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1995-2010 Volkswagen Sharan VAN Starter, current supply, CCS User Manual

MY CAR USER MANUAL

Starter, current supply, CCS for Your Volkswagen Sharan VAN First Generation (1995-2010)

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...  
Electrical System, General Information - Edition 07.2010  
27 – Starter, current supply, CCS  
1
Battery  
WARNING  
Danger of injury! Observe warning notices and safety regula‐  
tions ⇒ page 2 !  
Caution  
To prevent damage to the battery and vehicle, the following  
should be observed concerning types of battery ⇒ page 1 .  
1.1  
Fundamentals for batteries  
To ensure long use of the battery, the battery must be checked,  
serviced and maintained according to the specifications in this  
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.  
1.2  
Types of batteries  
General notes  
Caution  
The description for the following batteries is for maintenance-  
free batteries. No stickers may be removed and do not replen‐  
ish with distilled water. Only perform a visual check. Refer to  
chapter, Checking battery ⇒ page 5 .  
1.2.1  
Battery with magic eye  
This is a maintenance-free battery with liquid electrolyte (wet bat‐  
tery).  
Caution  
No stickers may be removed and do not replenish with distilled  
water. Only perform a visual check. Refer to chapter, Checking  
battery ⇒ page 5 .  
WARNING  
Batteries where the magic eye is colourless or light yellow must  
not be checked or charged. Do not slave/jump start the vehicle!  
Danger of explosion when checking and charging or slave/  
jump starting.  
These batteries must be renewed.  
1. Battery  
1
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Electrical System, General Information - Edition 07.2010  
This battery is equipped with a magic eye. The magic eye pro‐  
vides information concerning the level of the electrolyte and the  
charge state of the battery via a coloured display. Checking colour  
display of the magic eye ⇒ page 6  
1.2.2  
Absorbent glass mat battery  
Maintenance-free battery with a contained electrolyte and no  
magic eye.  
Lead-acid battery where the electrolyte is contained within a mi‐  
croscopic glass mat (AGM). The battery is sealed and fitted with  
valves.  
AGM is the abbreviation for absorbent glass mat.  
Due to containment of the electrolyte, this type of battery may not  
have a magic eye. Absorbent glass mat batteries are identified by  
the abbreviation AGM on the battery.  
lk  
Note  
Always replace an absorbent glass mat battery with another ab‐  
sorbent glass mat battery.  
1.3  
Warning notices and safety regulations  
1.3.1  
Dangers when handling vehicle batter‐  
ies  
Recognition and avoidance of dangers  
Batteries can be dangerous. These dangers can be avoided when  
the warnings on the battery, in the operating manual and in ELSA  
are observed.  
2
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Electrical System, General Information - Edition 07.2010  
WARNING  
♦ Untrained personnel e.g. apprentices, trainees etc. may  
only work on batteries when supervised by a vehicle me‐  
chanic/foreman or vehicle electrician/foreman.  
♦ Acid is highly corrosive. There is a considerable danger of  
acid burns if personnel do not handle batteries correctly.  
Therefore suitable measures must be taken to ensure that  
equipment/solutions etc. are available to neutralize acid  
burns. A suitable solution is: e.g. a soap solution.  
♦ If electrolyte leaks from a battery it may cause skin burns  
or acid corrosion and rusting on the vehicle. This may  
damage safety relevant components on the vehicle.  
♦ The gas which forms when charging and the gas which  
may escape through vent valves is explosive. In extreme  
cases a battery may explode if the battery is not handled  
lk  
correctly.  
♦ Batteries must be renewed where the magic eye is col‐  
ourless or light yellow. They must not be checked or  
charged and do not slave/jump start. Danger of explosion  
when checking and charging or slave/jump starting.  
♦ It is prohibited to cause sparks through grinding, welding,  
cutting operations and use naked lights in the vicinity of  
batteries. Smoking is also prohibited. Sparks generated  
by electrostatic charging must also be avoided. Always  
touch the vehicle body before touching the battery.  
♦ Only work on batteries in well ventilated and suitable  
rooms.  
1.3.2  
Safety markings on battery  
Safety markings on battery  
1. - Fires, sparks, naked flames and smoking are prohibited when  
handling batteries. Avoid sparks as well as electrostatic discharge  
when working with cables and electrical units. Avoid short circuits.  
Therefore never lay a tool on a battery.  
2. - Wear eye protection before commencing work on battery.  
3. - Keep children away from acid and batteries.  
4. - Disposal: old batteries are classed as hazardous waste. They  
may only be disposed of through a suitable collection centre and  
only in accordance with respective legislation.  
5. - Never dispose of old batteries in household waste system!  
6. - There is a danger of an explosion when working with batteries.  
A highly explosive gas is produced when batteries are charged.  
7. - Always follow instructions on battery, in ELSA "Electrical Sys‐  
tem, General Information" and in owner's manual.  
8. - Battery acid is very caustic; therefore wear eye protection and  
gloves when working with batteries. Do not tilt battery. Acid can  
leak out of the gas vents of some batteries.  
1. Battery  
3
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1.4  
Battery terminal connection  
Caution  
lk  
To prevent damage to the battery clamps and battery termi‐  
nals, the following should be observed:  
♦ The battery clamps should only be fitted by hand and with‐  
out using force.  
♦ Battery terminals should not be coated with grease.  
♦ The battery clamps should be fitted so that the battery ter‐  
minal is either flush with the clamp or protruding from it.  
♦ Once the battery clamps have been tightened to the speci‐  
fied torque, the threaded connections should not be tight‐  
ened any further.  
4
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2
Checking battery  
WARNING  
Danger of injury! Observe warning notices and safety regula‐  
tions ⇒ page 2 !  
Caution  
To prevent damage to the battery and vehicle, the following  
should be observed concerning types of battery ⇒ page 1 .  
2.1  
2.1.1  
Checking the various types of batteries  
Checking battery with magic eye  
WARNING  
Danger of injury! Observe warning notices and safety regula‐  
tions ⇒ page 2 !  
Carry out procedure in sequence as follows:  
1.  
2.  
Visual check ⇒ page 6  
Check colour display of „3-colour“ magic eye ⇒ page 6  
or „2-colour“ magic eye ⇒ page 7 .  
WARNING  
lk  
Batteries where the magic eye is colourless or light yellow must  
not be checked or charged. Do not slave/jump start the vehicle!  
Danger of explosion when checking and charging or slave/  
jump starting  
These batteries must be renewed.  
3.  
Perform a battery load test using battery tester with printer  
-VAS 5097 A- ⇒ page 9 .  
– Battery test with battery tester with printer -VAS 6161-  
⇒ page 14 .  
4.  
Depending on the result of the battery test, „perform current  
draw test“ ⇒ page 22 .  
2.1.2  
Absorbent glass mat battery  
Carry out procedure in sequence as follows:  
1.  
2.  
Visual check ⇒ page 6  
Perform a battery load test using battery tester with printer  
-VAS 5097 A- ⇒ page 9 .  
– Battery load test with battery tester with printer -VAS 6161-  
⇒ page 14  
2. Checking battery  
5
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3.  
Depending on the result of the battery test, „perform current  
draw test“ ⇒ page 22 .  
2.2  
Visual check  
WARNING  
Danger of injury! Observe warning notices and safety regula‐  
tions ⇒ page 2 !  
It is essential to visually inspect the external condition, to check  
the terminals and to ensure proper attachment of the battery be‐  
fore performing extensive tests.  
Caution  
♦ The battery will be damaged if the battery is not secured  
correctly.  
♦ Vibrations shorten the life of the battery, there is a danger  
of an explosion, the cell plates may be damaged and the  
clamping bracket may damage the battery housing.  
♦ Check battery is securely seated, if necessary tighten se‐  
curing bolt to specified torque.  
Performing this test establishes:  
♦ If battery housing is damaged Electrolyte can leak out if the  
housing is damaged. If battery acid leaks out, slekrious damage  
to the vehicle could be caused. Treat components affected by  
leaked battery acid immediately with acid neutraliser or a soap  
solution.  
♦ Check whether the battery terminals (battery wire connec‐  
tions) are damaged. The necessary contact on the battery  
clamps cannot be guaranteed if the battery terminals are dam‐  
aged. When connecting the battery clamps, tighten the battery  
clamps to torque specified in this workshop manual „Electrical  
system“ for the respective vehicle. If the battery clamps are  
not correctly seated and tightened, the wiring may burn. Which  
will cause malfunctions in the electrical system. Therefore it  
can no longer be guaranteed that the vehicle will function cor‐  
rectly.  
2.3  
Checking colour display of magic eye  
2.3.1  
Checking colour display of „3-colour“  
magic eye  
WARNING  
Danger of injury! Observe warning notices and safety regula‐  
tions ⇒ page 2 !  
6
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General information on magic eye:  
Applies for all batteries with „1J0“, „7N0“ and „3B0“ indexes in  
original equipment and for all replacement batteries 191 915 105  
AB and from „000 915 105 AX“ index.  
The magic eye provides information concerning electrolyte level  
and the charge state of the battery.  
Before carrying out a visual check, tap the magic eye lightly and  
carefully using the handle of a screwdriver. The air bubbles, which  
can influence the display, will dissipate when doing this. The col‐  
our display of the magic eye will therefore be more accurate.  
Note  
♦ Air bubbles can form below the magic eye particularly when  
the battery is being charged, including during normal vehicle  
operation. These distort the colour displayed by the magic eye.  
♦ Because the magic eye is located in only one cell, the display  
applies only to this cell. An exact determination of the battery  
condition is only possible through a battery load test  
⇒ page 9 or a battery test ⇒ page 14 .  
♦ The magic eye can be located at various positions on the bat‐  
tery.  
lk  
Three different colour displays are possible:  
♦ »Green«, battery is charged sufficiently.  
♦ »Black«, battery partly discharged, charge state < 65 % or  
completely discharged  
♦ »Colourless or light yellow«, battery must be renewed.  
WARNING  
Batteries where the magic eye is colourless or light yellow must  
not be checked or charged. Do not slave/jump start the vehicle!  
Danger of explosion when checking and charging or slave/  
jump starting  
These batteries must be renewed.  
2.3.2  
Checking colour display of „2-colour“  
magic eye  
WARNING  
Danger of injury! Observe warning notices and safety regula‐  
tions ⇒ page 2 !  
2. Checking battery  
7
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Electrical System, General Information - Edition 07.2010  
General information on magic eye:  
For batteries from „5K0“ index in original equipment and for re‐  
placement batteries 191 915 105 AC from „000 915 105 DX“  
index, the »green« colour display for charge state display has  
been discontinued. The introduction of the new colour display will  
take place gradually, i.e. there will be a transition period for both  
displays. In the future, the only remaining colours will be »black«  
or »colourless or light yellow«.  
The magic eye provides information concerning the electrolyte  
level of the battery.  
The charge state of the battery can no longer be read from the  
magic eye, a battery load test must be carried out for this  
⇒ page 9  
Before carrying out a visual check, tap the magic eye lightly and  
carefully using the handle of a screwdriver. The air bubbles, which  
can influence the display, will dissipate when doing this. The col‐  
our display of the magic eye will therefore be more accurate.  
Note  
♦ Air bubbles can form below the magic eye particularly when  
the battery is being charged, including during normal vehicle  
operation. These distort the colour displayed by the magic eye.  
♦ Because the magic eye is located in only one cell, the display  
applies only to this cell. An exact determination of the battery  
condition is only possible through a battery load test  
⇒ page 9 .  
lk  
♦ The magic eye can be located at various positions on the bat‐  
tery.  
Three different colour displays are possible:  
♦ »Black«, electrolyte level is OK.  
♦ »Colourless or light yellow«, electrolyte level too low. The bat‐  
tery must be renewed.  
WARNING  
Batteries where the magic eye is colourless or light yellow must  
not be checked or charged. Do not slave/jump start the vehicle!  
Danger of explosion when checking and charging or slave/  
jump starting  
These batteries must be renewed.  
2.4  
Battery tester with printer -VAS 5097 A-  
WARNING  
Danger of injury! Observe warning notices and safety regula‐  
tions ⇒ page 2 !  
It is not necessary to remove or disconnect battery when using  
battery tester with printer -VAS 5097 A- .  
Battery tester with printer -VAS 5097 A- can be used to test 12 V  
starter batteries.  
8
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♦ 80 - 520 A low-temperature test current according to DIN  
(Deutsche Industrie Norm (German Industrial Standard))1)  
♦ 95 - 574 A cold cranking current according to IEC (Interna‐  
tional Engineering Consortium)  
♦ 136 - 855 A cold cranking current according to EN/ SAE (Eu‐  
ropean Norm/Standard of Automotive Engineers)  
1) Batteries with cold cranking current higher than 499 A according to DIN (e.g.  
520 A, 580 A or 600 A) can be temporarily tested using setting for 499 A according  
to DIN.  
lk  
For test purposes the battery is loaded with a current which is  
similar to the starting current required to start the vehicle. The  
battery is assessed on this loading and the result is printed out.  
Note  
Observe the ⇒ instruction manual of Battery tester with printer -  
VAS 5097 A- or the sticker ⇒ Brief instructions for battery tester  
with printer -VAS 5097 A- on the unit or table: Cold cranking cur‐  
rent ⇒ page 11 .  
2.4.1  
Description of battery tester with printer  
-VAS 5097 A-  
Battery tester with printer -VAS 5097 A-  
1 - Green LED, „unit operating“  
2 - Red LED, „unit reverse-polarity connected“  
3 - Red LED, „battery cannot be tested“, recharge battery.  
4 - Start button  
5 - Cold cranking current selection switch  
6 - ON/OFF and functions switch  
7 - Selection switch (battery tester to pick-off point on battery/  
external test point in engine compartment)  
8 - Paper feed button  
9 - Printer  
2.4.2  
Performing battery load test using bat‐  
tery tester with printer -VAS 5097 A-  
WARNING  
Danger of injury! Observe warning notices and safety regula‐  
tions ⇒ page 2 !  
Special tools and workshop equipment required  
2. Checking battery  
9
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♦ Battery tester with printer -VAS 5097 A-  
lk  
Note  
Observe technical product information TPI 2012182 for battery  
tester with printer -VAS 5097 A- .  
Performing battery load test:  
WARNING  
Batteries where the magic eye is colourless or light yellow must  
not be checked or charged. Do not slave/jump start the vehicle!  
Danger of explosion when checking and charging or slave/  
jump starting  
These batteries must be renewed.  
Note  
The battery must have a temperature of at least 10 °C.  
– Switch off ignition and all electrical consumers.  
– Check magic eye on batteries with magic eye ⇒ page 5 .  
– Check low-temperature test current in amperes (A) according  
to DIN from indications on battery or set setting range on bat‐  
tery tester with printer -VAS 5097 A- according to table  
⇒ „2.4.3 Table: cold cranking current“, page 11 .  
Note  
If the battery values are shown in IEC or EN/SAE instead of DIN  
then convert figures using table  
⇒ „2.4.3 Table: cold cranking current“, page 11 or using table  
on unit.  
– Select low-temperature test current via low-temperature test  
current selection switch ⇒ page 9 .  
– Select measuring range 80 - 379 A or 380 - 499 A with ON/  
OFF and functions switch ⇒ page 9 .  
10  
Rep. gr.27 - Starter, current supply, CCS  
lk  
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Electrical System, General Information - Edition 07.2010  
Note  
Batteries with cold cranking current higher than 499 A according  
to DIN (e.g. 520 A, 580 A or 600 A) can be temporarily tested  
using setting for 499 A according to DIN.  
– Connect red terminal „+“ of tester to positive terminal.  
– Connect black terminal „-“ of tester to negative terminal.  
Note  
♦ Ensure test clamps have a good contact!  
♦ Observe technical product information TPI 2012182 for battery  
tester with printer -VAS 5097 A- .  
– Select point of connection of test terminals with selection  
switch ⇒ page 9 .  
1 - Connected directly to battery  
2 - Connected to external test points in engine compartment  
– Check that the figures given on the battery are correct for the  
settings on the battery tester.  
– Press start test button ⇒ page 9 .  
The green LED lights up ⇒ page 9 . The test program runs through  
automatically. The test result is printed out by the printer  
⇒ page 12 . If the unit does not start (LED does not light up, no  
print out), recharge battery ⇒ page 25 and test again.  
– Switch off unit ⇒ page 9 .  
– Remove test terminals.  
Note  
♦ The test is completed after about 20 seconds.  
♦ The result of the test is printed out by the printer.  
♦ Perform test once only. Repeating the test falsifies the result.  
♦ The tester requires approx. 30 minutes to cool down before it  
is ready for the next test.  
2.4.3  
Table: cold cranking current  
Cold cranking current in A  
EN/ SAE  
IEC  
⇒
DIN  
136 – 17  
178 – 219  
220 – 261  
262 – 303  
304 – 345  
346 – 387  
388 – 429  
430 – 471  
472 – 513  
95 – 124  
125 – 154  
155 – 184  
185 – 214  
215 – 244  
245 – 274  
275 – 304  
305 – 334  
335 – 364  
⇒
⇒
⇒
⇒
⇒
⇒
⇒
⇒
⇒
80 – 104  
105 – 129  
130 – 154  
155 – 179  
180 – 204  
204 – 229  
230 – 254  
255 – 279  
280 – 304  
2. Checking battery  
11  
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Electrical System, General Information - Edition 07.2010  
Cold cranking current in A  
EN/ SAE  
IEC  
⇒
DIN  
514 – 555  
556 – 597  
598 – 639  
640 – 657  
658 – 675  
676 – 693  
694 – 711  
712 – 729  
730 – 747  
748 – 765  
766 – 783  
784 – 801  
802 – 819  
820 – 837  
838 – 855  
365 – 394  
395 – 424  
425 – 454  
455 – 464  
465 – 474  
475 – 484  
485 – 494  
495 – 504  
505 – 514  
515 – 524  
525 – 534  
535 – 544  
545 – 554  
555 – 564  
565 – 574  
⇒
⇒
⇒
⇒
⇒
⇒
⇒
⇒
⇒
⇒
⇒
⇒
⇒
⇒
⇒
305 –329  
330 – 354  
355 – 379  
380 – 389  
390 – 399  
400 – 409  
410 – 419  
420 – 429  
430 – 439  
440 – 449  
450 – 459  
460 – 469  
470 – 479  
480 – 489  
490 – 4992) 1)  
1)  
2)  
Batteries with cold cranking current higher than 499 A according to DIN (e.g. 520 A, 580 A or 600 A) can be temporarily tested using  
lk  
setting for 499 A according to DIN.  
2.4.4  
Evaluating test result of battery load test  
Because of the high load on the battery during this test (a high  
current flows) the battery voltage drops.  
♦ If the battery is OK, the voltage value drops only to the mini‐  
mum voltage.  
♦ If the battery is defective or has a low charge, the battery volt‐  
age quickly drops below the minimum voltage.  
♦ After the test is completed, this low voltage value remains over  
a longer period, and the voltage increases very slowly again.  
♦ Perform test once only. Repeating the test falsifies the result.  
♦ The tester requires approx. 30 minutes to cool down before  
carrying out another test or testing another battery to ensure  
the results are not falsified.  
12  
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2.4.5  
Comments concerning test print out  
1 - Measuring range selected on tester  
2 - Diagram -arrow- indicates battery condition.  
3 - Test result  
4 - Battery voltage during load test.  
5 - Vehicle data and date Must be completed by test personnel  
lk  
Note  
♦ The test printout is required for warranty claims.  
♦ Perform test once only. Repeating immediately the test falsi‐  
fies the result.  
2.4.6  
Assessing test results  
Printout from battery tester  
Starting capability very good  
Starting capability good  
Measure to be performed  
Battery OK.  
Battery OK.  
Starting capability sufficient  
Evaluation by carrying out a  
current draw test when charg‐  
ing ⇒ page 22  
Starting capability poor  
Starting capability very poor  
Cannot be tested  
Evaluation by carrying out a  
current draw test when charg‐  
ing ⇒ page 22  
Evaluation by carrying out a  
current draw test when charg‐  
ing ⇒ page 22  
Perform battery charging  
⇒ page 25 and repeat test.  
2. Checking battery  
13  
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2.5  
Battery tester with printer -VAS 6161-  
General description  
WARNING  
Danger of injury! Observe warning notices and safety regula‐  
tions ⇒ page 2 !  
It is not necessary to remove or disconnect battery when using  
battery tester with printer -VAS 6161- .  
The battery tester with printer -VAS 6161- does not load the bat‐  
tery any more. It works on the principle of dynamic conductance  
acquisition.  
Every battery type is stored in the tester.  
Data can be stored on an SD card.  
The battery tester with printer -VAS 6161- can be updated via an  
interface or an SD card, so that battery data from Volkswagen are  
always up to date.  
The integrated temperature sensor improves measurement qual‐  
ity.  
A 2D scanner is available as an option to read data directly from  
the bar code of the battery.  
Note  
Observe the ⇒ operating manual of the battery tester with printer  
-VAS 6161- .  
lk  
2.5.1  
Description of battery tester with printer  
-VAS 6161-  
1 - Integrated printer  
2 - Operating lever for paper compartment  
3 - Paper slot  
4 - LCD screen with main menu  
5 - Control panel with On/Off button  
6 - Connection for battery test cable  
7 - Memory card slot  
8 - Infrared temperature sensor  
9 - Data transmitter for PC  
14  
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2.5.2  
Perform battery test with battery tester  
with printer -VAS 6161- .  
WARNING  
Danger of injury! Observe warning notices and safety regula‐  
tions ⇒ page 2 !  
Special tools and workshop equipment required  
♦ Battery tester with printer -VAS 6161-  
lk  
Performing battery test:  
WARNING  
Batteries where the magic eye is colourless or light yellow must  
not be checked or charged. Do not slave/jump start the vehicle!  
Danger of explosion when checking and charging or slave/  
jump starting  
These batteries must be renewed.  
– Switch off ignition and all electrical consumers.  
– Check magic eye on batteries with magic eye ⇒ page 5 .  
– Switch on unit.  
– Connect red terminal „+“ of tester to positive terminal.  
– Connect black terminal „-“ of tester to negative terminal.  
Note  
Ensure test clamps have a good contact!  
– Select one of the following functions.  
♦ Maintenance test (only in new cars before registration, in sta‐  
tionary and stock maintenance programme ⇒ page 16 )  
♦ Service test ⇒ page 16  
♦ Guarantee test ⇒ page 17  
2. Checking battery  
15  
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Note  
♦ The test is completed after about 10 seconds.  
♦ The result of the test is printed out by the printer.  
♦ The tester requires no cooling phase before it is ready for the  
next measurement.  
lk  
2.5.3  
Performing maintenance test  
WARNING  
Batteries where the magic eye is colourless or light yellow must  
not be checked or charged. Do not slave/jump start the vehicle!  
Danger of explosion when checking and charging or slave/  
jump starting  
These batteries must be renewed.  
– Select „Maintenance test“ in the menu.  
– Connect scanner.  
Note  
If no scanner is available, write vehicle identification number on  
test printout by hand.  
– Scan in vehicle identification number.  
– Select „On battery terminal“ or „On jump-start point“.  
– Scan in barcode or select type and manufacturer manually in  
menu.  
– Measure temperature. Hold temperature sensor about 5 cm  
above terminal connection until temperature stabilises.  
– Start test.  
– Print out test log if necessary.  
2.5.4  
Perform service test  
WARNING  
Batteries where the magic eye is colourless or light yellow must  
not be checked or charged. Do not slave/jump start the vehicle!  
Danger of explosion when checking and charging or slave/  
jump starting  
These batteries must be renewed.  
– Select „Service test“ in the menu.  
– Select „On battery terminal“ or „On jump-start point“.  
– Select vehicle type.  
– Measure temperature. Hold temperature sensor about 5 cm  
above one battery terminal until temperature stabilises.  
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– Select battery type „Normal“, „AGM“, „2*6V“ or „Gel“.  
– Select „CCA“, „JIS“, „DIN“, „SAE“, „IEC“ or „EN“ norm.  
– Start test.  
– Print out test log if necessary.  
2.5.5  
Perform guarantee test  
WARNING  
Batteries where the magic eye is colourless or light yellow must  
not be checked or charged. Do not slave/jump start the vehicle!  
Danger of explosion when checking and charging or slave/  
jump starting  
These batteries must be renewed.  
– Select „Guarantee test“ in the menu.  
– Select „In vehicle“ or „Outside vehicle“.  
– Select „On battery terminal“ or „On jump-start point“.  
– Select vehicle type.  
– Measure temperature. Hold temperature sensor about 5 cm  
above one battery terminal until temperature stabilises.  
– Select battery type „Normal“, „AGM“, „2*6V“ or „Gel“ or scan  
in.  
– Select battery capacity or scan in.  
– Start test.  
lk  
– Print out test log if necessary.  
2.5.6  
Comments concerning test print out  
1 - Check type.  
2 - Battery test result  
3 - Measured voltage  
4 - Measured cold start value of battery.  
5 - Nominal cold start value of battery selected on tester.  
6 - Measured temperature of battery.  
7 - Fitting location of battery  
8 - Position of battery clamp selected on tester  
9 - Selected battery technology.  
Note  
The test printout is required for warranty claims.  
2.5.7  
Assessing test results  
Evaluating battery test results for guarantee and service tests  
Battery test results  
Battery OK  
Measures  
No measures on battery  
2. Checking battery  
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Battery test results  
Measures  
Battery OK - recharge.  
Charge battery ⇒ page 25 . In  
case of discharging, look for  
fault  
Perform current draw test  
Perform current draw test  
⇒ page 22 . Fully charge bat‐  
tery ⇒ page 25 andlkrepeat  
test.  
Renew battery.  
Disconnect battery and repeat  
test. The result „Renew battery“  
may be caused by a weak cable  
contact.  
Battery cell defective - renew. Renew battery.  
Check connection.  
Connect cable directly to bat‐  
tery and not to jump start termi‐  
nal.  
Evaluating battery test results for maintenance test  
Battery test results  
Battery OK  
Measures  
No measure  
Charge battery immediately.  
Charge battery fully  
⇒ page 25 .  
Mark as defective.  
Mark as defective.  
Check tester connection.  
Disconnect battery and repeat  
test. The result „Check tester  
connection“ may be caused by  
a weak cable contact.  
Check connection.  
Noises  
Connect cable directly to bat‐  
tery and not to jump start termi‐  
nal.  
Wait until measured value ap‐  
pears on display.  
2.6  
Midtronics -MCR340V- battery tester  
only for USA/Canada vehicles  
General description ⇒ page 18  
Perform battery test with Midtronics -MCR340V- battery tester  
⇒ page 19 .  
Dealing with problems with Midtronics -MCR340V- battery tester  
⇒ page 21  
2.6.1  
General description  
WARNING  
Danger of injury.  
Before working on the battery, read through the warning and  
safety regulations carefully, and comply with them ⇒ page 2 .  
Dispose of electrolyte (mixture of sulphuric acid and water)  
safely! Waste electrolyte is only allowed to be disposed of at  
appropriately indicated collecting points. Comply with the lo‐  
cally applicable disposal guidelines.  
Do not test batteries that are liberating gas. Otherwise, there  
is a danger of explosion.  
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WARNING  
Batteries where the magic eye is colourless or light yellow must  
not be checked or charged. Do not slave/jump start the vehicle!  
Danger of explosion when checking and charging or slave/  
jump starting  
These batteries must be renewed.  
Note  
To prevent damage to the battery and vehicle, note the types of  
battery and the remarks given ⇒ page 1 .  
Batteries in VW vehicles are only allowed to be tested with battery  
testers approved by VW. In the USA/Canada, it is permitted for  
the Midtronics -MCR340V- battery tester to be used.  
Read all the information about safety, setup and operation in the  
operating instructions for the Midtronics -MCR340V- battery test‐  
er and follow the instructions to the letter.  
lk  
Refer to ⇒ Self-study programme No. ; Vehicle batteries for more  
information.  
The following charging and analysis procedures apply to all bat‐  
teries, all battery installation locations (engine compartment or  
luggage compartment) and battery purposes (starter battery or  
second/convenience battery).  
Always comply with the safety regulations, the regulations for  
setting up the battery tester, the display menu/display buttons,  
LEDs and the operating procedures described in the ⇒ operating  
manual MCR340V .  
Note  
Observe and comply with all subsections, remarks and referen‐  
ces to the vehicle and battery type, etc. to be tested.  
2.6.2  
Performing battery test with Midtronics -  
MCR340V- battery tester  
Prerequisites:  
WARNING  
Before working on the battery, read through the warning and  
safety regulations carefully, and comply with them ⇒ page 2 .  
Batteries where the magic eye is colourless or light yellow must  
not be checked or charged. Do not slave/jump start the vehicle!  
Danger of explosion when checking and charging or slave/  
jump starting  
These batteries must be renewed.  
– Read general description ⇒ page 18 .  
– Perform visual check ⇒ page 6 .  
2. Checking battery  
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– Open bonnet or cover for other installation location of battery.  
– Determine whether battery type is „Standard“ or „AGM“.  
– Remove covers from battery positive and negative terminals.  
– Use wing covers or other kinds of cover before you use equip‐  
ment in engine compartment or interior.  
– Close all doors.  
Note  
♦ Battery temperature must be at least 10 °C.  
lk  
♦ For additional information, refer to the ⇒ operating manual  
INC 940 .  
Perform test:  
WARNING  
Batteries where the magic eye is colourless or light yellow must  
not be checked or charged. Do not slave/jump start the vehicle!  
Danger of explosion when checking and charging or slave/  
jump starting  
These batteries must be renewed.  
– Switch off ignition and all electrical consumers.  
– Check magic eye on batteries with magic eye ⇒ page 5 .  
– Switch on tester.  
– Connect red terminal „+“ of tester to positive terminal.  
– Connect black terminal „-“ of tester to negative terminal.  
Note  
Ensure test clamps have a good contact!  
– Select „In vehicle“ or „Outside vehicle“.  
– Select „Warranty test“.  
Note  
Use the print function of the Midtronics -MCR340- tester if the test  
results are required for handling warranty applications.  
– Select battery type „Standard “ or „AGM“.  
– Make a note of the DIN value of the battery as shown on the  
battery sticker. If there is no DIN value on the sticker, make a  
note of the SAE value.  
– Enter DIN value in tester and perform battery test ⇒ operating  
manual MCR340V .  
– If you are using SAE value, access „Miscellaneous“ menu and  
change from „DIN“ to „SAE“ ⇒ operating manual MCR340V .  
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Note  
Always use DIN value from battery sticker! Otherwise, test result  
will be falsified.  
2.6.3  
Assessing test results  
Results of battery test:  
Battery test results  
Battery OK  
Measures  
None  
Good - charge  
Use Incharge  
Renew battery.  
Charge battery ⇒ page 55 .  
Charge battery ⇒ page 55 .  
Renew battery ⇒ Electrical sys‐  
tem; Rep. gr. 27 ; Removing  
and installing battery  
Battery cell defective  
Renew battery ⇒ Electrical sys‐  
tem; Rep. gr. 27 ; Removing  
and installing battery  
2.6.4  
Dealing with problems with Midtronics -  
MCR340V- battery tester  
Under certain circumstances, the display may show errors or  
messages according to status.  
The most frequent display messages are listed below, together  
with suggested solutions.  
Note  
For messages not listed here, please refer to ⇒ operating manual  
MCR340V .  
lk  
Display message  
No display  
Measures  
– Check whether terminals of  
battery tester are firmly con‐  
nected to battery terminals.  
– Check battery terminals are  
tightened according to reg‐  
ulations and do not have  
corrosion.  
– Charge battery  
⇒ page 55 .  
System noise  
– Switch off all electrical con‐  
sumers.  
– Wait until all electrical loads  
monitored by onboard sup‐  
ply control unit have switch‐  
ed off.  
– Remove ignition key.  
– Disconnect any suspect  
electrical equipment not  
connected to onboard sup‐  
ply as standard.  
2. Checking battery  
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Wait a few minutes and test again ⇒ page 19 .  
Note  
If you have performed test at jump-start point and message does  
not disappear, perform test directly on battery.  
2.7  
Current draw test  
WARNING  
Batteries where the magic eye is colourless or light yellow must  
not be checked or charged. Do not slave/jump start the vehicle!  
lk  
Danger of explosion when checking and charging or slave/  
jump starting  
These batteries must be renewed.  
Note  
♦ Ensure that the correct charging mode is set on the charger  
so that the current draw test is not falsified.  
♦ VAS 5095 A ⇒ page 26  
♦ VAS 5900 ⇒ page 30  
♦ VAS 5903 ⇒ page 41  
To quickly ascertain the state of discharged batteries, the battery  
current draw test whilst charging helps to determine whether the  
battery must be replaced or fully recharged.  
Note  
For battery tester with printer -VAS 6161- , the current draw test  
must always be performed when the test result „Perform current  
draw test“ appears on the display.  
The current draw test must be carried out when the test result with  
battery tester with printer -VAS 5097A- is as follows:  
1 - Starting output sufficient  
2 - Starting output poor  
3 - Starting output very poor  
4 - Cannot be tested – charge battery and repeat test.  
- and when the tester will not switch on (no LED, no printout)  
Depending on the test result ⇒ page 13 with battery tester with  
printer -VAS 5097A- , further procedures or tests may be required  
before making a final decision on the condition of the battery.  
Performing a current draw test whilst charging a battery will quick‐  
ly establish whether a partly or fully discharged battery  
⇒ page 59 can be recharged to return it to a serviceable condi‐  
tion.  
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Test requirements  
♦ When charging a battery, battery temperature must be at least  
≥ +10 °C.  
♦ The charger must be capable of outputting a charge current of  
at least 30 A, as for example with VAS 5095A, VAS 5900, VAS  
5903  
♦ The battery's current draw must be measured with a current  
pick-up clamp, e.g. VAS 5051B/7, when charging with battery  
charger -VAS 5095A- . Battery charger -VAS 5900- and bat‐  
tery charger -VAS 5903- display the current draw on the unit.  
– Connect battery to battery charger and start charging se‐  
quence.  
– Measure charging current of 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 battery and test  
again.  
Note  
For Eos with two 6V absorbent glass mat batteries, the charge  
current must only be 5 % higher than the nominal capacity of the  
battery. Example for Eos: the 50 Ah battery must have a charge  
current higher than 2.5 A after 5 minutes of starting the charging  
sequence.  
– Fully charge the battery when the charge current is higher than  
10 % of the nominal capacity (observe exception for Eos in  
above note).  
– Perform battery test after allowing battery to rest for two hours  
⇒ page 9 .  
If the charge current, in amperes, lies below 10 % of the nominal  
capacity after 5 minutes of starting the charging sequence (5 %  
for the 2 x 6 volt batteries in Eos) (example for 50 Ah battery <  
5A), renew battery. For Guarantee and ex-gratia cases: complete  
battery test sheet and keep it with the battery.  
2.8  
Checking no-load voltage of battery on  
stock and stored vehicles  
WARNING  
Danger of injury! Observe warning notices and safety regula‐  
tions ⇒ page 2 !  
Note  
♦ The no-load voltage test may only be carried out to assess the  
condition of the battery on stock and stored vehicles within the  
framework of prescribed maintenance.  
♦ The no-load test serves to determine whether a battery on a  
stock or stored vehicle requires recharging ⇒ Maintenance  
tables „Service for stock and stored vehicles“ .  
Special tools and workshop equipment required  
2. Checking battery  
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♦ Hand multimeter -V.A.G 1526 B-  
Test conditions  
The battery must not have been charged or discharged within the  
last 2 days.  
– Check battery no-load voltage with hand multimeter -V.A.G  
1526 B- .  
No-load voltage  
11.60 V  
Charge  
0 %  
Condition of battery  
Discharged, no capacity Heavily discharged ⇒ page 59 .  
lk  
Measured value  
Measure to be performed  
No-load voltage ≥ 12.5 V  
No-load voltage < 12.5 V  
No-load voltage OK  
Charging battery ⇒ page 25  
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3
Charging battery  
WARNING  
lk  
Danger of injury! Observe warning notices and safety regula‐  
tions ⇒ page 2 !  
Caution  
To prevent damage to the battery and vehicle, the following  
should be observed concerning types of battery ⇒ page 1 .  
WARNING  
Batteries where the magic eye is colourless or light yellow must  
not be checked or charged. Do not slave/jump start the vehicle!  
Danger of explosion when checking and charging or slave/  
jump starting  
These batteries must be renewed.  
3.1  
Battery charger -VAS 5095 A-  
This chapter describes the basic functions of the battery charger  
-VAS 5095 A- . For additional information refer to ⇒ operating  
instructions for battery charger -VAS 5095 A- .  
Note  
♦ The effective charging current can not be read on these units.  
The charge current must be read externally using a pick-up  
clamp.  
♦ Observe ⇒ operating instructions for battery charger -VAS  
5095 A- .  
3.1.1  
Description of battery charger -VAS  
5095 A-  
The battery charger -VAS 5095- is suitable for charging all 12V  
batteries supplied by Volkswagen.  
3. Charging battery  
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The battery charger charges without peaks in amperage or volt‐  
age. This will not adversely effect the onboard electronics. The  
battery can remain in the vehicle while it is being charged and  
need not be disconnected.  
Battery charger -VAS 5095 A-  
1 - ON / OFF switch (0 = charger OFF)  
2 - Charging current indicator (I > 12 A)  
3 - Charging current indicator, battery partially charged > 90 %  
4 - Maintaining charge; lights up green when battery is fully charg‐  
ed  
5 - Malfunction indicator  
6 - Support mode indicator  
7 - Support mode/normal mode changer-over switch  
8 - Charger cable, red terminal „+“, black terminal „-“  
9 - Battery type change-over switch (on base of charger unit)  
3.1.2  
Charging battery with battery charger -  
VAS 5095 A-  
WARNING  
Danger of injury! Observe warning notices and safety regula‐  
tions ⇒ page 2 !  
Special tools and workshop equipment required  
♦ Battery charger -VAS 5095 A-  
Caution  
Always set battery type 2.4 V/C (volts/battery cell) when charg‐  
ing! This applies for all batteries.  
Note  
The battery must have a temperature of at least 10 °C.  
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WARNING  
Batteries where the magic eye is colourless or light yellow must  
not be checked or charged. Do not slave/jump start the vehicle!  
Danger of explosion when checking and charging or slave/  
jump starting  
These batteries must be renewed.  
lk  
– Switch off ignition and all electrical consumers.  
– Check setting for battery type on type of battery switch  
⇒ page 25 . Must be set to 2.4 V/C (volts/battery cell).  
– Connect red terminal clamp „+“ of charger unit to positive ter‐  
minal on battery.  
Note  
In vehicles with start/stop function and battery monitor control unit  
-J367- fitted, black terminal clamp „-“ must be connected to body  
earth. Connecting it to battery negative terminal will cause start/  
stop system to malfunction.  
– Connect black terminal clamp „-“ of battery charger to negative  
terminal.  
– Switch on battery charger ⇒ page 25 .  
The charging current indicators ⇒ page 26 -2- and -3- light up  
yellow. When only the light emitting diode (LED) -3- lights up yel‐  
low, battery is partially discharged (approx. 90 %).  
If the LED lights up green ⇒ page 26 -4- the charger has switched  
to "maintaining charge". The battery is fully charged.  
– Switch off charging unit ⇒ page 25 .  
– Remove charger unit terminals from battery terminals.  
3.1.3  
Charging totally discharged battery with  
battery charger -VAS 5095 A-  
WARNING  
Danger of injury! Observe warning notices and safety regula‐  
tions ⇒ page 2 !  
The charger unit automatically recognises totally discharged bat‐  
teries and initiates a gentle charging procedure with a low charg‐  
ing current. The charging current is automatically adapted to suit  
the charge condition of the battery.  
Note  
♦ Observe notes in chapter ⇒ page 59 .  
♦ Totally discharged batteries in vehicles before registration  
must be exchanged prior to delivery. Preliminary damage can‐  
not be excluded.  
♦ The battery voltage must be at least 0.6 V.  
3. Charging battery  
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WARNING  
Batteries where the magic eye is colourless or light yellow must  
not be checked or charged. Do not slave/jump start the vehicle!  
Danger of explosion when checking and charging or slave/  
jump starting  
lk  
These batteries must be renewed.  
– Charge battery ⇒ page 26 .  
3.1.4  
Charging battery in support mode with  
battery charger -VAS 5095A-  
General notes:  
The support mode provides the onboard supply with power when  
the battery is removed or disconnected.  
For further information, refer to the ⇒ operating manual VAS  
5095A .  
The support mode is suitable in the following situations:  
♦ Support mode of onboard supplies without installed battery  
♦ Power conservation when renewing the battery  
♦ Ancillaries test without battery  
WARNING  
Danger of injury! Observe warning notices and safety regula‐  
tions ⇒ page 2 !  
WARNING  
Batteries where the magic eye is colourless or light yellow must  
not be checked or charged. Do not slave/jump start the vehicle!  
Danger of explosion when checking and charging or slave/  
jump starting  
These batteries must be renewed.  
– Switch off ignition and all electrical consumers.  
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Caution  
♦ The terminal polarity protection in operating mode „charg‐  
ing totally discharged batteries/support mode“ is not ac‐  
tive. Connect battery charger terminal clamps correctly to  
battery terminals.  
♦ It can cause sparks through a short-circuit.  
♦ Danger of explosion  
lk  
♦ Ensure charger terminal clamps are seated securely.  
♦ Do not press START / STOP button when charger unit  
cables are connected incorrectly. The charger unit may be  
damaged.  
– Remove battery.  
Caution  
When battery is removed, ensure there is no contact between  
terminal clamp connected to positive clamp and body earth.  
Also ensure there is no contact between battery clamps.  
– Connect red terminal clamp „+“ to positive terminal of vehicle.  
Note  
In vehicles with start/stop function and battery monitor control unit  
-J367- fitted, black terminal clamp „-“ must be connected to body  
earth. Connecting it to battery negative terminal will cause start/  
stop system to malfunction.  
– Connect black terminal clamp „+“ to negative terminal of ve‐  
hicle.  
– Check setting for battery type on normal/support mode switch  
⇒ page 25 . It must be switched on support mode.  
– Check polarity of charger unit cables.  
– Switch on battery charger.  
The battery charger starts with support mode.  
End battery support mode:  
– Switch off battery charger.  
– Disconnect black terminal clamp „-“ of charger unit from neg‐  
ative terminal of vehicle.  
– Disconnect red terminal clamp „+“ of charger unit from positive  
terminal of vehicle.  
– Pull charger plug out of battery charger.  
3. Charging battery  
29  
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3.1.5  
Charging battery in maintenance mode  
with battery charger -VAS 5095 A-  
WARNING  
Danger of injury! Observe warning notices and safety regula‐  
tions ⇒ page 2 !  
WARNING  
Batteries where the magic eye is colourless or light yellow must  
not be checked or charged. Do not slave/jump start the vehicle!  
Danger of explosion when checking and charging or slave/  
jump starting  
These batteries must be renewed.  
In maintenance mode the battery charger -VAS 5095 A- ensures  
that the battery is charged correctly and is maintained in fully  
charged condition.  
– Proceed as for charging battery ⇒ page 26 .  
Note  
♦ When a battery is being charged in maintenance mode and a  
electrical consumer draws current from the battery, the battery  
charger -VAS 5095 A- automatically compensates the charge.  
♦ The maintenance mode can be continued for an unlimited pe‐  
riod.  
♦ The battery is always ready for use.  
3.2  
Battery charger -VAS 5900-  
WARNING  
Danger of injury! Observe warning notices and safety regula‐  
tions ⇒ page 2 !  
WARNING  
Batteries where the magic eye is colourless or light yellow must  
not be checked or charged. Do not slave/jump start the vehicle!  
Danger of explosion when checking and charging or slave/  
jump starting  
These batteries must be renewed.  
This chapter describes the basic functions of the battery charger  
-VAS 5900- . For additional information refer to ⇒ operating in‐  
structions for battery charger -VAS 5900- .  
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Note  
♦ The effective charging current can be read directly on these  
charging units.  
♦ Observe ⇒ operating instructions for battery charger -VAS  
5900- .  
3.2.1  
Description of battery charger -VAlSk  
5900-  
The battery charger -VAS 5900- is suitable for charging all 12V  
batteries supplied by Volkswagen.  
Battery charger -VAS 5900-  
1 - Display  
2 - Adjustment button „Up“ ↑  
3 - Adjustment button „Down“ ↓  
4 - START / STOP  
5 - INFO  
3.2.2  
Charging battery with battery charger -  
VAS 5900-  
WARNING  
Danger of injury! Observe warning notices and safety regula‐  
tions ⇒ page 2 !  
WARNING  
Batteries where the magic eye is colourless or light yellow must  
not be checked or charged. Do not slave/jump start the vehicle!  
Danger of explosion when checking and charging or slave/  
jump starting  
These batteries must be renewed.  
Special tools and workshop equipment required  
♦ Battery charger -VAS 5900-  
3. Charging battery  
31  
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Note  
The battery must have a temperature of at least 10 °C.  
– Switch off ignition and all electrical consumers.  
– Connect charger plug to battery charger. The last selected  
type of battery will appear on display.  
– Set battery to respective operating mode with INFO.  
In the display the symbol -1- for „standard charge for wet batter‐  
ies“ or symbol -2- for „standard charge for gel/absorbent glass  
mat batteries“ will appear.  
– Set battery capacity (Ah) of battery for charging using respec‐  
tive button „Up“ ↑ or „Down“ ↓ .  
– Connect red terminal clamp „+“ to positive terminal on battery.  
Note  
In vehicles with start/stop function and battery monitor control unit  
-J367- fitted, black terminal clamp must be connected to body  
earth. Connecting it to battery negative terminal will cause start/  
stop system to malfunction.  
– Connect black terminal clamp „-“ to negative terminal.  
The charger unit recognises the voltage required for the connec‐  
ted battery (6 V, 12 V or 24 V) and initiates the charging sequence.  
At a charge condition of approx. 80 - 85 % the battery charger  
switches to the „final charge“ mode. The fourth bar appears in  
display -1-. The battery is ready for use.  
lk  
32  
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Electrical System, General Information - Edition 07.2010  
At a charge condition of 100 % all bars appear in display.  
Note  
lk  
♦ In the battery type „standard charge“ the parallel use of con‐  
sumers while charging is possible. The charging period will be  
longer.  
♦ The battery charger will switch to maintenance mode after  
about 1-7 hours, depending on type of battery. To achieve a  
100 % charge the battery should remain connected for this  
period.  
Possible faults and fault rectification  
1 - Displayed battery voltage is not as per nominal voltage:  
– Press respective button „Up“ ↑ or „Down“ ↓ until charging  
sequence starts.  
2 - Displayed battery voltage is not as per nominal voltage –  
charging sequence already started:  
– Press START / STOP twice.  
– Press respective button „Up“ ↑ or „Down“ ↓ until charging  
sequence starts again.  
3 - Battery charger does not detect a battery, when battery volt‐  
age is less than 2 V:  
Display remains unchanged.  
The battery type and ampere hours (Ah) as set is displayed.  
Ending battery charging sequence:  
– Press START / STOP.  
– Disconnect black terminal clamp „-“ of charger from negative  
terminal.  
– Disconnect red terminal clamp „+“ of charger from positive  
terminal on battery.  
– Pull charger plug out of battery charger.  
3.2.3  
Charging battery in service mode with  
battery charger -VAS 5900-  
WARNING  
Danger of injury! Observe warning notices and safety regula‐  
tions ⇒ page 2 !  
Caution  
The operating mode „service charge“ is not permitted on VW  
vehicles as the voltage peaks will damage the onboard elec‐  
tronics.  
If there is a requirement to use „service charge“ the battery  
must be disconnected from the onboard supply.  
3. Charging battery  
33  
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WARNING  
Batteries where the magic eye is colourless or light yellow must  
not be checked or charged. Do not slave/jump start the vehicle!  
Danger of explosion when checking and charging or slave/  
jump starting  
These batteries must be renewed.  
Caution  
When charging always set the battery charger to the correct  
type of battery ⇒ operating instructions for battery charger -  
VAS 5900- !  
The „service mode“ is suitable for:  
♦ Wet batteries where the magic eye allows charging (magic  
eye black or green)  
The operating mode „service charge (SERV)“ is only used on  
sulphated batteries. The battery is charged at a voltage of  
> 14.4 V. This can result in a partial reduction of the sulphated  
layer. After charging, always check the colour of the magic eye  
before using the battery ⇒ page 6 .  
lk  
Special tools and workshop equipment required  
♦ Battery charger -VAS 5900-  
Note  
The battery must have a temperature of at least 10 °C.  
– Switch off ignition and all electrical consumers.  
– Connect charger plug to battery charger. The last selected  
operating mode will appear on display ⇒ page 31 .  
34  
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Electrical System, General Information - Edition 07.2010  
– Set battery to respective battery type with INFO.  
In the display, the symbol -1- for „Service charge for wet batteries“  
or symbol -2- for „Service charge for gel/absorbent glass mat bat‐  
teries“ will appear.  
– Set battery capacity (Ah) of battery for charging using respec‐  
tive button „Up“ ↑ or „Down“ ↓ .  
– Connect red terminal clamp „+“ to positive terminal on battery.  
Note  
lk  
In vehicles with start/stop function and battery monitor control unit  
-J367- fitted, black terminal clamp „-“ must be connected to body  
earth. Connecting it to battery negative terminal will cause start/  
stop system to malfunction.  
– Connect black terminal clamp „-“ to negative terminal.  
The charger unit recognises the voltage required for the connec‐  
ted battery (6 V, 12 V or 24 V) and initiates the charging sequence.  
At a charge condition of approx. 80 - 85 % of the battery voltage,  
the battery charger switches to the „final charge“ mode. The fourth  
bar appears in display -1-. The battery is ready for use.  
Note  
The success of the „service charge“ depends on the severity of  
the sulphation of the battery  
Possible faults and fault rectification:  
1 - Displayed battery voltage is not as per nominal voltage:  
– Press respective button „Up“ ↑ or „Down“ ↓ until charging  
sequence starts.  
2 - Displayed battery voltage is not as per nominal voltage –  
charging sequence already started:  
– Press START / STOP twice.  
– Press respective button „Up“ ↑ or „Down“ ↓ until charging  
sequence starts.  
3 - Battery charger does not detect a battery, when battery volt‐  
age is less than 2 V:  
Display remains unchanged.  
The operating mode and ampere hours (Ah) as set are displayed.  
Ending battery charging sequence:  
– Press START / STOP.  
– Disconnect black terminal clamp „-“ of charger from negative  
terminal.  
– Disconnect red terminal clamp „+“ of charger from positive  
terminal on battery.  
– Pull charger plug out of battery charger.  
3. Charging battery  
35  
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3.2.4  
Charging totally discharged batteries  
with battery charger -VAS 5900-  
WARNING  
Danger of injury! Observe warning notices and safety regula‐  
tions ⇒ page 2 !  
WARNING  
Batteries where the magic eye is colourless or light yellow must  
not be checked or charged. Do not slave/jump start the vehicle!  
lk  
Danger of explosion when checking and charging or slave/  
jump starting  
These batteries must be renewed.  
Caution  
♦ The terminal polarity protection in operating mode „charg‐  
ing totally discharged batteries/support mode“ is not ac‐  
tive. Connect battery charger terminal clamps correctly to  
battery terminals.  
♦ When charging always set the battery charger to the cor‐  
rect type of battery ⇒ operating instructions for battery  
charger -VAS 5900- !  
♦ Totally discharged battery is not recognised by battery  
charger ⇒ page 59 .  
♦ Do not press START / STOP button when charger unit  
cables are connected incorrectly. The charger unit may be  
damaged.  
Batteries with a voltage of less than 2 volts will not be recognised  
automatically by battery charger -VAS 5900- .  
Special tools and workshop equipment required  
♦ Battery charger -VAS 5900-  
36  
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Electrical System, General Information - Edition 07.2010  
Note  
♦ Observe notes in chapter ⇒ page 59 .  
♦ Totally discharged batteries in vehicles before registration  
must be exchanged prior to delivery. Preliminary damage can‐  
not be excluded.  
♦ The battery must have a temperature of at least 10 °C.  
– Switch off ignition and all electrical consumers.  
– Connect charger plug to battery charger. The last selected  
operating mode will appear on display ⇒ page 31 .  
lk  
3. Charging battery  
37  
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– Set battery to respective battery type with INFO.  
In the display, the symbol -1- for „Service charge for wet batteries“  
or symbol -2- for „Service charge for gel/absorbent glass mat bat‐  
teries“ will appear.  
– Set battery capacity (Ah) of battery for charging using respec‐  
tive button „Up“ ↑ or „Down“ ↓ .  
– Connect red terminal clamp „+“ to positive terminal on battery.  
Note  
In vehicles with start/stop function and battery monitor control unit  
-J367- fitted, black terminal clamp must be connected to body  
earth. Connecting it to battery negative terminal will cause start/  
stop system to malfunction.  
– Connect black terminal clamp „-“ to negative terminal.  
– Press START / STOP for approx. 5 seconds. The menu  
„charging totally discharged batteries/support mode“ will be  
activated.  
– Press respective button „Up“ ↑ or „Down“ ↓ to set respective  
battery voltage (6 V, 12 V or 24 V).  
Note  
If a button is not pressed within 5 seconds the charger will return  
to the main menu (select operating mode).  
– Confirm the selected battery voltage with START / STOlkP.  
Then follows the enquiry for "is charger cable terminal polarity  
correct".  
– Check polarity of charger unit cables.  
– Confirm polarity of charger unit cables with START / STOP.  
Charger will start charging sequence for totally discharged bat‐  
tery.  
Ending battery charging sequence:  
– Press START / STOP.  
– Disconnect black terminal clamp „-“ of charger from negative  
terminal.  
– Disconnect red terminal clamp „+“ of charger from positive  
terminal on battery.  
– Pull charger plug out of battery charger.  
3.2.5  
Charging battery in support mode with  
battery charger -VAS 5900-  
General notes:  
The support mode provides the onboard supply with power when  
the battery is removed or disconnected.  
For further information, refer to the ⇒ operating manual VAS  
5900 .  
The support mode is suitable in the following situations:  
38  
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Electrical System, General Information - Edition 07.2010  
♦ Support mode of onboard supplies without installed battery  
♦ Power conservation when renewing the battery  
♦ Ancillaries test without battery  
WARNING  
Danger of injury! Observe warning notices and safety regula‐  
tions ⇒ page 2 !  
WARNING  
Batteries where the magic eye is colourless or light yellow must  
not be checked or charged. Do not slave/jump start the vehicle!  
lk  
Danger of explosion when checking and charging or slave/  
jump starting  
These batteries must be renewed.  
– Switch off ignition and all electrical consumers.  
Caution  
♦ The terminal polarity protection in operating mode „charg‐  
ing totally discharged batteries/support mode“ is not ac‐  
tive. Connect battery charger terminal clamps correctly to  
battery terminals.  
♦ It can cause sparks through a short-circuit.  
♦ Danger of explosion  
♦ Ensure charger terminal clamps are seated securely.  
♦ Do not press START / STOP button when charger unit  
cables are connected incorrectly. The charger unit may be  
damaged.  
– Remove battery.  
– Connect charger plug to battery charger. The last selected  
operating mode will appear on display ⇒ page 31 .  
Caution  
When battery is removed, ensure there is no contact between  
terminal clamp connected to positive clamp and body earth.  
Also ensure there is no contact between battery clamps.  
– Connect red terminal clamp „+“ to positive terminal of vehicle.  
Note  
In vehicles with start/stop function and battery monitor control unit  
-J367- fitted, black terminal clamp must be connected to body  
earth. Connecting it to battery negative terminal will cause start/  
stop system to malfunction.  
3. Charging battery  
39  
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Electrical System, General Information - Edition 07.2010  
– Connect black terminal clamp „+“ to negative terminal of ve‐  
hicle.  
– Press START / STOP for approx. 5 seconds. The menu  
„charging totally discharged batteries/support mode“ will be  
activated.  
– Press respective button „Up“ ↑ or „Down“ ↓ to set respective  
battery voltage (6 V, 12 V or 24 V).  
Note  
If a button is not pressed within 5 seconds the charger will return  
to the main menu (select operating mode).  
– Confirm the selected battery voltage with START / STOP.  
Then follows the enquiry for "is charger cable terminal polarity  
correct".  
– Check polarity of charger unit cables.  
– Confirm polarity of charger unit cables with START / STOP.  
The battery charger starts with support mode.  
End battery support mode:  
– Press START / STOP.  
– Disconnect black terminal clamp „-“ of charger unit from neg‐  
ative terminal of vehicle.  
– Disconnect red terminal clamp „+“ of charger unit from positive  
terminal of vehicle.  
– Pull charger plug out of battery charger.  
lk  
3.2.6  
Charging battery in maintenance mode  
with battery charger -VAS 5900-  
Note  
♦ When a battery is being charged in the maintenance mode and  
an electrical consumer draws current from the battery, the  
battery charger -VAS 5900- automatically compensates the  
charge.  
♦ The maintenance mode can be continued for an unlimited pe‐  
riod.  
♦ The battery is always ready for use.  
♦ Observe battery manufacture's maintenance instructions!  
WARNING  
Danger of injury! Observe warning notices and safety regula‐  
tions ⇒ page 2 !  
40  
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Electrical System, General Information - Edition 07.2010  
WARNING  
Batteries where the magic eye is colourless or light yellow must  
not be checked or charged. Do not slave/jump start the vehicle!  
Danger of explosion when checking and charging or slave/  
jump starting  
These batteries must be renewed.  
When the battery is fully charged the battery charger -VAS 5900-  
switches to maintenance mode.  
lk  
– Proceed as for charging battery ⇒ page 31 .  
At a charge condition of 100 % all bars appear in display.  
3.3  
Battery charger -VAS 5903-  
WARNING  
Danger of injury! Observe warning notices and safety regula‐  
tions ⇒ page 2 !  
WARNING  
Batteries where the magic eye is colourless or light yellow must  
not be checked or charged. Do not slave/jump start the vehicle!  
Danger of explosion when checking and charging or slave/  
jump starting  
These batteries must be renewed.  
This chapter describes the basic functions of the battery charger  
-VAS 5903- . For additional information refer to ⇒ operating in‐  
structions for battery charger -VAS 5903- .  
Note  
Observe ⇒ operating instructions for battery charger -VAS 5903- .  
3. Charging battery  
41  
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3.3.1  
Description of battery charger -VAS  
5903-  
The battery charger -VAS 5903- is suitable for charging all 12V  
batteries supplied by Volkswagen.  
Battery charger -VAS 5903-  
1 - Display  
2 - Adjustment button „Up“ ↑  
3 - Adjustment button „Down“ ↓  
4 - START / STOP  
5 - INFO  
3.3.2  
Charging battery with battery charger -  
VAS 5903-  
WARNING  
lk  
Danger of injury! Observe warning notices and safety regula‐  
tions ⇒ page 2 !  
WARNING  
Batteries where the magic eye is colourless or light yellow must  
not be checked or charged. Do not slave/jump start the vehicle!  
Danger of explosion when checking and charging or slave/  
jump starting  
These batteries must be renewed.  
Special tools and workshop equipment required  
♦ Battery charger -VAS 5903-  
Note  
The battery must have a temperature of at least 10 °C.  
– Switch off ignition and all electrical consumers.  
– Connect charger plug to battery charger. The last selected  
operating mode will appear on display ⇒ page 42 .  
42  
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Electrical System, General Information - Edition 07.2010  
– Set battery to respective operating mode with INFO.  
In the display the symbol -1- for „standard charge for wet batter‐  
ies“ or symbol -2- for „standard charge for gel/absorbent glass  
mat batteries“ will appear.  
– Set battery capacity (Ah) of battery for charging using respec‐  
tive button „Up“ ↑ or „Down“ ↓ .  
– Connect red terminal clamp „+“ to positive terminal on battery.  
Note  
In vehicles with start/stop function and battery monitor control unit  
-J367- fitted, black terminal clamp must be connected to body  
earth. Connecting it to battery negative terminal will cause start/  
stop system to malfunction.  
– Connect black terminal clamp „-“ to negative terminal.  
The charger unit recognises the voltage required for the connec‐  
ted battery (6 V, 12 V or 24 V) and initiates the charging sequence.  
At a charge condition of approx. 80 - 85 % the battery charger  
switches to the „final charge“ mode. The fourth bar appears in  
display -1-. The battery is ready for use.  
lk  
3. Charging battery  
43  
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At a charge condition of 100 % all bars appear in display.  
Note  
♦ In the battery type „standard charge“ the parallel use of con‐  
sumers while charging is possible. The charging period will be  
longer.  
♦ The battery charger will switch to maintenance mode after  
about 1-7 hours, depending on type of battery. To achieve a  
100 % charge the battery should remain connected for this  
period.  
Possible faults and fault rectification:  
1 - Displayed battery voltage is not as per nominal voltage:  
– Press respective button „Up“ ↑ or „Down“ ↓ until charging  
sequence starts.  
2 - Displayed battery voltage is not as per nominal voltage -  
charging sequence already started:  
– Press START / STOP twice.  
– Press respective button „Up“ ↑ or „Down“ ↓ until charging  
sequence starts again.  
3 - Battery charger does not detect a battery, when battery volt‐  
age is less than 2 V:  
lk  
Display remains unchanged.  
The battery type and ampere hours (Ah) as set is displayed.  
Ending battery charging sequence:  
– Press START / STOP.  
– Disconnect black terminal clamp „-“ of charger from negative  
terminal.  
– Disconnect red terminal clamp „+“ of charger from positive  
terminal on battery.  
– Pull charger plug out of battery charger.  
3.3.3  
Charging battery in refresh charge  
mode with battery charger -VAS 5903-  
WARNING  
Danger of injury! Observe warning notices and safety regula‐  
tions ⇒ page 2 !  
WARNING  
Batteries where the magic eye is colourless or light yellow must  
not be checked or charged. Do not slave/jump start the vehicle!  
Danger of explosion when checking and charging or slave/  
jump starting  
These batteries must be renewed.  
44  
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Electrical System, General Information - Edition 07.2010  
lk  
Caution  
The operating mode „refresh charge“ is not permitted on VW  
vehicles as the voltage peaks will damage the onboard elec‐  
tronics.  
If there is a requirement to use „refresh charge“ mode the bat‐  
tery must be disconnected from the onboard supply.  
Caution  
When charging always set the battery charger to the correct  
type of battery ⇒ operating instructions for battery charger -  
VAS 5903- !  
The „refresh charge“ mode is suitable for:  
♦ Wet batteries, where distilled water can be replenished.  
Do not use operating mode „refresh charge“ with maintenance-  
free wet batteries.  
The „refresh charge (refr)“ operating mode is only used on sus‐  
pect defective batteries (e.g. sulphation). The battery will be  
charged to maximum specific gravity and the plates will be reac‐  
tivated (dissipation of sulphur layer).  
Special tools and workshop equipment required  
♦ Battery charger -VAS 5900-  
Note  
The battery must have a temperature of at least 10 °C.  
– Switch off ignition and all electrical consumers.  
– Connect charger plug to battery charger. The last selected  
operating mode will appear on display ⇒ page 42 .  
3. Charging battery  
45  
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– Set battery to respective operating mode with INFO.  
In the display the symbol -1- for „refresh charge for wet batteries“  
or symbol -2- for „refresh charge for gel/absorbent glass mat bat‐  
teries“ will appear.  
– Set battery capacity (Ah) of battery for charging using respec‐  
tive button „Up“ ↑ or „Down“ ↓ .  
– Connect red terminal clamp „+“ to positive terminal on battery.  
Note  
In vehicles with start/stop function and battery monitor control unit  
-J367- fitted, black terminal clamp must be connected to body  
earth. Connecting it to battery negative terminal will cause start/  
stop system to malfunction.  
– Connect black terminal clamp „-“ to negative terminal.  
The charger unit recognises the voltage required for the connec‐  
ted battery (6 V, 12 V or 24 V) and initiates the charging sequence.  
At a charge condition of approx. 80 - 85 % of the battery voltage,  
the battery charger switches to the „final charge“ mode. The fourth  
bar appears in display -1-. The battery is ready for use.  
Note  
The success of the „refresh charge“ depends on the severity of  
the sulphation of the battery.  
Possible faults and fault rectification:  
1 - Displayed battery voltage is not as per nominal voltage:  
– Press respective button „Up“ ↑ or „Down“ ↓ until charging  
sequence starts.  
2 - Displayed battery voltage is not as per nominal voltage –  
charging sequence already started:  
– Press START / STOP twice.  
– Press respective button „Up“ ↑ or „Down“ ↓ until charging  
sequence starts.  
3 - Battery charger does not detect a battery, when battery volt‐  
age is less than 2 V:  
Display remains unchanged.  
The operating mode and ampere hours (Ah) as set are displayed.  
Ending battery charging sequence:  
– Press START / STOP.  
– Disconnect black terminal clamp „-“ of charger from negative  
terminal.  
– Disconnect red terminal clamp „+“ of charger from positive  
terminal on battery.  
– Pull charger plug out of battery charger.  
46  
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Electrical System, General Information - Edition 07.2010  
3.3.4  
Charging totally discharged battery with  
battery charger -VAS 5903-  
WARNING  
Danger of injury! Observe warning notices and safety regula‐  
tions ⇒ page 2 !  
WARNING  
Batteries where the magic eye is colourless or light yellow must  
not be checked or charged. Do not slave/jump start the vehicle!  
Danger of explosion when checking and charging or slavel/k  
jump starting  
These batteries must be renewed.  
Caution  
♦ The terminal polarity protection in operating mode „charg‐  
ing totally discharged batteries/support mode“ is not ac‐  
tive. Connect battery charger terminal clamps correctly to  
battery terminals.  
♦ When charging always set the battery charger to the cor‐  
rect type of battery ⇒ operating instructions for battery  
charger -VAS 5903- !  
♦ Totally discharged battery is not recognised by battery  
charger ⇒ page 59 .  
♦ Do not press START / STOP button when charger unit  
cables are connected incorrectly. The charger unit may be  
damaged.  
Batteries with a voltage of less than 2 volts will not be recognised  
automatically by battery charger -VAS 5903- .  
Special tools and workshop equipment required  
♦ Battery charger -VAS 5903-  
3. Charging battery  
47  
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Electrical System, General Information - Edition 07.2010  
Note  
♦ Observe notes in chapter ⇒ page 59 .  
♦ Totally discharged batteries in vehicles before registration  
must be exchanged prior to delivery. Preliminary damage can‐  
not be excluded.  
♦ The battery must have a temperature of at least 10 °C.  
– Switch off ignition and all electrical consumers.  
lk  
– Connect charger plug to battery charger. The last selected  
operating mode will appear on display ⇒ page 42 .  
48  
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– Set battery to respective operating mode with INFO.  
In the display, the symbol -1- for „Service charge for wet batteries“  
or symbol -2- for „Service charge for gel/absorbent glass mat bat‐  
teries“ will appear.  
– Set battery capacity (Ah) of battery for charging using respec‐  
tive button „Up“ ↑ or „Down“ ↓ .  
– Connect red terminal clamp „+“ to positive terminal on battery.  
Note  
In vehicles with start/stop function and battery monitor control unit  
-J367- fitted, black terminal clamp must be connected to body  
earth. Connecting it to battery negative terminal will cause start/  
stop system to malfunction.  
– Connect black terminal clamp „-“ to negative terminal.  
– Press START / STOP for approx. 5 seconds. The menu  
„charging totally discharged batteries/support mode“ will be  
activated.  
lk  
– Press respective button „Up“ ↑ or „Down“ ↓ to set respective  
battery voltage (6 V, 12 V or 24 V).  
Note  
If a button is not pressed within 5 seconds the charger will return  
to the main menu (select operating mode).  
– Confirm the selected battery voltage with START / STOP.  
Then follows the enquiry for "is charger cable terminal polarity  
correct".  
– Check polarity of charger unit cables.  
– Confirm polarity of charger unit cables with START / STOP.  
Charger will start charging sequence for totally discharged bat‐  
tery.  
Ending battery charging sequence:  
– Press START / STOP.  
– Disconnect black terminal clamp „-“ of charger from negative  
terminal.  
– Disconnect red terminal clamp „+“ of charger from positive  
terminal on battery.  
– Pull charger plug out of battery charger.  
3.3.5  
Charging battery in support mode with  
battery charger -VAS 5903-  
General notes:  
The support mode provides the onboard supply with power when  
the battery is removed or disconnected.  
For further information, refer to the ⇒ operating manual VAS  
5903 .  
The support mode is suitable in the following situations:  
3. Charging battery  
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♦ Support mode of onboard supplies without installed battery  
♦ Power conservation when renewing the battery  
♦ Ancillaries test without battery  
WARNING  
Danger of injury! Observe warning notices and safety regula‐  
tions ⇒ page 2 !  
WARNING  
Batteries where the magic eye is colourless or light yellow must  
not be checked or charged. Do not slave/jump start the vehicle!  
lk  
Danger of explosion when checking and charging or slave/  
jump starting  
These batteries must be renewed.  
– Switch off ignition and all electrical consumers.  
Caution  
♦ The terminal polarity protection in operating mode „charg‐  
ing totally discharged batteries/support mode“ is not ac‐  
tive. Connect battery charger terminal clamps correctly to  
battery terminals.  
♦ It can cause sparks through a short-circuit.  
♦ Danger of explosion  
♦ Ensure charger terminal clamps are seated securely.  
♦ Do not press START / STOP button when charger unit  
cables are connected incorrectly. The charger unit may be  
damaged.  
– Remove battery.  
– Connect charger plug to battery charger. The last selected  
operating mode will appear on display ⇒ page 31 .  
Caution  
When battery is removed, ensure there is no contact between  
terminal clamp connected to positive clamp and body earth.  
Also ensure there is no contact between battery clamps.  
– Connect red terminal clamp „+“ to positive terminal of vehicle.  
Note  
In vehicles with start/stop function and battery monitor control unit  
-J367- fitted, black terminal clamp must be connected to body  
earth. Connecting it to battery negative terminal will cause start/  
stop system to malfunction.  
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– Connect black terminal clamp „+“ to negative terminal of ve‐  
hicle.  
– Press START / STOP for approx. 5 seconds. The menu  
„charging totally discharged batteries/support mode“ will be  
activated.  
– Press respective button „Up“ ↑ or „Down“ ↓ to set respective  
battery voltage (6 V, 12 V or 24 V).  
Note  
If a button is not pressed within 5 seconds the charger will return  
to the main menu (select operating mode).  
– Confirm the selected battery voltage with START / STOP.  
Then follows the enquiry for "is charger cable terminal polarity  
correct".  
– Check polarity of charger unit cables.  
– Confirm polarity of charger unit cables with START / STOP.  
The battery charger starts with support mode.  
End battery support mode:  
– Press START / STOP.  
– Disconnect black terminal clamp „-“ of charger unit from neg‐  
ative terminal of vehicle.  
– Disconnect red terminal clamp „+“ of charger unit from positive  
terminal of vehicle.  
– Pull charger plug out of battery charger.  
3.3.6  
Charging battery in maintenance mode  
with battery charger -VAS 5903-  
Note  
♦ When a battery is being charged in the maintenance mode and  
an electrical consumer draws current from the battery, the  
battery charger -VAS 5903- automatically compensates the  
charge.  
♦ The maintenance mode can be continued for an unlimited pe‐  
riod.  
♦ The battery is always ready for use.  
♦ Observe battery manufacture's maintenance instructions!  
WARNING  
Danger of injury! Observe warning notices and safety regula‐  
tions ⇒ page 2 !  
3. Charging battery  
51  
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WARNING  
Batteries where the magic eye is colourless or light yellow must  
not be checked or charged. Do not slave/jump start the vehicle!  
Danger of explosion when checking and charging or slave/  
jump starting  
These batteries must be renewed.  
When the battery is fully charged the battery charger -VAS 5903-  
switches to maintenance mode.  
– Proceed as for charging battery ⇒ page 42 .  
At a charge condition of 100 % all bars appear in display.  
lk  
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3.4  
Battery charger -VAS 5906-  
General description  
3.4.1  
Battery charger - VAS 5906-  
WARNING  
Danger of injury! Observe warning notices and safety regula‐  
tions ⇒ page 2 !  
lk  
WARNING  
Batteries where the magic eye is colourless or light yellow must  
not be checked or charged. Do not slave/jump start the vehicle!  
Danger of explosion when checking and charging or slave/  
jump starting  
These batteries must be renewed.  
Battery charger -VAS 5906- has been specially developed for  
charging in vehicle onboard supply during vehicle presentation.  
It has an automatic charging characteristic for starter batteries, 3  
- 300 AH.  
The maximum charging voltage 14.4 V is not exceeded. All elec‐  
trical loads are supported by up to 30 A by the trickle charging.  
For sustained operation, battery charger -VAS 5906- changes to  
trickle charging once battery is fully charged.  
Tester starts fully automatically and does not require any settings.  
All that is required is to connect crocodile clips and mains cable.  
For further information, refer to the ⇒ operating manual VAS  
5906 .  
3.4.2  
Charging battery with battery charger -  
VAS 5906-  
WARNING  
Danger of injury! Observe warning notices and safety regula‐  
tions ⇒ page 2 !  
WARNING  
Batteries where the magic eye is colourless or light yellow must  
not be checked or charged. Do not slave/jump start the vehicle!  
Danger of explosion when checking and charging or slave/  
jump starting  
These batteries must be renewed.  
3. Charging battery  
53  
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Overview of operating panel:  
1 - Charge condition display 25 %.  
2 - Charge condition display 50 %.  
3 - Charge condition display 75 %.  
4 - Charge condition display 100 %.  
5 - Display ready  
6 - Start/stop and Setup buttons for interrupting and resuming  
charging process. Entry to Setup menu and selection of  
characteristic type (press for 10 s).  
7 - Malfunction display.  
– Place charger in engine compartment or under vehicle.  
– Connect mains cable to charger and plug it into mains.  
Charger is in no-load operation - ready light is on.  
WARNING  
Danger of injury! Observe warning notices and safety regula‐  
tions ⇒ page 2 !  
– Switch off ignition.  
– Connect red charging cable to positive terminal „+“ on battery.  
Note  
In vehicles with start/stop function and battery monitor control unit  
-J367- fitted, black terminal clamp must be connected to bodylk  
earth. Connecting it to battery negative terminal will cause start/  
stop system to malfunction.  
– Connect black charging cable to negative terminal „-“ on bat‐  
tery.  
Charging starts after about 2 seconds.  
Number of LEDs lit indicates charge condition of battery. Battery  
has been charged up once all lights are lit.  
When battery is fully charged, battery charger -VAS 5906- auto‐  
matically switches over to trickle charging.  
Caution  
Danger of sparking if charging terminals are removed too soon.  
Terminate charging by pressing start/stop button.  
– Press start/stop button to terminate charging.  
– Disconnect black charging cable from negative terminal „-“ on  
battery.  
– Disconnect red charging cable from positive terminal „+“ on  
battery.  
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3.5  
Midtronics -INC 940- battery charger on‐  
ly for USA/Canada  
Warning and safety regulations ⇒ page 2  
General description ⇒ page 55  
Charge battery ⇒ page 56 .  
lk  
Dealing with problems with Midtronics -INC 940- battery tester  
⇒ page 58  
3.5.1  
General description of Midtronics -INC  
940- battery tester  
Batteries in VW vehicles are only allowed to be charged with bat‐  
tery chargers approved by VW. In the USA/Canada, it is permitted  
for the Midtronics -INC 940- battery charger to be used.  
Midtronics -INC 940- battery charger combines battery charging  
with a charge condition checks and a battery test.  
The following charging and analysis procedures apply to all bat‐  
teries, all battery installation locations (engine compartment or  
luggage compartment) and battery application purposes (starter  
battery or second/convenience battery).  
Always comply with the safety regulations, the regulations for  
setting up the battery charger, the display menu/display buttons,  
LEDs and the operating procedures described in the ⇒ operating  
manual INC 940 .  
Read through ⇒ operating manual INC 940 carefully.  
Refer to ⇒ Self-study programme No. ; Vehicle batteries for more  
information.  
WARNING  
Danger of injury! Observe warning notices and safety regula‐  
tions ⇒ page 2 !  
No naked flames, sparking or smoking in the vicinity of batter‐  
ies.  
Battery charger must be switched off before cables are con‐  
nected or disconnected.  
Do not remove cell plugs during charging.  
Overcharging sulphated batteries can lead to explosions.  
Do not store precision tools in rooms where batteries are  
charged, because corrosion can ensue due to chemical reac‐  
tions.  
WARNING  
Batteries where the magic eye is colourless or light yellow must  
not be checked or charged. Do not slave/jump start the vehicle!  
Danger of explosion when checking and charging or slave/  
jump starting  
These batteries must be renewed.  
3. Charging battery  
55  
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3.5.2  
Charging battery  
Prerequisites:  
WARNING  
Batteries where the magic eye is colourless or light yellow must  
not be checked or charged. Do not slave/jump start the vehicle!  
Danger of explosion when checking and charging or slave/  
jump starting  
These batteries must be renewed.  
INC 940 initial setup performed (dealership number, date/time) ⇒  
operating manual INC 940 .  
– Check general information ⇒ page 55 .  
– Open bonnet or cover for other installation location of battery.  
lk  
– Perform visual check of battery ⇒ page 6 .  
– Determine whether battery type is „Standard“ (wet battery) or  
„AGM“ (absorbent glass mat battery).  
– Close all vehicle doors.  
Note  
♦ Battery temperature must be at least 10 °C.  
♦ For additional information, refer to the ⇒ operating manual  
INC 940 .  
Perform charging procedure:  
– Switch off all electrical consumers.  
– Switch off ignition and remove ignition key.  
– Connect red terminal clamp „+“ of charger unit to positive ter‐  
minal on battery.  
Note  
In vehicles with start/stop function and battery monitor control unit  
-J367- fitted, black terminal clamp must be connected to body  
earth. Connecting it to battery negative terminal will cause start/  
stop system to malfunction.  
– Connect black terminal clamp „-“ of battery charger to negative  
terminal.  
– Connect Midtronics -INC 940- battery charger to an earthed  
socket.  
– Set „ON/OFF“ switch of Midtronics -INC 940- battery charger  
to „ON“.  
– Select „Automatic“ or „Manual“ charging mode.  
– Select test „In vehicle“ or „Outside vehicle“.  
– Select battery type „Standard “ or „AGM“ (absorbent glass  
mat).  
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– Select test type „Warranty“ or „Miscellaneous“. Note additional  
details (depending on type of test).  
Note  
♦ For additional information, refer to the ⇒ operating manual  
INC 940 .  
♦ If necessary, make a note of menu items required for „War‐  
ranty“ test type ⇒ Warranty service circular .  
Midtronics -INC 940- battery charger tests battery and starts  
charging procedure. Display then shows one of three results, as  
well as approximate charging time.  
Result:  
Measures:  
Battery OK  
Battery can be returned to op‐  
eration.  
Charging required  
♦ Test found low charge level.  
♦ Charging starts and approx‐  
imate charging duration is  
displayed.  
♦ Achieved cold-start per‐  
formance and remaining  
charging time are displayed,  
and are updated regularly.  
Renew battery.  
Note  
Battery defective. Charging  
procedure is interrupted. Re‐  
new battery.  
lk  
In case Midtronics -INC 940- shows fault messages or text dis‐  
plays other than those listed above, please refer to  
⇒ page 58 .  
WARNING  
Stop charging if battery is liberating a lot of gas. Press „Stop“  
button on front.  
When charging and testing procedure has finished, Midtronics -  
INC 940- battery charger displays „Battery good“ or „Renew  
battery“ and total charging time.  
There are three possible messages depending on individual cir‐  
cumstance (printout for warranty, repair job, evaluation and filing):  
♦ Generate test code (only possible after automatic charging  
and test).  
♦ Print last test result (for warranty).  
♦ Display last test results.  
Note  
For additional information, refer to the ⇒ operating manual INC  
940 .  
3. Charging battery  
57  
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3.5.3  
Dealing with problems with Midtronics -  
INC 940- battery tester  
Under certain circumstances, the display may show errors or  
messages according to status.  
The most frequent display messages are listed below, together  
with suggested solutions.  
Note  
For messages not listed here, please refer to ⇒ operating manual  
INC 940 .  
Display message  
Check connection.  
Measures  
– Check whether terminals of  
battery charger are firmly  
connected to battery termi‐  
nals.  
– Check battery terminals are  
tightened according to reg‐  
ulations and do not have  
corrosion.  
Terminals connected?  
System noise  
Safety function of tester.  
lk  
– Connect terminals to battery  
before starting charging pro‐  
cedure.  
– Switch off all electrical con‐  
sumers.  
– Wait until all electrical loads  
monitored by onboard sup‐  
ply control unit have switch‐  
ed off.  
– Remove ignition key.  
– Disconnect any suspect  
electrical equipment not  
connected to onboard sup‐  
ply as standard.  
Wait a few minutes and repeat charging procedure ⇒ page 56 .  
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3.6  
Solar panel -VAS 6102A-  
3.6.1  
Charging battery in maintenance mode  
with solar panel -VAS 6102A-  
Solar panel VAS 6102A  
General description:  
Solar panel -VAS 6102A- supports onboard supply and prevents  
spontaneous battery discharging.  
Solar panel -VAS 6102A- achieves max. voltage of 14.3 V and a  
charging current of max. 255 mA.  
Solar panel -VAS 6102A- is allowed to be used for charging all  
rechargeable lead or lead gel batteries.  
Solar panel -VAS 6102A- is connected to diagnostic connection  
in vehicle.  
A green LED is integrated in the frame to indicate its function. The  
brighter the LED, the higher the charging current.  
Integrated electronics prevent battery overcharging.  
– Secure solar panel -VAS 6102A- on interior mirror -1-.  
– Place underside on dash panel -2-.  
Note  
Solar panel -VAS 6102A- is not allowed to lie fully on dash panel.  
It is only allowed to be positioned with the bottom edge for sup‐  
port. Placing it fully on the surface can result in discolouration of  
the dash panel.  
– Pull attachment string tight so that solar panel -VAS 6102A- is  
positioned close to windscreen.  
– Connect solar panel -VAS 6102A- to diagnostic connection of  
vehicle. Connection procedure is as for vehicle diagnostic  
tester ⇒ page 78  
– Check function of solar panel -VAS 6102A- . Green LED indi‐  
cates function of solar panel -VAS 6102A- .  
3.7  
Totally discharged batteries  
WARNING  
Danger of injury! Observe warning notices and safety regula‐  
tions ⇒ page 2 !  
A battery is designated „totally discharged“ when the no-load volt‐  
age is less than 11.6 V.  
3. Charging battery  
59  
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WARNING  
Batteries where the magic eye is colourless or light yellow must  
not be checked or charged. Do not slave/jump start the vehicle!  
Danger of explosion when checking and charging or slave/  
jump starting  
These batteries must be renewed.  
Caution  
♦ Totally discharged batteries freeze prematurely.  
♦ Frozen batteries should no longer be used.  
Note  
lk  
♦ Totally discharged batteries in vehicles before registration  
must be exchanged prior to delivery. Preliminary damage can‐  
not be excluded.  
♦ Batteries that have not been used for a long period of time  
discharge themselves, e.g. those fitted in stored vehicles.  
♦ In totally discharged batteries, the electrolyte is comprised al‐  
most entirely of water because the acid content is so low.  
♦ Totally discharged batteries sulphate, that means, the entire  
plate surfaces of the battery harden.  
♦ If a battery is recharged shortly after it has totally lost its  
charge, the sulphation will mostly dissipate.  
♦ If these batteries are not recharged, the plates continue to  
harden and the ability to recharge is reduced. The result of  
which is a reduction in the battery output.  
– Check battery no-load voltage ⇒ page 25 .  
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4
Cruise control system (CCS)  
General description:  
The functions of the cruise control system are controlled by the  
engine control unit.  
– The cruise control system can be activated/deactivated  
⇒ page 61 .  
Fault detection and fault display  
lk  
Faults on the CCS are output via the engine control unit.  
For fault finding, use vehicle diagnosis, testing and information  
system in „Guided fault finding“ mode.  
4.1  
Activating and deactivating cruise con‐  
trol system (CCS)  
– Connect vehicle diagnostic tester ⇒ page 78 .  
– Select „Guided fault finding“ mode in vehicle diagnostic tester .  
– Using „GoTo“ button, select „Functions/component“ and the  
following menu options in succession:  
♦ Drive  
♦ Engine code  
♦ 01 - On Board Diagnostic capable systems  
♦ Engine management/diesel direct injection and glow plug sys‐  
tem  
♦ Functions  
♦ Activating and deactivating cruise control system (CCS)  
4. Cruise control system (CCS)  
61  

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