Selected battery type
Note
The printed test results are required for warranty claims.
Test Result Evaluation
Evaluating the Battery Test Results for the Warranty and Service Tests
Evaluating the Battery Test Results for the Maintenance test
Battery Tester with Printer -VAS5097A-
WARNING
Risk of injury. Follow all warning messages and safety precautions. Refer to → Chapter "Warnings and Safety Precautions".
It is not necessary to disconnect or remove the Battery -A- when using the Battery Tester with Printer -VAS5097A-.
The following Batteries -A- can be tested using the Battery Tester with Printer -VAS5097A-:
1) Batteries -A- with cold crank amps greater than 499 A according to DIN can be tested with the setting for 499 A according to DIN.
The Batteries -A- are tested by being loaded with current that corresponds to the starter current of a vehicle. Under this load, the Battery -A- is evaluated and the measured results are output through the printer.
Note
Read the Battery Tester with Printer -VAS5097A- Operating Instructions and Battery Tester with Printer -VAS5097A- Quick Reference Guide label on the Battery Tester with Printer -VAS5097A- and the cold crank amps table. Refer to → Chapter "Cold Crank Amps Table".
Battery Tester with Printer -VAS5097A- Device Description
Battery Tester with Printer -VAS5097A-
1 - LED green, "Device in use"
2 - LED red, "Device connected with terminals reversed"
3 - LED red "Battery cannot be tested", the Battery -A- must be replaced.
4 - Start button
5 - Cold cranking output selector switch
6 - ON/OFF function switch
7 - Sliding switch (battery hook-up to the Battery -A-/at jump start point)
8 - Paper-feed -button
9 - Printer
Battery Load Test
WARNING
Risk of injury. Follow all warning messages and safety precautions. Refer to → Chapter "Warnings and Safety Precautions".
Special tools and workshop equipment required
Always note the TPL 2012182.
Procedure
WARNING
Do not check or charge a Battery -A- when the visual indicator has "no color or is bright yellow". Jump starting must not be used!
There is a risk of explosion during testing, charging or jump starting.
These Batteries -A- must be replaced.
Note
The Battery -A- temperature must be at least 10 ºC (50 ºF).
Caution
- Check the visual indicator on Batteries -A- with visual indicator. Refer to → Chapter "Battery, Checking, Vehicles with Battery Monitoring Control Module J367 or Energy Management Control Module J644 and Data Bus On Board Diagnostic Interface J533".
- Switch on the Battery Tester with Printer -VAS5097A-. Refer to → Chapter "Battery Tester with Printer -VAS5097A- Device Description".
- Determine the cold crank amps according to specifications on the Battery -A- in ampere (A) according to DIN and determine the Battery Tester With Printer -VAS5097A- adjustment range using the table. Refer to → Chapter "Cold Crank Amps Table".
Note
If the Battery -A- does not state this value in DIN but rather in IEC or EN/SAE, then convert the value using the table (refer to → Chapter "Cold Crank Amps Table") or the table on the Battery Tester with Printer -VAS5097A-.
- Set the cold crank amps with the cold crank amps selector switch. Refer to → Chapter "Battery Tester with Printer -VAS5097A- Device Description".
- Set the measuring range (80 to 379 A or 380 to 499 A) using the ON/OFF switch. Refer to → Chapter "Battery Tester with Printer -VAS5097A- Device Description".
Note
Batteries -A- with cold crank amps greater than 499 A according to DIN can be tested with the setting for 499 A according to DIN.
- Connect the red terminal (+) to the positive terminal of the Battery -A-.
- Connect the black terminal (-) to the negative terminal for the Battery -A-.
Note
- Using the sliding switch, select the test clamp connection point. Refer to → Chapter "Battery Tester with Printer -VAS5097A- Device Description".
1 - Direct connection to the Battery -A-
2 - Connection on the battery jump start terminal
- Check if the cold crank amps indicated on the Battery -A- matches the selected value on the Battery Tester with Printer -VAS5097A-.
- Press theStart-button. Refer to → Chapter "Battery Tester with Printer -VAS5097A- Device Description".
The green LED lights up. Refer to → Chapter "Battery Tester with Printer -VAS5097A- Device Description". The test program runs automatically. The test results are output through the printer. Refer to → Chapter "Battery Load Test Results". If the Battery Tester with Printer -VAS5097A- does not start, (the LED does not come on and there is no print out), then charge the Battery -A-. Refer to → Chapter "Battery, Charging".
- Switch off the Battery Tester with Printer -VAS5097A-. Refer to → Chapter "Battery Tester with Printer -VAS5097A- Device Description".
- Remove the test terminals.
Note
Cold Crank Amps Table
1) Batteries -A- with cold crank amps greater than 499 A according to DIN can be tested with the setting for 499 A according to DIN.
Battery Load Test Results
By placing the battery under a strong load during the Battery -A- load test, the battery voltage will be reduced.
Printed Test Results Explanations
1 - Measuring range set on the Battery Tester with Printer -VAS5097A-
2 - Diagram, the -arrow- points to the Battery -A- status.
3 - Test result
4 - Battery -A- voltage during the battery load test.
5 - Vehicle data and date. For tester to fill out.
Note
Test Result Evaluation
Current Draw Test
WARNING
Do not check or charge a Battery -A- when the visual indicator has "no color or is bright yellow". Jump starting must not be used!
There is a risk of explosion during testing, charging or jump starting.
These Batteries -A- must be replaced.
Make sure the correct charging mode is set on the battery charger so the current draw test is not inaccurate.
In order to receive an indication as quickly as possible of the battery condition of discharged Batteries -A-, a conclusion can be made during the charging process using the Battery -A- current draw as to whether the Battery -A- should be replaced or charged completely.
Note
In the case of the Battery Tester -VAS6161-, the current draw test must always be conducted when the test result "conduct current draw test" appears in the display.
The current draw test should always be performed if the test using the Battery Tester with Printer -VAS5097A- had the following results:
1 - Starting power sufficient
2 - Starting power insufficient
3 - Starting power very insufficient
4 - Cannot be tested - charge the Battery -A- and perform the test again
5 - Battery Tester with Printer -VAS5097A- does not turn on (no LED, no printout)
Depending on the test results Battery Tester with Printer -VAS5097A- (refer to → Chapter "Test Result Evaluation"), additional test steps or work for a clear evaluation of the battery charge must be made.
By checking a current draw capacity on a Battery -A- during the charging procedure, it can be determined in a short time whether a partially discharged or severely discharged Battery -A- can become operable again by further charging. Refer to → Chapter "Severely Discharged Batteries".
Test Prerequisites
Procedure
- Connect the Battery -A- to the Battery Charger and start the charging process.
- Measure the Battery -A- charge current after five minutes.
Test Result
The charge current must be above 10% of the nominal capacity 5 minutes after charging begins.
Example
With a 60 Ah battery, the charge current must be greater than 6 A 5 minutes after charging begins.
- Fully charge the Battery -A- if the charge current is higher than 10% of the nominal capacity.
- Let the Battery -A- sit for two hours and then perform the battery load test. Refer to → Chapter "Battery Load Test".
If the charge current is less than 10% of the nominal capacity (less than 6 A for a 60 Ah battery) five minutes after starting the charging, then replace the Battery -A-. Refer to → Electrical Equipment; Rep. Gr.27; Battery; Battery, Removing and Installing.
- In warranty and Goodwill cases, fill out the battery test sheet and keep it with the Battery -A-.
Battery, Checking Resting Voltage, Vehicles in Storage or Inventory
WARNING
Risk of injury. Follow all warning messages and safety precautions. Refer to → Chapter "Warnings and Safety Precautions".
Note
Special tools and workshop equipment required
Test Conditions
The Battery -A- may not be charged or discharged for at least two days.
Procedure
- Measure the Battery -A- resting voltage using the Analog/Digital Multimeter -FLU83III-.
Test Result