V271501 2011894

Technical Bulletin
Model(s)
Year
Eng. Code
Trans. Code
VIN Range From
VIN Range To
1998-2015
All
All
All
All
All
(except Routan)
Condition
27 15 01 February 16, 2015 2011894 Supersedes Technical Bulletin V271402 dated December 3, 2014 to update
GRX3000VAS charger tool number.
Battery, Testing and Charging Using Midtronics VAS6161, MCR340V, InCharge 940, or GRX3000VAS
Charger
Note:
This technical bulletin covers testing and repair procedures for multiple vehicle lines, model years and engine
combinations. To prevent mis-diagnosis, you must ensure that the testing/repair procedure is applicable to the
vehicle you are servicing.
Technical Background
The VAS6161, MCR340V, In-Charge 940 (INC-940), and GRX3000VAS are the only VW approved battery testers
and chargers that can be used to test and charge batteries in VW vehicles. Use of non-approved battery testers
and chargers is not allowed, as internal battery damage may occur.
Production Solution
No production change required.
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Service
WARNING
Danger of injury! Prior to handling or servicing batteries, read, understand and observe all Warnings and
Safety Measures for lead-acid batteries.
Note:
In order to prevent damage to battery or vehicle, observe battery type descriptions and notes.
Tip:
• Switch off all electrical consumers.
• Switch ignition OFF and remove ignition key.
Battery Testing/Charging Sections:
2-1 All Models 1998 - 2015, Except Passat/CC 3.6L, Eos 3.2L, Golf VR4/R32, Touareg and Phaeton
2-2 Passat, Passat Wagon and CC with 3.6L 2006-2013 (Rear Battery)
2-3 Eos 3.2L 2006 - 2008
2-4 Golf VR4/R32 2008
2-5 Touareg 2004 - 2015
2-6 Phaeton 2003 - 2006
2-7 MCR340V, VAS6161, INC-940, GRX3000VAS Trouble Shooting Error Messages
2-1 All Models 1998 - 2015, Except Passat/CC 3.6L, Eos 3.2L, Golf VR4/R32, Touareg and Phaeton
Tip:
DO NOT remove battery from vehicle to test; always test battery in vehicle except for the following conditions:
• Battery was removed for a separate repair prior to performing battery test.
• Over the counter (after market) parts.
Page 2 of 17
© 2015 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
When testing or charging a battery either installed or removed from vehicle select appropriate battery type:
• Select “Standard” (Lead-Acid) function for ALL NON-AGM batteries.
• Select “AGM” function for Absorbent Glass Mat (AGM) batteries with “AGM” on battery label.
Always use actual DIN rating as shown on battery label -arrow-.
Tip:
Label shown is for example only. DIN or SAE specifications may
vary from battery to battery.
If DIN rating is not shown:
• Use SAE value as printed on the battery label.
If using SAE value rating:
• Midtronics tester menu option must be changed to achieve accurate results.
• A change from DIN to SAE can be made from the “Other” menu option on Midtronics tester.
2-2 Passat, Passat Wagon and CC with 3.6L 2006-2015 (Rear Battery)
Testing/Charging at Battery
Tip:
DO NOT remove battery from vehicle to test; always test battery in vehicle except for the following conditions:
• Battery was removed for a separate repair prior to performing battery test.
• Over the counter (after market) parts.
Passat Sedan, CC, 3.6L only 2006-2015:
• Select Lead Acid Battery for 3.6L engine (located in left side of trunk). 450 DIN.
Page 3 of 17
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All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
B6 Passat Wagon 3.6L only 2006-2008:
• Select Regular or AGM (Absorbed Glass Mat) for 3.6L engine (located in left side of trunk) as specified on the
battery label. 480-520 DIN AGM.
When testing or charging battery installed in vehicle:
• DO NOT Test/Charge from Remote Location.
• (3.6L) DO NOT use remote location (+) -arrow-.
• (3.6L) DO NOT use engine bracket (-) -arrow-.
Always use actual DIN rating as shown on battery label:
• (3.6L) Test/charge battery located in left rear trunk -arrow-.
• Passat Sedan / Passat CC 3.6L uses a lead acid battery 450
DIN.
• B6 Passat Wagon 3.6L uses an AGM battery. 480 or 520 DIN.
Page 4 of 17
© 2015 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
2-3 Eos 3.2L 2006 - 2008
Testing/Charging at Battery (Two 6-Volt batteries)
Eos 3.2L engine is equipped with two 6-volt AGM batteries which are connected in series to achieve 12-volts. The
battery system must always be treated as a 12-volt battery system. Never attempt to charge only one 6-volt
battery. If battery replacement is necessary, never replace one 6-volt battery; both batteries must be
replaced as a pair!
• Eos 3.2L AGM batteries shown are connected in series.
Tip:
DO NOT remove battery from vehicle to test; always test battery in vehicle except for the following conditions:
• Battery was removed for a separate repair prior to performing battery test.
• Over the counter (after market) parts.
Testing/Charging 6-Volt Batteries Out of Vehicle:
If batteries have been removed from vehicle, never attempt to test/charge one 6-volt battery; as stated above.
Treat batteries as a 12-volt system.
• Connect cable (Part No: 1Q0971226) to inner battery terminals.
Page 5 of 17
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All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
• Connect battery tester.
Tip:
Cable has (+) and (–) stamps on each terminal. Positive (+) terminal is a larger diameter than Negative (–)
terminal. DO NOT attempt to force the wrong terminal of harness onto a battery terminal if it does not fit.
1. Connect cable with positive (+) stamp to inner positive (+) terminal of 1st battery. When doing so, ensure that
the other end of the cable (negative) does not make contact with ground or any object. Tighten to 6Nm.
2. Connect the negative (–) terminal of the cable to the inner negative (–) terminal of the 2nd battery. Tighten to
6Nm (53 in. lbs).
3. Connect Midtronics tester positive (+) clamp (red color) to outer positive (+) terminal of 2nd battery.
4. Connect Midtronics tester negative (–) clamp (black color) to outer negative (–) terminal of 1st battery.
When testing/charging is completed:
1. Remove Midtronics tester negative (–) clamp (black color).
2. Remove Midtronics tester positive (+) clamp (red color).
3. Remove battery cable negative (–) connection at 2nd battery negative (–) terminal.
4. Remove battery cable positive (+) connection at 1st battery positive (+) terminal.
Page 6 of 17
© 2015 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Testing/charging 6-Volt Batteries in Vehicle:
INC-940 and GRX3000VAS
1. Connect Midtronics tester positive (+) clamp (red color) to outer
positive (+) terminal of battery.
2. Connect Midtronics tester negative (–) clamp (black color) to
outer negative (–) terminal of other battery.
MCR340V and VAS6161
1. Connect Midtronics tester positive (+) clamp (red color) to outer
positive (+) terminal of battery.
2. Connect Midtronics tester negative (–) clamp (black color) to
outer negative (–) terminal of other battery.
Testing/Charging In or Out of Vehicle:
Always verify using DIN rating as shown on battery label.
• Select AGM for 3.2L engine (located in the trunk, one 6-volt battery on each side of the ski-chute). 380 DIN.
Tip:
Label shown is for example only. DIN or SAE specifications may vary
from battery to battery.
Tip:
Two 6-volt batteries are connected in series to achieve 12-volts, the same current value will flow through each
battery. As a result, only use a DIN value of 380A, DO NOT double or halve this value when entering data into
Midtronics tester.
Page 7 of 17
© 2015 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
If DIN rating is not shown:
• Use SAE value as printed on battery label.
If using SAE value rating:
• Midtronics tester menu option must be changed to achieve accurate results.
• A change from DIN to SAE can be made from the “Other” menu option on Midtronics tester.
When testing or charging battery installed in vehicle:
• DO NOT Test/Charge from Remote Location (3.2L).
• (3.2L) DO NOT use remote location (+) -arrow-.
• (3.2L) DO NOT use engine bracket (-) -arrow-.
Page 8 of 17
© 2015 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
• (3.2L) Test/charge AGM battery located in trunk - one 6V
battery located on each side of ski chute, as shown.
2-4 Golf VR4/R32 2008
Testing/Charging at Battery
Tip:
DO NOT remove battery from vehicle to test; always test battery in vehicle except for the following conditions:
• Battery was removed for a separate repair prior to performing battery test.
• Over the counter (after market) parts.
When testing or charging battery either installed or removed from vehicle:
• Select Standard (Lead-Acid) battery. Located in right trunk area under spare tire and tool kit.
• Always use actual DIN rating from battery label.
When testing or charging battery installed in vehicle:
• DO NOT Test/Charge from Remote Location (3.2L).
• (3.2L) DO NOT use remote location (+) -arrow-.
Page 9 of 17
© 2015 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
• (3.2L) DO NOT use engine bracket (-) -arrow-.
Always use actual DIN rating from battery label.
• (3.2L) Test/charge (Lead Acid) battery located in the trunk.
2-5 Touareg 2004 – 2015
Testing/Charging at Battery
Single System – 3.0L (TFSI), 3.0L (TDI), 3.6L, and 4.2L Engines.
2.51 Start/Accessory battery
Always use actual DIN rating as shown on battery label.
Select Standard (Lead-Acid) for 3.0L TFSI 3.0 TDI, 3.6L, and 4.2L
engines (Battery located under driver's seat).
Tip:
MY 2004-2010 3.6L, 4.2L (450DIN)
MY 2009-2015 3.0L TDI (520DIN)
MY 2011-2015 3.0L, 3.6L (520DIN)
MY 2011-2015 3.0L TFSI Hybrid (420DIN)
Page 10 of 17
© 2015 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Dual System – 5.0L (TDI) Engine (2004-2008)
Accessory battery
Select Standard (Lead Acid) for 5.0L (TDI) (located under the
driver seat). 520 DIN
Starter battery
For 5.0L (TDI) engine (battery in trunk without rim). AGM 520 DIN.
(PR J2R)
For 5.0L (TDI) engine (battery in trunk located under spare tire).
Standard (Lead Acid) 450 DIN. (PR J2Q)
Note:
Starter battery must be checked independently of accessory
battery.
Starter battery cannot be tested or charged via the remote location
in engine compartment. To test or charge starter battery, go
directly to battery terminals.
Always use actual DIN rating as shown on battery label -arrow-.
Tip:
Label shown is for example only. DIN or SAE specifications may
vary from battery to battery.
Page 11 of 17
© 2015 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
If DIN rating is not shown:
• Use SAE value as printed on battery label
• If using SAE value rating:
• The Midtronics tester menu option must be changed to achieve accurate results.
• A change from DIN to SAE can be made from the “Other” menu option on Midtronics tester.
Testing/Charging from Remote Location (Reduced DIN Rating Requirement)
When using remote location terminals -arrows-, located in engine
compartment, always reduce DIN rating on MCR340V, INC-940,
VAS6161 and GRX3000VAS testers.
• 3.6L, and 4.2L engines: 270 DIN.
• 3.0L TDI, 5.0L(TDI) engine: 295 DIN.
• MY2011-2015 3.6L engine: 295DIN
Note:
For 5.0L (TDI) engine (dual battery system), starter battery cannot
be tested or charged via remote location in engine compartment.
To test or charge starter battery, go directly to battery
terminals.
Tip:
Use of these reduced DIN ratings are required to compensate for the internal battery manager and/or the
extended length of cable due to battery location.
2-6 Phaeton 2003 - 2006
Testing/Charging at Battery
Tip:
DO NOT remove battery from vehicle to test; always test battery in vehicle except for the following conditions:
• Battery was removed for a separate repair prior to performing battery test.
• Over the counter (after market) parts.
When testing or charging battery either installed or removed from vehicle:
• Select Standard (Lead-Acid) for 4.2L and 6.0L engines (located in right front trunk).
• Select AGM (Absorbed Glass Mat) for 4.2L and 6.0L engines (located in left side trunk).
Page 12 of 17
© 2015 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Always use actual DIN rating as shown on battery label -arrow-.
Tip:
Label shown is for example only. DIN or SAE specifications may
vary from battery to battery.
If DIN rating is not shown:
• Use SAE value as printed on battery label.
If using SAE value rating:
• Midtronics tester menu option must be changed to achieve accurate results.
• A change from DIN to SAE can be made from the “Other” menu option on Midtronics tester.
Dual System
Starter battery
Always use actual DIN rating as shown on battery label.
• Starter battery (Standard) located in right side trunk, as shown:
330 DIN.
Page 13 of 17
© 2015 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
On-board accessory battery
Always use actual DIN rating as shown on battery label.
• (AGM) On-board accessory battery located in left side trunk, as
shown: 480 DIN or 520 DIN.
When testing or charging battery installed in vehicle:
• DO NOT Test/Charge from remote location
• DO NOT use remote location (+) or (-), -arrows-, as shown.
• Test/charge batteries directly, located in trunk.
Tip:
There is a plastic sleeve on remote location (-), -arrow-.
2-7 MCR340V, VAS6161, INC-940, GRX3000VAS Trouble Shooting Error Messages
MCR340V / INC-940 Displays "System Noise" at Beginning of Test
MCR340V and INC-940 may display "System Noise" at beginning of battery test when testing directly at battery.
This is an infrequent and a normal message which may be caused by:
• Ignition left in "ON" position.
• Accessories or loads turned ON, with key in "ON" position.
• Loads running with ignition switched "OFF" such as: cooling fan or after-run coolant pump.
• Aftermarket equipment (due to improper installation), such as entertainment, security, remote starters,
televisions, lighting, etc.).
Page 14 of 17
© 2015 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
This may be overcome by verifying:
• Ignition is switched "OFF".
• All loads (cooling fan or after-run coolant pump) are OFF prior to testing.
• Any aftermarket equipment is disconnected from vehicle's electrical system.
Wait a few minutes, and then retest battery again.
Battery Testing Results: Midtronics MCR340V, VAS6161 Analyzer vs. INC-940, GRX3000VAS Charging
Station
In some cases, when testing a battery using the MCR340V tester:
Test results may be “Good Battery - Recharge”.
However, when attempting to charge the same battery with INC-940 Charger:
Results may be to “Replace Battery” either after testing or during charging process.
Tip:
This is normal since MCR340V, VAS6161 and INC-940, GRX3000VAS use a conductance test, but the INC-940,
GRX3000VAS also incorporates use of a 150A load test and ”sophisticated” charging algorithm which monitors
charging state of the battery.
In this case, results of INC-940, GRX3000VAS should always be used instead of MCR340V or VAS6161.
Testing/Charging: INC-940 Charging Station -Automatic ModeWhen using INC-940 Battery Charging Station in “Automatic Mode”, and testing or charging a deeply discharged
battery:
INC-940 may continuously display a message “Are clamps connected?”
In order to test battery:
• Manually charge battery for 30 minutes and perform test again.
Testing/Charging: INC-940 Charging Station -Manual ModeWhen using INC-940 Battery Charging Station in “Manual Mode”, and testing or charging a deeply discharged
battery:
INC-940 may display a message “Are clamps connected?” twice.
This is not a result of defective INC-940 test equipment, but is a safety feature of the INC-940 to ensure cables are
connected to battery before power is turned ON.
Page 15 of 17
© 2015 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
INC-940 Charging Station Always Displays “Check Connections”
INC-940 may constantly display a message to “Check Connections” after cables are connected to battery
terminals.
This is most likely due to the sensing probe making contact with the clamp.
Tip:
There is one sensing probe on each clamp, (+) and (-), make sure to check both!
• There must be no contact between the inside connection
and outside jaw of clamp -arrows-.
• Inside connection is bent and touching outside of the clamp,
-arrows-.
If clamp is incorrect:
• Use a small flat tool and gently bend sensing probe so it does not make contact with clamp.
If this does not resolve the issue:
• Contact Midtronics Corporation Customer Service Department at 1-800-776-1995 for assistance.
Page 16 of 17
© 2015 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Warranty
Information only.
Required Parts and Tools
Information only.
Additional Information
All part and service references provided in this Technical Bulletin are subject to change and/or removal.
Always check with your Parts Dept. and Repair Manuals for the latest information.
Page 17 of 17
© 2015 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.