Get Electrics -> 4.2 Battery and cables Guide for Volkswagen Amarok Truck Second Generation (2022-2025)

4.2 Battery and cables

4.2.1 Battery information

When a battery is disconnected, no reprogramming of the vehicle is required. The vehicle retains its “normal” power management setting

and remembers exactly what its previous configuration was (although central locking may cycle if a door or lock has been manually opened

in the meantime ). All radio settings are retained. The clock has to be reset. The window control unit also has to be reset. For more

information, refer to the owner's manual for the vehicle.

Battery voltage requirements and testing

All voltages must be measured to an accuracy of +/- 5% of the published values.

To maximise battery life, all batteries must have a minimum closed-circuit voltage (CCV) of not less than 12.75 V at the time of arrival at the

body builder.

When the battery is installed and connected to the vehicle’s electrical system with no load, the open-circuit voltage (OCV) must not be less

than 12.65 V. When the vehicle is delivered to the customer, the open-circuit voltage must not be less than 12.50 V.

Discharging surface charges

Before performing manual voltage tests, ensure the battery voltage is stable and free of surface charges that may be present due to certain

engine running conditions, making voltage measurements unreliable and inaccurate. To ensure that surface charges are not present, we

recommend the following measures:

1. Turn on the headlights for five seconds or the parking lights for 15 seconds.

2. Turn off all electrical equipment (including lamps, blowers, heaters etc.).

3. Wait 10 minutes.

Vehicles on hold

For vehicles that are parked at the body builder and not used for more than four days, the negative battery wire should be disconnected.

Before transporting to the customer, the negative battery wire must be reconnected and the voltage rechecked. The voltage should not be

less than 12.5 V.

Battery charging procedure

Warning note

–

Always follow the instructions from the manufacturer

of the battery charger.

Do not start with a battery charging system from

another vehicle.

Do not overcharge a battery as this can cause acid

leaks resulting in damage to the vehicle and possible

personal injury

Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition

The new Amarok – Page 72 of 166

Practical note

–

Do not rely on the alternator to recharge a discharged

battery. It would take more than eight hours of

continuous driving with no additional loads on the

charging system.

–

Make sure the battery electrolyte reaches the

specified maximum mark.

Connect the battery charger cables to the

rechargeable battery before switching on the charger.

Turn off the battery charger before disconnecting the

battery charger cables from the rechargeable battery.

Information

–

Batteries generally do not require maintenance, but

under certain conditions it is possible for the

electrolyte in a battery to fall below the minimum

level.

–

We recommend using the Midtronics GR-590 Battery

Management Centre, which was specifically designed

for use with silver-calcium batteries. Once connected

to the battery, the battery charger detects the

battery’s state of charge and then applies the

appropriate charge rate and duration. When the

rechargeable battery is fully charged, the battery

charger switches to standby mode and maintains the

battery in a fully charged state, preventing excessive

gassing and overcharging.

–

The Midtronics DCA-8000 Battery Management Centre

also includes a software program that can assist in the

recovery of deeply discharged (sulphated) batteries.

There are many different charging methods and types

of battery charger. Regardless of which method is

used, it must be done carefully to avoid battery

damage and possible personal injury. Specific

instructions are included with each battery charger

and must be followed carefully. The operator should

not ignore the safety precautions provided by the

equipment manufacturer.

–

A battery that has been stored in a severely

discharged condition may initially be slow to accept

charging. In these cases, the initial charge rate may be

so low that the ammeter on some battery testers will

not indicate a charge for five to 10 minutes.

Batteries should be recharged before they are put into

storage. Batteries should not be left in a discharged

state as this will result in the formation of sulphate

Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition

The new Amarok – Page 73 of 166

crystals that cannot be broken by conventional

charging. This will have a significant adverse effect on

battery performance. Batteries should be connected

to trickle chargers during storage. Conventional

battery chargers should not be rated below 10% of the

Ah nominal power to prevent excessive gassing.

Intelligent multi-stage battery chargers can also be

used for better performance.

–

Automatic battery chargers are also protected against

reverse polarity and require no adjustment or

monitoring.

Slow charging easily restores a battery to a full state of

charge, and because the charge current is relatively

low, the possibility of overcharging a battery is

minimised. The charge rate used should be

approximately 5% of the reserve capacity of the

battery being charged (approximately three to six

amps depending on battery size). The charging current

should be adjusted 10 minutes after the initial setting

and again after one hour before the rechargeable

battery can be charged for between eight and 12

hours.

–

A constant voltage battery charger charges a battery

at a set maximum voltage. The voltage used depends

on the design and condition of the battery charger and

the age and temperature of the battery. This type of

battery charger initially charges at a high current rate

that decreases as the battery voltage is restored.

When a constant voltage battery charger is used, the

charge current should be recorded after five minutes

and the charger turned off when the charge current

drops to one-third of the recorded value, or after eight

hours, whichever comes first.

–

Multiple battery chargers are designed to recharge

more than one battery at the same time. Of the two

different types of multiple battery chargers available,

only those that recharge batteries in series should be

used, and it is important that batteries have the same

or very similar ratings and voltages. Multiple battery

chargers that charge batteries in parallel are not

recommended.

–

We do not recommend using a fast (boost) battery

charger as it can damage a battery. Fast direct current

charging only puts a battery into a state of charge that

allows it to perform its critical function of cranking the

engine. Fast charging does not put a battery into a full

state of charge and therefore must be followed by a

period of slow charging. Excessively fast charging can

damage a battery. For this reason, charging times

must be carefully controlled. Fast battery chargers

Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition

The new Amarok – Page 74 of 166

vary widely in design, so it is very important to strictly

follow the equipment manufacturer’s instructions. A

30-A charge for up to 30 minutes is the most common

fast charge application. If the rechargeable battery is

severely discharged and requires additional

restoration, an additional charge of 20 A for a period

of up to one and a half hours should be applied. Fast

charging for a period longer than two hours greatly

increases the risk of damaging the rechargeable

battery.

–

When connecting and disconnecting the battery from

the vehicle, make sure the battery earthing wire is

disconnected first and connected last, and that all

electrical equipment is turned off.

Remove the rechargeable battery.

Disconnect the battery earth cable.

–

The maximum battery electrolyte level is

approximately 40 mm below the top of the battery

housing. This corresponds to a point just below the

bottom edge of the battery housing.

–

Check that the battery electrolyte reaches the

maximum level indicated. Top up with distilled/de-

ionised water if necessary.

Connect the positive red terminal from the battery

charger to the positive battery clamp.

-

Connect the negative black terminal from the battery

charger to the negative battery terminal.

-

Follow the instructions provided with the battery

charger to charge the rechargeable battery.

To disconnect the battery charger, reverse the

connection procedure.

40 mm

Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition

The new Amarok – Page 75 of 166

Battery cable fixing torque

The correct fixing torque for battery clamps can be found in the Workshop Manual. Please contact your Volkswagen Commercial Vehicles

partner or importer.

Battery specifications

Warning note

–

For vehicles equipped with non-sealed (maintenance-

free) batteries, regular controls must be carried out to

determine whether the electrolyte level is correct.

When charging, make sure the battery charger is

firmly connected to the vehicle earth and not to the

negative battery terminal. This will ensure that the

BMS detects the battery charge.

–

Practical note

–

When externally charging batteries, ensure that the

maximum voltage of 14.6 V is not exceeded.

Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition

The new Amarok – Page 76 of 166

Battery part numbers and usage

If a vehicle’s battery type is changed to other compatible derivatives, the dealership must reconfigure the vehicle to the new battery types.

The central vehicle configuration can be updated by a Volkswagen Commercial Vehicles partner or importer.

Production plant

Type

Performance specification

Size

Standard rechargeable

battery

75 Ah, 750CCA

H7

Thailand/South Africa

Auto start stop

80 Ah, 800CCA, AGM Deep Cycle technology

92 Ah, 850CCA, AGM Deep Cycle technology

H7

H8

rechargeable battery

Auto start stop

rechargeable battery

Battery management system (BMS)

Information

-

Installing an additional battery with a voltage

dependent control unit can prevent all batteries (main

and additional battery) from reaching a full state of

charge. This is due to the Smart Regenerative Charging

(SRC) function, which is designed to reduce fuel

consumption. Deactivating the SRC function allows

each battery to reach a full state of charge, optimising

the performance of the electrical system. A

Volkswagen Commercial Vehicles dealership can

deactivate the SRC function. Note that deactivating

SRC will have a negative impact on fuel consumption.

-

If multiple accessories or accessories with high energy

consumption are connected to the vehicle’s primary

battery that was installed in the factory, deactivating

Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition

The new Amarok – Page 77 of 166

SRC will optimise the performance of the electrical

system. Note that deactivating SRC will have a negative

impact on fuel consumption.

-

No electrical equipment should be connected directly

to the NEG-B battery terminal, as this would bypass

the battery management sensor and produce false

charge level display (State of Charge, SOC).

The Amarok is equipped with a feature known as the

Battery Management Sensor (BMS). This system

measures battery charge to efficiently charge the

battery while simultaneously reducing fuel

consumption and emissions.

-

It is important to ensure that all additional electrical

equipment or accessories are properly earthed to the

vehicle body so that the system can detect the

additional load. If a connection is made to the negative

battery terminal, the battery management sensor will

not detect the load or charging. This may result in the

battery being undercharged and consequently unable

to restart the vehicle.

Additional battery on vehicles with a battery management sensor (BMS)

Information

–

For high loads, a battery isolator switch should be

used to disconnect the primary battery at 12.7 V

(75 SOC) to ensure that you can start the vehicle after

the regular idle time. Examples of high load

connections include winches / trailer accessories /

refrigerators etc.

–

Additional loads must always be connected to the

vehicle earth and not to the negative battery terminal.

Ensure that the additional battery connection is

securely fastened with suitable brackets to prevent

vibration damage or contact with surrounding

components.

–

For vehicles equipped with a battery management

sensor, an additional battery can be connected using

an on-board battery charger (DC/DC converter), which

is connected via an additional terminal to the B+

terminal of the starter with a fused and grounded 30 A

connection.

–

The maximum thickness of the additional terminal

installed over the terminal of the starting post must

not exceed 2.0 mm.

If present, ensure that the existing nut is reused.

Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition

The new Amarok – Page 78 of 166

B+ terminal for charging auxiliary batteries

There is one empty position available on the positive battery fuse block. This empty position can be used to connect the auxiliary battery

system and for all aftermarket installations that require a 12-V battery supply.

Battery connections should be properly tightened. Contact your authorised Volkswagen Commercial Vehicles partner or importer for the

correct torque specifications.

Information

Ensure that the secured connection is secured with

appropriate devices to reduce vibration damage or contact

with surrounding components.

Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition

The new Amarok – Page 79 of 166

Engine compartment earth points

Item

Description

1

Earth point on the bonnet

2

3

4

5

6

Earth point on the bonnet

Earth point on upper part of rear left fender

Earth point on panel below vehicle battery

Earth point on panel under air filter assembly (behind fender liner)

Earth point on upper material of rear right fender

Earth point connections must be properly tightened.

Contact your authorised Volkswagen Commercial Vehicles partner or importer for the correct torque specifications.

Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition

The new Amarok – Page 80 of 166

4.2.2 Connecting auxiliary loads / accessories – vehicles with factory-fitted auxiliary switches, wiring and fuse box

Warning note

–

Make sure that all electrical connections and wiring

comply with local regulatory standards.

Under no circumstances should unsecured

connections be made directly to any of the vehicle’s

battery terminals.

–

Information

–

Auxiliary load earthing points must always be

connected to the nominated earthing points and not

to the negative battery terminal.

–

Refer to the vehicle operating manual for an overview

of auxiliary switches.

Vehicles equipped with a diesel engine should only

use the auxiliary switches when the engine is running.

The diesel engine’s glow plug can cause a reduction in

battery power if the ignition key is in the ON position.

Using the auxiliary switches, even for a short period of

time, may drain your battery and prevent the engine

from starting.

–

Vehicles may be equipped with factory-installed

auxiliary switches, fuses, and wiring that make it

possible to install electrical accessories that operate

with fuse-protected relays. The auxiliary switches,

fuses, and wiring include:

–

Auxiliary switch panel

Auxiliary fuse box with integrated relays

Auxiliary wiring connections

The auxiliary switches will only operate when the

ignition is in the ON position, or in the OFF position if

the accessory delay is active, whether the engine is

running or not.

Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition

The new Amarok – Page 81 of 166

Localisation of the auxiliary switches, fuse box and wiring

Auxiliary switches, fuse box and wiring locations

A = located near the auxiliary fuse box

B = auxiliary fuse box located near left headlight

C = located near the electric trailer tow point

Item

Description

1

Auxiliary switch pack

2

3

4

5

6

Auxiliary fuse box (with relay) – POSITION B

Wiring circuit near electrical connection point for trailer towing – POSITION C

Wiring circuit near the auxiliary fuse box – POSITION A

Wiring circuit near the radiator support panel

Engine compartment fuse box

Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition

The new Amarok – Page 82 of 166

Information

Circuits from the auxiliary fuse box are powered during the

run/start condition. All other wiring is disconnected at both

ends.

Identifying the auxiliary fuse box connections

Overhead console Wire colour

additional

Wire size

Fuse

Protected

Position

Note

component

switches

AUX 1

AUX 2

AUX 3

AUX 4

AUX 5

Purple/green

Blue/green

Yellow/orange

Brown

1.5 mm²

2.5 mm²

5 A

Scale 1

Relay 2

Scale 3

Scale 4

B

C

B

-

15 A

25 A

Green/brown

Relay 5 – driving

lights

AUX 6

-

Yellow

-

2.5 mm²

-

25 A

-

Relay 6 – driving

lights

A

-

Scale 7

This relay only operates

when the main beam

headlights are switched on

as per German federal

requirements.

-

Scale 8

-

Auxiliary switch power

AUX 3 – FLOOR

AUX 4 – FLOOR

Black/grey

Black/green

1.5 mm²

2.5 mm²

-

C

A

-

AUX 6 – FLOOR Black/yellow

Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition

The new Amarok – Page 83 of 166

4.2.3 Alternator

Power output of the alternators

Contact your local Volkswagen Commercial Vehicles dealership for alternator output current specifications for your vehicle.

Drive train

Current output

Amps @ 80.6°F (27°C)

Pulley type

Voltage regulator type

2.0 l Diesel Single

Turbo / 2.0 l Diesel

Bi-Turbo

155

100 A at 750 rpm (min) to 155 A at

2,500 rpm (max)

Overflow alternator

decoupler (OAD)

Electronic internal

2.0 l Diesel Single

Turbo / 2.0 l Diesel

Bi-Turbo (vehicles

with auxiliary switch

pack or A/C

250

155 A at 750 rpm (min) to 250 A at

2,300 rpm (max)

inverter)

3.0 l Diesel

250

145 A at 750 rpm (min) to 250 A at

2,500 rpm (max)

3.0L petrol

110 A at 625 rpm (min) to 250 A at

2,500 rpm (max)

4.2.4. Ignition signal

A run-start/ignition signal is provided as a butt cut wire and is secured to the wiring harness branch behind the footboard

of the A-pillar on the left. The wire is white/green in colour and has a current rating of 10 A.

Volkswagen Commercial Vehicles – Body builder guidelines – February 2023 edition

The new Amarok – Page 84 of 166

Electrics -> 4.2 Battery and cables for Your Volkswagen Amarok Truck Second Generation (2022-2025)

Related Topics

Popular Owner Manuals

Latest Owner Manuals