VAG Vehicle Batteries Self Study

Service Training
Self-study Programme 504
Vehicle Batteries
Design and Function
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To “get the engine running” in a passenger vehicle, the engine first needs to be started.
The era in which drivers used their energy by starting the engine with a crank is long since gone – for good.
Nowadays, this strenuous task is “easily” accomplished by any vehicle battery (starter battery).
The vehicle battery – an integral and indispensable part of every passenger vehicle – ensures that:
1. the engine starts

2. electrical energy is available in every load situation
3. excess electrical energy is stored – and is fed back into the system when required.
As one of the most important electronic components, the vehicle battery forms a focal point in each and every
vehicle. There are good reasons why it is often referred to as the “heart of the vehicle”.
A vehicle battery should always perform its tasks in the vehicle flawlessly.
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Appropriate handling of the battery is therefore particularly
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This Self-study Programme contains the knowledge about vehicle batteries and rprovides
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important basic
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information on the correct, service-oriented handling of batteries.

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The self-study programme describes For current testing, adjustment and repair
the design and function of new instructions, refer to the relevant service
developments. literature. Important
The contents will not be updated. Note
2
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Historical details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Batteries yesterday, today and tomorrow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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The basics d.b.y V. . . . . . . . . . . . . . . . . . . . . .ot.gu. a.r . . . . . . . . .
o
.................. 6
e a
Battery risdesign . . . . . . . . . . . . . . . . . . . . . . . n.te.e . . . . . . .
................... 6
utho or
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Sulphuric
ss acid . . . . . . . . . . . . . . . . . . . . . . . . . . a. c. . . . .................... 8
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nl
Charging and discharging processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
pt
du
an
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Technical variables and terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
y li
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Battery types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
, is n
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Wet batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
spec
es, in part or in w
Good value batteries (economy batteries) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
t to the co
Enhanced flooded batteries (EFB). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Absorbent glass mat batteries (AGM batteries). . . . . . . . . . . . . . . . . . . . . . . . 15
rrectness of i
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VOLKSWAGEN batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Special features and characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
nform
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Battery installation locations in the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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Energy management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ion 30

c
in t
or
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Effects on energy management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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Vehicle electrical system concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

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Battery and alternator interaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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Discharge and temperature response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
agen
Prote AG.
Battery check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Jump starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Battery – operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Infosheet on handling starter batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Dangers when handling batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Test your knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3
Introduction
Historical details
The very first electrical cells, including the so-called “Baghdad Battery”, were already being produced 2000 years
ago. However, the actual history of the battery only begins in the 18th century. The battery is also referred to as an
accumulator. The word accumulator originates from the Latin term cumulus = heap, or the term
cumulare = accumulate. The accumulator is a rechargeable battery which stores electrical energy on an
electrochemical basis.
The battery was by no means invented overnight – it has many pioneers, such as:
Luigi Galvani (1737–1798), and Italian doctor, biophysicist, physiologist and physicist. He was able to observe
that the legs of dead frogs twitch as soon as he put them in contact with two different metals connected to each
other. Galvani unknowingly discovered that the combination nofAG. Volkswagmetals
different en AG (electrodes) form an element when
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placed in a suitable solution (brine in the frog's leg). o
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ara element, or galvanic
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cell, in honour of Galvani. A galvanic cell can ise
rconvert chemical energy into electrical nte
energy.
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Alessandro Giuseppe Antonio Anastasio Gerolamo Umberto Volta (1745–1827), Italian physicist. Inspired by
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the discoveries made by Luigi Galvani, he constructed the first viable battery. He alternated plates made of copper
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and zinc, layering them into a column. He placed pieces of cardboard or leather soaked in muriatic acid between
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the plates. This produced a series of galvanic cells connected in succession. This column was the very first viable
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source of electricity, and is known as a voltaic column. Following Volta's death, the unit of measurement for
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electrical voltage was named the Volt.
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Johann Wilhelm Ritter (1776–1810), German physicist and philosopher. Apart from discovering UV radiation,
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he also built a battery in the form of a column, which was named the Ritterian pile after him. The column was
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comprised of pieces of copper and cardboard, soaked in NaCl = sodium chloride (table salt), and layered
consecutively. This apparatus could be charged with an electric current, and emitted current when discharged.
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The Ritterian pile is therefore considered the original prototype of the batteries used today.
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Wilhelm Josef Sinsteden (1803–1891), German physician and physicist, who developed the first lead battery. He
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placed two lead plates, which weren't touching, in a container with diluted sulphuric acid, and connected a voltage
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source to them. After being charged and discharged repeatedly, the system achieved a certain capacity.
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Gaston Raimond Louis Planté (1834–1889), French physicist and palaeontologist. He improved the battery
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designed by Sinsteden by arranging the lead plates in a spiral shape. However, this lead battery was never
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Camille Alphonse Faure (1840–1898), French engineer and physicist. He made decisive enhancements to the
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lead battery. He covered both sides of a lead plate with a paste agmade ofollead
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Henri Owen Tudor (1859–1928), Luxembourgian ss engineer and inventor. He made the trial the lead model ofc
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battery suitable for industrial applications. He enlarged the surface and the layout of the electrodes in a way which
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increased capacity and the lifespan of the lead battery significantly. He gave the battery its box shape, which it
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retains to this day. Diluted sulphuric acid was used as an electrolyte. The negative electrode was made of lead, and
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the positive electrode of lead dioxide. Tudor produced casting moulds which made industrial-scale manufacture of
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lead plates possible. He developed the first lead battery used for technical applications.
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From then on, there was no stopping the success of the lead battery. Numerous companies were founded which
produced lead batteries. Initially, batteries were only installed in passenger vehicles to provide lighting. The battery
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has only been used as a starter battery since 1914.
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Primary advantages of the lead battery are:
• Good price-performance ratio

• High reliability
• Mass production
• Suitability for use
The evolution of the battery has not, however, come

to a standstill. In combination with the growing
prevalence of the electrical hybrid drive in particular,
and with the growth of electromobility now underway, S504_118
we can expect any number of innovations in battery
technology.
The battery is assuming an increasingly important role

in passenger vehicles. An overview of design and
operating principles of the batteries currently in use at
Volkswagen is given in the following.
5
The basics
Battery design
A 12-volt battery is comprised of six cells connected in
series. They are integrated into a housing divided into
sections by partitions. Positive plate set Plate block
The cornerstone of every battery is the cell. The cell is
comprised of a plate block which, in turn, consists of a AG. Volkswagen AG d
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The set of plates consist of electrodes and ss
separators.
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Each electrode is formed by a lead grid and an active
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material. The separator (microporous isolating
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material) is used to separate electrodes of different
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polarities. The electrodes or "plate blocks" are
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immersed in a 38-percent sulphuric acid solution
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urposes, in part or in wh
(electrolyte) when fully charged.
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Separator Negative plate set
The terminals, the cells and the plate connectors are
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all made of lead. The positive and negative terminal
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have different diameters. The positive battery terminal
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is always thicker than the negative battery terminal.
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The differing diameters prevent incorrect connection
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of the battery (reverse polarity protection).
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Taped-over cell plugs
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The cell connectors are guided through the cell
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Central gas vent opening
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The battery housing (the block box) is manufactured op
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features base bars on the outside for securing the co lksw
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battery. The housing is sealed by a cover at the top.
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Housing
The following types of battery are used at

Base bar
Volkswagen:
S504_005
• Wet batteries
• Good value batteries (economy) Because many parts of the battery are made of
• Enhanced flooded batteries (EFB) lead or lead compounds, and because sul-
• Absorbent glass mat batteries (AGM batteries) phuric acid is highly corrosive, utmost caution is
necessary when handling batteries.
6
The cells are connected in series by cell connectors. The required battery voltage is produced by connecting the
cells using the cell connectors. The negative pole of a cell is always connected to the positive pole of the next cell.
The battery fluid (electrolyte) is made of diluted sulphuric acid, which fills up the vacant space in the cell to the
“MAX” or “max” marking, as well as the pores in the plates and separators.
A number of cover designs feature screw-type cell plugs. This feature originates from a time when batteries needed
maintenance and were regularly refilled with distilled water. Nowadays, all VOLKSWAGEN batteries are
maintenance-free. Opening cell plugs in places where it is still possible to do so is no longer necessary, and is no
longer permitted by Volkswagen for safety reasons. The cell plugs are now only used for the first fill. When
charging, an explosive mixture of hydrogen (H2) and oxygen (O2) is produced in the battery. The gas is discharged
via the central gas vent opening.
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Cell connector
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Plate connector
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Positive plate set

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Positive lead plate

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Complete plate block

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Negative lead grid
Positive lead plate
Positive lead grid
7
The basics
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Sulphuric acid
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Motile sulphuric acid Bonded sulphuric acid
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Diluted sulphuric acid is used together with distilled To prevent damage due to the escape of sulphuric
water in a lead-acid battery. When fully charged, the acid, the sulphuric acid can be sealed in a glass mat.
proportion of sulphuric acid totals approx. 38%, with The mat binds the sulphuric acid and prevents the
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the remainder being water. Due to its ions, the battery fluid from escaping, for example in the event
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sulphuric acid is able to conduct an electric current of damage to the housing.

between the electrodes. An ion is an electrically
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or
charged atom or molecule.
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The density of the sulphuric acid changes according

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Acid density Charge level No-load voltage

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to the charge level of the battery; see table.
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The designations used in the table apply only for

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load-free batteries after resting. After the battery has
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1.10 g/cm3 0% 11.7 V
Charging and discharging processes
DC voltage source
Electron current
Lead sulphate
Lead sulphate
S504_007 S504_008
Battery when discharged Battery is charging
Hydrogen Oxygen Sulphate ions Lead Electrolyte
8
Charging Discharging
Feeding electric energy back into the battery is TheVremoval of electrical energy from the battery is
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referred to as charging. During the charging process, olks
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electric energy is converted into chemical energy. ed process, chemical energy ra nconverted into electric
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As soon as the engine is running, charge is supplied
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to the battery via the alternator. In electric vehicles, If a consumer is connected to the battery, it starts
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the 12-volt battery is supplied by the high-voltage discharging. The proportion of sulphuric acid
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battery; see SSP 499. This allows the lead sulphate decreases, and the proportion of water increases.
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(PbSO4) and water (H2O) formed during the Lead sulphate (PbSO4) is produced on both the
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discharging process to be turned back into lead (Pb), positive and negative plate.
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lead dioxide (PbO2) and sulphuric acid (H2SO4).
PbO2 + 2H2SO4 + Pb → 2PbSO4 + 2H2O
2PbSO4 + 2H2O → PbO2 + 2H2SO4 + Pb
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The result is -> the acid density decreases.
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The result is -> the acid density increases.
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The chemical energy required for discharging electric

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energy is available again.
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Electron stream
Lead dioxide
Lead
S504_009 S504_010
Battery when charged Battery is being discharged
Optimal regulated voltage is important for the charging process. If the regulated voltage is too high, more water is
electrolysed during the charging process. This causes the fluid level in, or saturation level of, the glass mat in the
battery to decrease. If the regulated voltage is too low, the battery will not be charged properly. Charging faults
decrease the lifespan of the battery and reduce its starting capacity.
Caution, risk of explosion! Oxyhydrogen gas is produced when a battery is charged.
9
The basics
Technical variables and terms

Capacity Cold test current
The capacity (C) is the amount of electricity (sum of The starting capability of a battery when it is cold is
the current rating and time)wwhich G. Volkswagen
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A A does
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a battery or cell, measuredy Vol in ampere-hours [Ah]. The ot gu The cold test current is the specified discharge current
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capacity depends orison the discharge current, battery atteewhich a new and fully charged battery, at -18 °C,
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temperaturessand ageing. will not fall below a defined voltage level before a
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The available capacity decreases significantly when defined period of time has elapsed (VW standard
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the discharge current increases and ambient 75073).
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temperatures fall.
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Current charge factor
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Nominal capacity C20
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When charging, the amount of energy fed into the
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The nominal capacity C20 is the battery capacity battery is always greater than the amount of energy
stipulated by the manufacturer in ampere-hours. It is which can be discharged.
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a measurement of the energy which can be stored in This is because energy losses always occur during
the battery when it is new. Standard EN 50 342 charging due to heat development and/or secondary
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specifies that a battery which is new and fully chemical reactions. inform
charged battery must, at a temperature of 25±2 °C
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and over the time period t20 = 20 hours, discharge a To charge a battery to 100%, it typically needs to be
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discharge current I20 = C20 / t20 without the battery fed current totalling 105% to 110% of the current
or
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voltage (U) falling below 10.5 V. discharge.

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Example: Cop
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One 12-volt battery, 80 Ah
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Battery voltage U 12 V
Nominal capacity C20 80 Ah
Discharge time t20 20 h
Discharge current I20 I20 = C20 / t20
Discharge current I20 I20 = 80 [Ah] / 20 [h] = 4 [A]
This means that a new and fully charged 80 Ah

battery must, given a discharge current of 4 A,
guarantee that the specified voltage of 10.5 V is only
reached after 20 hours have elapsed.
The nominal capacity is important when, for example,

designing the layout of the permanent consumers in
the vehicle electrical system.
10
Cell voltage Open-circuit voltage and no-load
voltage
The cell voltage is the voltage between the positive
and the negative plates of a cell. It largely depends The open-circuit voltage, or no-load voltage, is the
on the charge level (acid density) and the battery voltage of a battery which is not under load.
temperature. The open-circuit voltage changes after a charging or
For lead batteries, the nominal voltage of a cell must discharging process. Only after a delay in which the
be constant, and total 2 volts. concentration of sulphuric acid is equalised between
gen AG. Volkswagen AG do
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not will the open-circuit voltage reach its final
Vol
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value is referred to as the no-load
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The nominal voltage of sa cell is defined by standards
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at a value of 2 volts for vehicle batteries.
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The nominal voltage of the entire battery is the
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product of the nominal voltage of a cell multiplied by
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the number of cells.
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For vehicle batteries with six cells, the standardised
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nominal voltage totals 6 x 2 [V] = 12 [V].
Clamping voltage rrectness of i

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The clamping voltage is the voltage between the two

terminals of a battery.
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Gassing voltage
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The gassing voltage is the charge voltage above

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which the battery starts gassing significantly. This

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voltage is highly dependent on the temperature. t. C py
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The gassing voltage totals 2.4 volts per cell. pyri by
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For a 12-volt battery, this voltage level usually totals Prote
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6 x 2.4 [V] = 14.4 [V].

The gassing is the electrolysis of the water which the
battery fluid contains. This produces hydrogen (H2)
and oxygen (O2), which together form a mixture – the
highly explosive oxyhydrogen gas.
11
Battery types
Wet batteries
Batteries with liquid, motile sulphuric acid are referred to as wet batteries.
Because all VOLKSWAGEN batteries are maintenance-free, wet batteries no longer need to be refilled with
distilled water. This makes opening the cell plugs AG. Volkswagen G d it is also now prohibited. They are only used
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the first time the battery is filled with dsulphuric
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S504_119
12
Good value batteries (economy batteries)
Good value batteries are, based on their design, wet batteries, however with less use of lead. There is therefore a
weight advantage, even if its power is slightly lower. The good value batteries are not used as original equipment.
They are intended for vehicles without a start/stop system, and which are more than five years old (except for
premium vehicles such as the Touareg and Phaeton). These batteries also satisfy the Volkswagen quality standards.
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S504_105
13
Battery types
Enhanced flooded batteries (EFB)

At present, enhanced flooded batteries can be used
in vehicles with start/stop systems. This type of battery
can be identified by the lettering EFB which appears
on the battery cover. EFB is the abbreviation for
Enhanced Flooded Battery – an improved, more
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active material, depending on the manufacturer. S504_117
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• Addition of carbon to the negative material; this
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results in better power absorption and therefore

better charging characteristics.
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• Slight increase in lead use and weight.
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• High performance capacity the cells, which in turn leads to a lack of acid in the
• Suitable for start/stop systems with petrol engines upper part.
(beginning from 22/11)
• In terms of charge-discharge frequency, it is
between the wet battery and the glass mat battery.
Passive mixer element

Disadvantages
• Not leak-proof
S504_114
14
Absorbent glass mat batteries (AGM batteries)
The glass mat batteries, also called AGM batteries or recombination batteries as well (see glossary on page 57),
are used for vehicles with start/stop and energy recuperation systems. Glass mat batteries are batteries in which
the sulphuric acid is sealed in an absorbent glass mat (AGM). This battery type can be identified by the lettering
AGM appearing on the battery cover and the completely black battery housing. AGM stands for Absorbent Glass
Mat. This refers to a ‘fleece’ mat which is made of very fine, interlinked glass fibres, and which is highly absorbent.
This allows the entire quantity of sulphuric acid to be absorbed by the fleece mat. Glass mat batteries are therefore
considered leak-proof.
When the battery housing is damaged, very small quantities of sulphuric acid can still escape – but just a few
millilitres.
The battery is sealed by a battery cover. The cell plugs and the degassing vent are incorporated into the cover.
In terms of the escape of gas during charging, glass mat (AGM) batteries are closed systems, meaning that each
cell is separated from the atmosphere by a valve.
Design characteristics:
AGM lettering QR information field
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replaced.
• Designed for a high charging and discharging
frequency
15
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VOLKSWAGEN batteries ol not
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Special features and characteristics
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Central gas venting system
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The central gas venting system allows the gas to
escape from the battery at a defined point.
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The gas venting hose helps to discharge the gas at a
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specific, uncritical point. Depending on the battery's

installation location, the gas can be discharged from
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Central gas vent opening

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As specified in the fitting instructions for

VOLKSWAGEN batteries, only one of the two central
gas vent openings may be sealed by a sealing plug.
All current types of battery generally discharge the

gas via the central gas vent opening on the negative
terminal side.
Cell plugs
On glass mat batteries (AGM batteries) with cell O-ring Degassing vent
plugs, the O-rings prevent the gases from escaping opening
around the outer cell plug wall.
Each cell plug features a pressure relief valve which
Cell plugs
allows the gas to escape into the central degassing
vent.
The valve is required to trigger recombination (see
glossary).
Pressure relief valve
O-ring
S504_013
16
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Labyrinth cover
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All wet batteries feature a double cover. It consists of two parts, an upper part and a lower one. The double cover
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features a labyrinth system. This is why it is also referred to as a labyrinth cover. Central degassing vents and
spec
flashback prevention are integrated into the labyrinth cover.
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Function of the labyrinth Function of the central degassing vent and
the flashback prevention
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The water vapour produced when the battery is
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charged condenses (liquefies) on the battery cover The central gas venting system integrated into the
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and flows through the labyrinth and back into the cover allows the hydrogen-oxygen mixture
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battery as water. The labyrinth cover also ensures (oxyhydrogen gas) produced to be discharged to the
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that, under normal circumstances, no acid can escape central gas vent opening in the cover.
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if the battery is tilted. This increases the safety when This also allows the mixture to be deliberately
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handling batteries enormously. op
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The flashback prevention system consists of a small,

round plastic disc made of ABS (ABS = acrylonitrile
Battery cover, upper part butadiene styrene) This disc is referred to as a frit. It
has, as an example, a diameter of approx. 15 mm
and is approx. 2 mm thick. The frit is found in front of
Condensate (water) the central gas vent opening.
Water dripping back It functions in a similar way to a valve, meaning it

allows the gas (oxyhydrogen gas) produced in the
Steam
battery during gassing to stream out at a faster rate
Labyrinth due to the narrower cross section. If the gases
escaping through the gas vent opening ignite from
Battery cover, lower part the outside, then the frit prevents the flames from
spreading to the inside of the battery, which could
potentially cause a battery explosion.
S504_022
17
VOLKSWAGEN batteries
Battery labelling
Information about handling Data describing the battery Pictogram for the
is explained in each operating manual. performance and category information brochure
Warnings, primarily
for the North American
market QR code
Legally required
information on disposal AG. Volkswagen AG d
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Protective cap for the
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Production date code Electrolyte level indicator with sprayed-on sealing
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Data describing the battery performance and category
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000 915 105 DE Volkswagen Genuine Parts number
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12 V Battery voltage, stated in volts
61 Ah Nominal capacity (C20), stated in ampere-hours
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330 A DIN Cold test current according to DIN, stated in amperes at -18 °C
540 A EN/SAE/GS Cold test current according to EN, SAE and GS, stated in amperes at -18 °C
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Key to abbreviations
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DIN Deutsches Institut für Normung

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SAE Society of Automotive Engineers yri
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All VOLKSWAGEN batteries comply with the guidelines in the VW standard 75073 and the technical terms of
delivery TL 82506.
The battery labels must not, under any circumstances, be pulled off. They are a battery safety component. They
reduce the risk of the battery gas igniting from the outside due to electrostatic discharge.
18
A G. Volkswagen AG d
Manufacturer, country of manufacture
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The manufacturer data sis encoded on the battery
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VARTA Manufacturer name
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Made in Germany Country of manufacture
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VAO Encoded designation for the Varta S504_106
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manufacturing plant (manufacturer
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QR code
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All batteries feature an individual QR code specific to

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The QR code has the following aims: py Co
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• The fixed assignment of the battery installed at the cted
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factory to the respective vehicle by allowing the
S504_107
individual code for this battery to be archived
together with the vehicle identification number
(VIN) in a database.
A large amount of information is encoded in the QR
• Allow the type of battery and method of
code, such as:
production to be traced.
• In the event of a recall campaign, internal staff will
• Part number
know immediately which vehicles are affected.
• Date of manufacture
• Manufacturing code
The QR code can be read by a scanner connected to
• International reference number of the
the battery tester VAS 6161, and then evaluated in
manufacturing plant (DUNS)
the battery tester. This makes fast identification of the
• Assembly number
battery possible.
• Battery technology code
• Capacity
• Cold test current
19
Production date code

Legend
The production date of the battery is either stamped
a 09 = 9th calendar week
on the top of the negative terminal or embossed in the
b 12= year 2012
plastic near the negative terminal.
The coding appears as “calendar week/year”.
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Date of manufacture
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Date of manufacture coding
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A colour sticker with a letter is affixed to the front of
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the battery cover. In addition to the production date
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code, the sticker shows, as a code, the quarter and
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the year of production. This sticker is intended to
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provide the dealerships with a basis for applying the
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FiFo principle; also see page 52.
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S504_110
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Pictogram for the information brochure

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The pictogram for the information brochure above the

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positive battery terminal indicates that there is an

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information brochure in a plastic bag. This plastic bag

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has been affixed to the front of the battery.

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Information brochure
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The information brochure contains important notes on

handing the battery, installation instructions and a
usage table. There is no usage table for the start/stop
batteries.
Because the information brochure also includes

relevant safety information, it must remain affixed to
the battery. This ensures that if the battery is used for
other purposes in the future (e.g. battery removal for
external recharging), the required warnings and
installation information remains available.
This is why the information brochure is stored in a
S504_109
heavy-duty, resealable transparent plastic bag.
Information brochure
20
Tilt angle optimisation
On a number of vehicles, the battery must be tilted or rotated during removal and installation. All VOLKSWAGEN
batteries have been designed so that, when new, they can even be inverted for short periods without battery fluid
escaping. This is ensured by a double cover featuring the labyrinth system.
For other battery brands, there is a risk of sulphuric acid
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escaping from a new battery when it is held at an angle.
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Maintenance-free batteries
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A battery is referred to as maintenance-free when it does not need to be refilled with distilled water.
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All VOLKSWAGEN batteries are maintenance-free.
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Maintenance-free batteries are differentiated according to their installation location.
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Cool, maintenance-free installation
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location
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When the total water consumption amounts to a

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maximum of 6 g/Ah of the nominal capacity after
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42 days.
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Hot, maintenance-free installation location
When the total water consumption amounts to a

maximum of 3 g/Ah of the nominal capacity after
42 days.
S504_024
VOLKSWAGEN batteries satisfy all requirements of a hot, maintenance-free installation location.

For the test procedure, please see VW Standard 75073.
21
Maintenance-free batteries with cell plugs
These batteries can be distinguished by the electrolyte

(battery acid) level indicator and the taped-over cell
plugs.
The cell plugs are only used for the first fill. Opening
the cell plugs is not permitted.
S504_025
The adhesive tape must not be pulled off.
Maintenance-free batteries without cell

plugs
These batteries feature an electrolyte (battery acid)

level indicator, but no cell plugs. The cell plugs are
integrated into the cover. The battery Ais
G.sealed
Volkswaat
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S504_026
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The cover must not be removed, otherwise the

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battery will be damaged.

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Transparent housing on wet batteries Black housing for absorbent glass mat
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batteries
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All wet batteries, which means wet batteries,

enhanced flooded batteries (EFB) and good value Glass mat batteries, or AGM batteries, have a black
nf
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or
batteries (economy) feature a transparent housing. housing and a black cover. Because there are no
m
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Wet batteries and enhanced flooded batteries have a free-moving electrolytes in AGM batteries, the
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black cover. The good value batteries have a grey electrolyte level is not visible from the outside. A
thi
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cover, making it easy to distinguish them. The transparent housing is not required. The different
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transparent housing allows a quick check of the housing colours allow absorbent glass mat batteries
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electrolyte level in all cells when the battery is t. Cop to be easily distinguished from wet cell batteries.
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delivered and before it is installed in the vehicle. This
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22
Acid level indicator
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The battery must be place horizontally to check the acid level. byV gu
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Two-colour acid level indicator (ALI – acid level sindicator) s c
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The acid level indicator integrated into the battery cover (round inspection window) allows the acid level in a cell to
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be examined during the battery's service life. The acid level is indicated by a colour indicator.
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From early 2009 on, all wet batteries (OEM batteries and VOLKSWAGEN batteries) feature a two-colour acid
h re
ole,
level indicator, referred to as an ALI (acid level indicator). The ALI is also sometimes referred to as a “two-colour
spec
magic eye”.
t to the co
No conclusions about the charge level of the battery can be drawn from the acid level indicator.
The ALI makes two different colour indications possible.
rrectne
The label for the ALI has changed recently. This is why a few batteries may still feature the old sticker (with text). The
new label only uses one easily comprehensible symbol to explain the meaning of the colour indicator.
ss o
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Old
Light yellow
New
Acid level is too low.
The battery must be replaced.
S504_116
On batteries with an acid level indicator which appears clear or light yellow, no electrical tasks may be performed.
There is a risk of explosion when testing, charging or jump starting. These batteries must be replaced.
The battery must not, under any circumstances, be opened. Refilling with distilled water is therefore also not
allowed. Glass mat batteries (AGM batteries) do not feature an acid level indicator.
If the acid level cannot be clearly identified using

the acid level indicator, the battery must be
removed. The acid level then needs to be
determined from the outside, using the transparent
housing.
S504_130
23
Three-colour acid level indicator
Older wet batteries (prior to 2009) used a three-colour display, a so-called “magic eye”, to indicate the acid level.
The magic eye uses a three-colour display to indicate the charge level of the battery as well as to indicate the acid
level.
To make an exact assessment of the condition of the battery, a battery test using a battery tester VAS 6161 or
VAS 5097 A is required.
“Magic eye”
Green
Acid level is OK and the battery is sufficiently

charged.
S504_131
AG. Volkswagen AG d
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Acid level is OK and the battery is partially charged –

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S504_132
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Light yellow
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Acid level is too low.

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The battery must be replaced.

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Glass mat batteries (AGM batteries) do not py
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S504_133
Prote AG.
24
Battery installation locations in the vehicle
The installation location of the battery in the vehicle has a significant impact on its operating performance.
An optimum installation location for the battery must satisfy the following criteria:
• Easy accessibility for service and maintenance tasks

• Protected from severe heat/cold
• Protected from moisture, oil, fuels and mechanical influences
• Passengers are protected from gases escaping from the battery and escaping sulphuric acid in the event of a
crash.
Battery in the engine compartment

If, for reasons of design, the battery is close to the engine or close to mechanical units which emit high levels of
heat, the high temperatures could have a negative impact on the durability
lkswage of the battery. Corrosion
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Vo ot g
grid, water consumption and self-discharge increase. by uara
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To counteract these processes, the batteries are ss fitted
usually with a battery heat shield made of fibreglass.
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Battery in the engine compartment with battery heat shield
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Prote AG.
S504_136
25
Battery heat shield

The battery heat shield consists of the following components:
• Bracket: insulated or non-insulated

• Shield/battery box
• Sleeve:
- With or without cover
- Thin or reinforced
- With or without hermetically sealed barrier layer
The battery heat shield is required to reduce the impact of the following causes of damage due to the heat emitted
onto the battery:
Examples of battery heat shields
Sleeve with cover Battery box
lkswage es n
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byV ua
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tho
u or
a ac
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S504_134
nl
S504_135
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Water loss
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When charging a battery at charge voltage levels of approx 14.4 volts or more, more water is electrolysed into
h re
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hydrogen and oxygen, which escape as gases. This water decomposition process is highly temperature-dependent,
es, in part or in w
and the law of Arrhenius applies, which states that the reaction speed doubles with every 10 °C increase in
t to the co
temperature. This leads to a decrease in the electrolyte level and an increase in the acid density, and therefore to a
shorter service life.
rrectness of i
When the acid level sinks, there is a risk of explosion due to the potential for sparks to be generated. This is why
l purpos
battery replacement is specified when the lower electrolyte level is reached (see page 23).
nform
ercia
Corrosion
m
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The positive grid is subject to corrosion, which means that metallic lead (Pb) is converted into lead dioxide (PbO2)
o
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on the surface of the grid. The aforementioned law of Arrhenius also applies to this corrosive process. The steep
do
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increase in internal resistance results in battery failure. In addition, the mechanical pressure of the lead dioxide,
f
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with its lower density, on the remainder of the grid can cause the grid to grow, a process which may end in a short-
Cop
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Prote AG.
26
Battery in the vehicle interior/luggage compartment
If a vehicle does not remain on its wheels following an accident, battery acid may escape. The passengers are then
exposed to a risk of injury. To reduce this risk, tilt angle-optimised wet batteries or leak-proof glass mat batteries
are used for installation in the vehicle interior and luggage compartment.
Batteries in the vehicle interior/luggage compartment are always fitted with a gas venting hose.
When replacing the battery, make sure the following is observed:
• Only batteries with these characteristics may be used.

This is always the case with VOLKSWAGEN batteries.
lkswagen AG
n AG. Voin
• The gas venting hose must always be connected to the same gas vent opening
wage
the battery.
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Battery isolator elements
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When a battery is installed in the vehicle interior/luggage compartment, then a battery isolator element is also
pe
ility
ot
used. The task of this isolator element is to interrupt the line from the starter battery to the starter and alternator.
wit
, is n
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Should this relatively long wire short-circuit in the event of an accident, a potential outbreak of fire is prevented by
hole
spec
disconnecting it. If an airbag is triggered in the event of an accident, the battery isolator element is also
es, in part or in w
t to the co
automatically activated. In the event of a rear-end collision, the battery isolator element is activated when the belt
tensioner unit is deployed.
rrectness of i
The following components are used as battery isolator elements:
l purpos
nform
• Battery isolation igniter N253
ercia
• Battery cut-off relay J655, with battery master/isolator switch E74

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Battery isolation igniter N253 (1st version) Start position

t.
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Cop py
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yri by
Battery isolation igniter
p Vo
This version features the battery isolation igniter co lksw
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Prote
N253 integrated in the battery safety terminal.
AG.
The battery safety terminal is attached directly to the

positive terminal of the battery. Positive terminal
Conical pin
S504_104
Battery safety terminal
27
Once the propellant in the battery isolation igniter Ignition

has charged, the expansion of the gases pushes the
conical pin out of its starting position, forcing it in the
direction of the arrow.
S504_103
Expanding gases
Once the conical pin has been pushed away by the Final position
expansion of the gas, a counter-bearing prevents it
from springing back. This ensures the wire from the
battery to the starter and alternator remains
disconnected.
AG. Volkswagen AG d S504_102
agen oes
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Counter-bearing
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Start position
, is n
Battery isolation igniter N253 (2nd version)
h re
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spec
Pin
es, in part or in w
This version features a battery isolation igniter N253
t to the co
which is integrated in a connecting element. The
connecting element joins the wire from the battery to
rrectness of i
the wire to the starter and alternator.
l purpos
S504_101
nform
ercia
Connecting element
m
at
Battery isolation igniter
om
io
with terminals
n
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or
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ate
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py Co
Co py
Once the propellant in the battery isolation igniter Final position
ht. rig
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rig by
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has charged, the expansion of the gas pushes the by c lksw
Prote
cted Isolated contact AG. Piston with pin
agen
piston and pin in a way which isolates the contact in
the connecting element between the terminals.
S504_100
28
Battery cut-off relay J655, with battery master/
isolator switch E74
Another component which allows the wire from the

Battery cut-off relay J655
battery to the starter and alternator to be
disconnected is the battery cut-off relay J655. A
battery master/isolator switch is integrated in this
relay.
An activated battery cut-off relay J655 can be

identified through the inspection window. When the
wire has been disconnected, a white cover can be
seen through the inspection window instead of a
copper coil.
AG. Volkswagen AG d
agen oes
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Inspection window
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spec
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The voltage supply for the vehicle electrical system is maintained for all important safety functions, such as lighting
and the hazard warning lights, in all three cases described.
rrectness of i
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nform
mercia
Any battery isolation relays, and the battery cut-off relay J655, which have been tripped must be replaced. More
com
tion in
detailed information can be found in the workshop manual for the relevant vehicle in ElsaPro (electronic service
r
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information system).
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Prote AG.
29
Energy management
Effects on energy olkmanagement

. gen AG Volkswa
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Among other factors, theth battery capacity, the power required by the consumers
o eo in the vehicle electrical system, the
au ra
ss the alternator transformation ratio, the engine idlingc speed and the driving conditions all
alternator output and
ce
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un
pt
have a decisive impact on the vehicle's energy management.
an
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The vehicle battery functions as an accumulator which absorbs the energy, saves (accumulates) it and discharges it
rm
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at another point in time to the different consumers which require power.
ot
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To ensure that the battery has a sufficient charge level at all times, it must be repeatedly charged by the alternator.
h re
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If more energy is discharged than is absorbed, the battery gradually becomes “empty”.
spec
es, in part or in w
t to the co
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The following applies for energy management:
l purpos
nform
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• Ideal conditions for sound energy management

Energy output Energy input
are guaranteed by balancing the ratio of energy
m
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absorbed (charging) and energy released
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(discharging).
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• Any additional consumers which have been
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installed, or extreme driving conditions, will disrupt en

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the equilibrium of the energy management. t. C py
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• The total amount of power consumed and copyri by
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individual driving conditions are determining Prote
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agen
factors for energy management.

Energy storage
S504_112
Good power ratio

The vehicle is being driven on country roads during
Medium or high
the day, the weather is good, and the engine speed is Alternator
alternator speed
high.
The alternator is producing more power that is being

consumed by the electrical consumers which are Battery
running, e.g. the daytime running light, the radio or
navigation system. The battery is being charged with Battery is charging
the excess power.
Consumers
S504_035
30
Poor power ratio
The vehicle is driving through the city on a cold, foggy
night. The engine is running at a low speed.
Low alternator speed

Although the alternator is producing power, this Alternator
power is not sufficient to supply all the electrical
consumers which are running, such as the low beam
headlights and fog lights, seat heating, exterior mirror
heating and heated rear window. To ensure that all Battery
consumers running still obtain enough power,
additional power is drawn from the battery. The Battery is discharged
battery is discharged.
Consumers
Even more critical is the lower level of power
absorption by the battery when it is very cold.
Recurring discharge (e.g. due to the Coming Home S504_036
function/Leaving Home function, running-on) will

hardly be compensated for when it is very cold.
AG. Volkswagen AG d
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Processes in the onboard supply controled byV gu
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unit J519 uthor eo
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Onboard supply control unitacJ519 in the Touareg
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nl
Information from the control units and relays installed

pt
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in the vehicle are processed in the onboard supply

erm
ab
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control unit.
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The onboard supply control unit is responsible for

spec
es, in part or in w
managing the loads on the various convenience

t to the co
consumers. It also monitors the charge level of the

battery.
rrectness of i
l purpos
When it reaches a specified threshold, the idling

speed of the engine is increased. As a result, the
nform
ercia
alternator speed increases and the voltage in the

m
at
vehicle electrical system improves again.

om
ion
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or
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S504_037
t
When a vehicle is started, or when the safety-relevant

a
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consumers are not being supplied with sufficient

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energy, the onboard supply control unit briefly op
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switches the convenience consumers, such as the rear rig
ht.
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rig
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window heating, off. by co Vo
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Prote AG.
31
AG. Volkswagen AG d
agen
Energy management
oes
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byV gu
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Vehicle electrical system concepts
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Single-battery vehicle electrical system concept
h re
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spec
es, in part or in w
t to the co
In standard vehicles, the function of the battery is to supply electrical consumers with power and ensure there is
energy to start the engine. All consumers are supplied by the battery in all operating modes. As a result of the high
rrectness of i
level of vehicle equipment and in particular the high levels of power required for a cold start, it is possible that only
one battery will not be adequate for a reliable power supply.
l purpos
nform
ercia
If this is the case, then either the

• Auxiliary battery
m
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or the
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• Two-battery vehicle electrical system
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is used.
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Auxiliary battery Cop py
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An auxiliary battery ensures that enough power is available to start the engine even after a prolonged standstill
agen
Prote AG.
with electrical consumers switched on, e.g. when camping.
Features
• When the engine is running, the battery and the auxiliary battery are connected in series and are charged by
the alternator.
• When the engine is switched off, both batteries are isolated by a isolator relay.
Auxiliary battery, e.g. in campervans
S504_064
32
AG. Volkswagen AG d
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Two-battery vehicle electrical system a ra
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an
d
Vehicles with a two-battery electrical system are itte When in driving mode, the battery monitor control
y li
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equipped with a vehicle battery as well as a starter unit uses a DC/DC converter to recharge the starter
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battery. battery to an optimal level. DC stands for Direct
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Current.
spec
es, in part or in w
The two-battery vehicle electrical system is, in the
t to the co
Phaeton for example, comprised of the starter battery In the two-battery vehicle electrical system in the
A, the vehicle battery A1, the battery parallel circuit Touareg (V10 TDI), the onboard supply control unit
rrectness of i
relay J581 and the battery monitor control unit J367. J519 assumes the function of the battery monitor
l purpos
control unit (J367).

The starter battery supplies the starter circuit with Starting the engine despite the vehicle battery being
nform
ercia
power to start the engine, while the vehicle battery discharged is also possible in this case. The starter
m
powers the 12-volt vehicle electrical system. battery is, however, only recharged when there is
a
com
tion in
excess power in the vehicle electrical system, meaning
r
te o
thi
Starting the engine when the vehicle battery is the DC/DC converter is not used.
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discharged is still possible. This is controlled by the
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battery monitor control unit and the battery parallel

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circuit relay. gh
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pyri by
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Prote AG.
Two-battery vehicle electrical system e.g. in the Phaeton
Starter battery A
Battery parallel circuit relay J581
Vehicle battery A1
Battery monitor control unit J367
S504_065
33
Energy management
Battery and alternator interaction

The alternator output, the battery capacity and the
power required by the consumers must be adequate
Alternating current
for the entire vehicle electrical system to be operated
reliably and without faults. Alternator
The size, type and design of an alternator are the

result of its function, which is to supply a sufficient
amount of power to supply the consumers and charge AG. Volkswagen AG d
agen oes
olksw not
the battery. by
V gu
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ed ran
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tho Rectifier
or
Alternators produce alternating current. However, the au ac
ss
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vehicle electrical system requires direct current. The

un
pt
an
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itte
alternating current is converted into direct current by
y li
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the rectifier in the alternator.
ility
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Consumer Battery
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spec
es, in part or in w
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rrectness of i
Direct current
S504_040
l purpos
nform
mercia
a
com
tion in
The power required by a consumer is calculated using the following equation:

r
te o
thi
s
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Example calculation:
r
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i t.
Rear fog light consuming power totalling 55 W and voltage of 12 V. py Co
t. Co py
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Power P [W] lksw
Rated current I [A] = Prote AG.
agen
Voltage U [V]
P
I=
U
Power 55 [W]
Rated current I [A] = = 4,6 [A]
Voltage 12 [V]
34
AG. Volkswagen AG d
agen oes
olksw not
byV gu
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au ra
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nl
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Discharge and temperature response
erm
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Self-discharge
hole
spec
es, in part or in w
t to the co
Even when no consumers have been connected to a battery, the electricity in a battery will still “run out” after a
certain amount of time. This process is called self-discharge. The cause of self-discharge are chemical processes
rrectness of i
which occur in the battery.
l purpos
The level of self-discharge largely depends on the battery technology and the temperature.
nf
ercia
orm
m
To minimise self-discharge, a lead-calcium alloy is used as the electrode material instead of an alloy made of lead
atio
om
n in
antimony. Another advantage of this alloy is that self-discharge does not increase despite advancing age of the
or c
thi
e
battery.
t
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Self-discharge amounts to approx. 0.1% per day, i.e. approx. 3% per month. yi
t.
Co
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The lead-calcium alloy allows the accelerating effect of the lead-antimony alloy to be avoided. The low self- by copy Vo
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discharge rate of the positive and negative plates remain virtually constant over the entire period of use. For every Prote AG.
10 °C increase in temperature, the self-discharge factor doubles (law of Arrhenius).
Self-discharge is of special significance for vehicles in seasonal use and which are not, or seldom, driven in winter.
This applies, for example, to the agricultural, forestry and construction industries, but also often to convertibles as
well.
35
Energy management
Discharge due to no-load current

The no-load current is the current which is sourced from the battery once the engine has been switched off and no
electrical consumers are running any more.
The cause of this no-load current is the control units which still need to react to external events despite being
seemingly inactive, such as the vehicle clock, traffic report memory, remote control and anti-theft alarm.
Furthermore, there are an increasing Vnumber of control units which are not activated by the ignition (terminal 15),
AG. olkswagen AG d
agento the battery and
but rather are always connected
sw ocan
es n only be activated via the CAN bus.
olk ot
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tho eo
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nl
pt
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ab
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, is n
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Transport mode
hole
spec
es, in part or in w
t to the co
Touareg model year 2011 with
Transport mode is a special vehicle state in which the
activated transport mode and
load placed on the battery by the vehicle is kept as battery charge level of 70%
rrectness of i
low as possible. When transport mode is active,
l purpos
functions which are not essential are shut down. These

include the interior monitoring, the radio, the clock,
nform
ercia
etc.
m
at
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ion
c
Transport mode is activated and deactivated by the

in t
or
his
te
vehicle diagnostic tester using the “Activate/

a
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deactivate transport mode” function in the operating

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mode “Guided Fault Finding” and “Guided i t.

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Functions”. rig
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Deactivating the functions mentioned above reduces Prote AG.
the power consumption. When transport mode is

activated, instead of the dash panel insert displaying S504_113
the odometer when the ignition is switched on, it
displays either the battery charge level in percent (%)
or the open-circuit battery voltage in volts (V),
depending on the brand and platform.
36
High temperature Low temperature
High temperatures speed up the chemical processes At low temperatures, the chemical processes are less
in the battery. The reaction speeds double with every effective due to the increasing viscosity of the
10 °C increase in temperature. sulphuric acid. The internal resistance of the battery
increases. Falling temperatures therefore lead to a
• Due to the low viscosity of the acid, the battery steady decrease in the available battery capacity. The
power increases. The capacity increases slightly. capacity of the battery should therefore not be
• The high temperatures damage the plates. An designed too small. Otherwise there is a risk that
increase in grid corrosion occurs. when the weather is very cold, the engine will not be
• The chemical self-discharge by the battery able to be started with the required engine speed.
increases due to the high temperatures.
AG. Volkswagen AG d
agen oes
olksw not
y V greater the level of battery discharge,
The gu the
d b ara
rise higher the proportion of water in the battery nte
tho e
s au fluid. During discharge, a chemical reaction or ac
s occurs in which the sulphuric acid reacts with
ce
le
un
pt
lead dioxide and lead. This produces lead
an
d
itte
y li
sulphate and water.
rm
ab
Discharge voltage
pe
ility
ot
wit
PbO2 + 2H2SO4 + Pb ----> 2PbSO4 + 2H2O
, is n
h re
hole
spec
20 °C The water produced this way increases the
es, in part or in w
t to the co
proportion of water in the battery fluid, thereby
changing the freezing point.
-40 °C 0 °C Totally discharged batteries can freeze at a
rrectness of i
temperature of just 0 °C, which can cause hair-
-20 °C line cracks to appear in the battery housing.
l purpos
nform
ercia
Discharge current S504_045

m
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com
tion in
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Cop py
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Voltage Charge level cop Acid density
yri Freezing point
by
Vo
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12.7 V 100% 1.28 g/cm3 Prote AG.
<-50 °C
12.5 V 80% 1.24 g/cm3 -40 °C
12.3 V 60% 1.21 g/cm3 -30 °C
12.1 V 40% 1.18 g/cm3 -20 °C
11.9 V 20% 1.14 g/cm3 -14 °C
11.7 V 0% 1.10 g/cm3 -5 °C
37
Energy management
Frozen battery acid

A battery in which the battery acid has frozen must
not be used or charged.
• Check the battery before winter starts.

Defective batteries must be replaced.
• Never charge a frozen battery.
• Volumetric expansion of the frozen
sulphuric acid could cause micro-hairline lkswage es n
o ot g
cracks to appear in the battery housing. b yV ua
d ran
ir se tee
This will result in damage to tthe
ho vehicle or
au ac
body. Volkswagen explicitly
ss states in the
ce
e
operating manual that batteries which

nl
pt
du
an
have frozen must be replaced.
itte
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ility
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S504_046
wit
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spec
es, in part or in w
t to the co
rrectness of i
Cold start
l purpos
nform
ercia
A cold start is the greatest possible strain which can be placed on a battery.
m
at
om
ion
c
Three additional factors occur when cold starting:

in t
or
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ate
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• The mechanical resistance of the engine is greater, as the engine oil is more viscous. The starter therefore needs
um
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t.
more energy. op
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C
• The output from the battery is reduced significantly by the cold and the resulting higher internal resistance.
t. rig
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pyri by
• The battery is not fully charged due to the low temperatures. co Vo
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Prote AG.
The battery must be in a good condition to be able to provide full power in the event of a cold start.
38
Service
Battery check
Visual inspection
Before any electrical work is carried out on the battery (e.g. measuring the no-load voltage, battery load test, etc.),
a visual inspection must be made.
Battery housing Battery heat shield
The battery housing and the battery cover must not To ensure the battery is protected from negative
sustain any damage. Damage to the housing or the effects of thermal radiation, the battery heat shield
cover could allow sulphuric acid to escape. Any (e.g. sleeve) must be fitted to the battery properly.
sulphuric acid which leaks out could cause severe If the battery is not adequately protected against
damage to the vehicle. Components which were in heat, then the positive grid corrosion increases due to
contact with acid need immediate treatment with acid the excessively high temperatures.
neutraliser or a mild soap solution.
Batteries with a damaged housing or cover must not
be repaired. It is essential they are replaced.
AG. Volkswagen AG d
agen oes
olksw not
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Battery terminals and clamps horis
Battery attachment eo
aut ra
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The battery terminals and clamps must not exhibit any The battery terminal strip must be checked for correct
un
pt
an
d
itte
signs of damage. The battery terminal clamps must be seating of the lugs on the base bar. Adapters may y li
rm
ab
pe
correctly installed and tightened with the appropriate have to be used. The fastening screw must be
ility
ot
wit
, is n
torque. If the battery terminal clamps have not been tightened with the specified torque.
h re
hole
installed and tightened correctly, the voltage supply Incorrect fastening of the battery can reduce its
spec
es, in part or in w
may be disrupted. This results in considerable lifespan considerably, due to vibration damage.
t to the co
malfunctions in the vehicle electrical system. Reliable Damage to the grid plates may occur, and the battery
vehicle operation is no longer guaranteed. may explode.
rrectness of i
Incorrect fastening of the battery terminal bar may

l purpos
cause damage to the battery housing.

Inadequate fastening of the battery may result in a
nform
ercia
loss of crash safety.

m
Older vehicles require batteries with a high base bar,

com
tion in
i.e. the corresponding base bar adapter (part number

r
te o
thi
000 915 413) must be used (see page 51). A secure

s
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do
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rp
battery fit is checked as part of the main inspection.

um
fo
en
ng
i t.
py Co
t. Co py
rig
h ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
39
Service
Acid level AG. Volkswagen AG d

agen oes
olksw not
byV gu
ara
The correct acid level d
ris in the battery is an important
e nte
tho eo
factor for operational
s au reliability and safety of the ra
c
s
battery.
ce
e
nl
pt
du
an
itte
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erm
ab
If the acid level is too low, then the conductive
ility
ot p
components made of lead (see page 7: plate
wit
, is n
h re
connectors, cell connectors and tabs) above the plate
hole
spec
set are exposed and no longer surrounded by the
es, in part or in w
t to the co
electrolyte.
rrectness of i
Corrosion will occur on these lead components. The
consequences include everything from malfunctions
l purpos
to battery explosions.
nform
ercia
If the acid level is too high, battery acid may escape

m
at
S504_137
om
io
and cause damage to the parts affected.
n
c
in t
or
his
ate
do
riv
The electrolyte in a battery can be identified using the

p
cum
for
acid level indicator, or from the outside using the

en
ng
t.
yi Co
op
“MAX”, “max” and “min” markings respectively on the . C py
rig
ht ht
rig
transparent battery housing. copy by
Vo
by lksw
cted agen
Prote AG.
Batteries with ALI do not feature the lettering “min”.
When a visual inspection of the electrolyte level is

made from the outside through the transparent box,
then attention must be paid to a uniform electrolyte
level in all cells. Substantial differences (e.g. >10 mm)
indicate an internal battery fault.
S504_098
Observe the safety information.

Please adhere to the instructions in ElsaPro (electronic service information system professional).
The sulphuric acid is sealed in a fibreglass mat in the glass mat batteries (AGM batteries). Glass mat batteries do
not feature an acid level indicator and have black housing. Checking the acid level is therefore not possible on
these batteries.
40
Electrical test
AG. Volkswagen AG d
agen oes
olksw not
Electrical battery tests can be performed using the battery testerby V VAS 6161 or VAS 5097 A. gu
ara
ed
ris nte
tho eo
au ra
ss c
ce
e
nl
pt
du
Battery tester VAS 6161
an
itte
y li
erm
ab
ility
The battery tester VAS 6161 should be used ot p
wit
, is n
h re
whenever possible when performing electrical tests on
hole
spec
the battery.
es, in part or in w
t to the co
When taking measurements using the battery tester
VAS 6161, no battery load test is performed, but
rrectness of i
rather a different measuring principle is used, namely
the so-called conductivity measurement. This involves
l purpos
measuring the internal resistance of the battery. The

measurement is immediately analysed by the tester
nf
ercia
orm
and the result appears on the display.
m
atio
m
Because testing with this tester does not place a load

o
n in
or c
on the battery, it is possible to test batteries with a low
thi
te
sd
iva
charge level as well.
o
r
rp
cu
o
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f
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yi
t.
Co S504_097
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
Advantages Prote
cted AG.
agen
• The battery does not need to be removed or

disconnected to conduct the test.
• The test only takes around 10 seconds.
• The test does not require a cooling down phase,
making several measurements in succession
possible.
• The tester features an integrated printer.
• The tester also contains an SD card for saving the
data collected.
• All VOLKSWAGEN genuine battery types are
stored in the battery tester VAS 6161.
• The tester can be updated.
• A temperature sensor has been integrated into the
tester, which allows a non-contact temperature
measurement using its infrared operating
principle. S504_111
• Using a QR scanner is also possible.
• By scanning the data from the QR code, incorrect
battery tester VAS 6161 settings can be avoided.
41
Service
. Volkswagen AG
gen AG does
swa
Battery tester VAS 6161 operating modes y Volk not
gu
edb ara
ris nte
ho eo
ut ra
The battery tester VAS 6161 can operate in three
ss a c
Tester designation
ce
le
different operating modes.
un
pt
an
d
itte
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rm
ab
pe
ility
ot
Maintenance mode
wit
, is n
h re
hole
spec
Workshop
Maintenance mode is used for new vehicles in the
es, in part or in w
t to the co
work and storage program prior to registration, as it Technician
allows the quality of the battery to be tested at every Vehicle
rrectness of i
point in time while in storage. registration
l purpos
Date and time

Guarantee mode
nform
ercia
Type of test
m
This mode is used for batteries in the guarantee
a
com
tio
Battery test result
n in
period. A clear statement is available straight after
r
te o
thi
testing, stating whether the battery can be invoiced on Voltage measured
s
iva
do
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the warranty or not.

rp
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Measured battery cold
fo
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i t. start value
py Co
Service mode Co py
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Preset nominal battery cold start
py by
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cted agen value on the tester
The service mode is suitable for all vehicles not Prote AG.
covered by a warranty, and for batteries made by
Measured battery
other brands. This mode provides good arguments for temperature
discussions with customers, and indicates the need for
prompt battery replacement. Battery installation location
Position of the battery clamp

S504_096 set on the tester
Battery technology setting
QR scanner VAS 6161/1
A QR scanner VAS 6161/1 can be ordered as an

optional accessory for the battery tester VAS 6161.
By scanning the QR code, the scanner allows lightning
fast recording of all battery data required for the
battery test. This data would otherwise have to be
inputed manually.
S504_121
42
Battery tester VAS 5097 A
AG. Volkswagen AG d
In a number of workshops, the electrical tests of the lkswagen oes
not
Vo gu
batteries are still conducted using an older tester, by
dthe ara
se nte
ri
battery tester VAS 5097 A. ho eo
ut a ra
ss c
ce
e
nl
pt
This battery tester allows the capacitance of the du
an
itte
y li
erm
battery to be tested. To do so, the battery is subject to
ab
S504_095
ility
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a cold test current for a certain amount of time. The
wit
, is n
cold test current is defined according to varying test
h re
hole
spec
conditions in different countries.
es, in part or in w
t to the co
The battery's ability to start when it is cold is usually
more important that the capacity of the battery. The
rrectness of i
cold test current is a measure of the battery's ability to
l purpos
start, as it is based on the current drain at low

temperatures.
nf
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orm
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atio
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or c
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Advantages
o
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f
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t.
yi Co
Cop py
t. Measuring range set on the
rig
• When performing the capacitance test, removing pyri
gh by
Vo
ht
device
co
the battery or disconnecting the battery is not by lksw
cted agen
Prote AG.
necessary. Diagram with the arrow
• The test results can be printed out on the showing the battery status
integrated printer.
Test result
Disadvantages
• The tester requires approx. 30 minutes to cool Battery voltage during the
test
down before being ready for the next test.
• The battery is only designed to be tested once.
Before repeating a test, it therefore has to be Vehicle data and the date must
recharged. be filled in by the person in
charge of the test
S504_094
43
lkswage es n
o ot g
Service byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
Charging the battery
ot p
wit
, is n
h re
hole
spec
If the electrical test of the battery reveals that the Battery charger VAS 5095 A
es, in part or in w
t to the co
battery needs charging, then the following points must
be taken into consideration:
rrectness of i
• Observe all accident prevention regulations
• Ensure adequate ventilation in the room l purpos
• Observe the minimum battery temperature of
nform
ercia
10 °C
m
at
om
• Discontinue charging the battery at an acid
ion
c
S504_122
in t
temperature of >55 °C
or
his
ate
• Do not quick-charge batteries; quick-charging
do
priv
cum
Battery charger VAS 5900
or
damages the battery

f
en
ng
t.
yi Co
Cop py
t. rig
The following special tools can be used for charging pyri
gh by
ht
co Vo
the battery: cted
by lksw
agen
Prote AG.
S504_123
• Battery charger VAS 5095 A
• Battery charger VAS 5900
• Battery charger VAS 5901 A Battery charger VAS 5901 A
S504_124
• Observe the operating manual for the

battery charger!
• Observe the instructions in ElsaPro
(electronic service information system
professional). S504_125
• On vehicles featuring a start/stop system
or an energy recovery function, the black
terminal clamp (–) must be clamped on the
earth connection. The cylinder block, for
example, or metal components firmly
bolted to the cylinder block, can be used as
an earth connection.
S504_126
44
Charging totally discharged Charge retention
batteries
If vehicles are parked for longer periods, the batteries
A battery is considered to be totally discharged when in the vehicles will discharge. To counteract the
the acid density falls below 1.14 g/cm3. Batteries in discharge process in parked vehicles, charge
vehicles which have not been driven for a long time retention is used. It is used to compensate the
are subject to considerable discharge. discharge. Low charge voltages are used to keep the
The battery is discharged by the no-load current and battery fully charged.
the effects of temperature.
To perform charge retention, the following special
tools can be used:
• Solar charger VAS 6102 A

• Battery charger VAS 5095A
• Totally discharged batteries may freeze in • Battery charger VAS 5900
winter due to the high proportion of water
in the battery fluid.
• Frozen batteries must be replaced. • Battery charger VAS 5903
• Totally discharged batteries will sulphate, • Battery charger VAS 5906
meaning the plate surfaces in the battery
start to harden. If totally discharged
batteries are charged immediately after
being drained, the layer of sulphate will
olkswagen AG
recede again. However, the ability en AG. V
agto does
olksw not
absorb the charge is limited y Vand the gu
is
battery capacity is reduced.
r
edb Solar charger ara VAS 6102 A
nte
ho eo
• The charging period aut must last for at least ra
ss c
The solar charger is fitted behind the windscreen so
ce
24 hours.
e
nl
pt
du
that it hangs from the inside rear mirror and its base is
an
• If totally discharged batteries are charged

itte
y li
erm
too quickly, they will not absorb any resting on the dash panel. The solar charger is
ab
ility
ot p
charge current or will indicate full charging connected to the diagnostic connection of the vehicle.
wit
, is n
too soon. However, they only seem to be

h re
hole
fully charged.
spec
• Totally discharged batteries initially only

es, in part or in w
t to the co
absorb a small charge current.

• Totally discharged batteries in stock or
stored vehicles must be replaced before
rrectness of i
delivery.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
i t.
py Co
t. Co S504_127
py
rig S504_020
h ht
rig by
copy Vo
by lksw
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Prote AG.
45
Service
The battery charger VAS 5906 has been specially

developed for charging the vehicle electrical system
of showroom vehicles.
The maximum charge voltage of 14.4 Vois l wage
ksnot es n
ot g
byV ua
exceeded. All electrical consumers edare balanced by ran
oris tee
th
the buffer charge of up to 30auA. or
s ac
s
To maintain operation, the battery charger switches to
ce
e
nl
pt
du
charge retention once the battery is fully charged. The
an
itte
y li
erm
unit starts automatically and no settings need to be
ab
ility
ot p
made. Only the terminal clamps and the mains cable
wit
, is n
S504_128
h re
need connecting.
hole
spec
es, in part or in w
t to the co
Backup power supply Battery charger VAS 5095 A
rrectness of i
l purpos
When service and maintenance work is performed on

networked vehicles (e.g. flashing control units), the
nf
ercia
battery is subject to a high load and needs the back
orm
m
up of a charging unit. The backup power supply
atio
om
n in
ensures that the battery does not discharge
or c
thi
e
excessively. The backup power supply connects the

t
sd
iva
o
r
rp
cu
battery, charging unit and the current consumers with

o
m
f
S504_122
en
ng
each other. The charging unit provides the current to yi

t.
Co
op py
maintain the charge level of the battery at 100%. ht. C rig
ht
rig by
py
The battery provides peak current to the consumers, by co Battery charger VAS 5900
Vo
lksw
cted agen
although it is charged at a constant voltage. Prote AG.
The following special tools can be used for the

backup power supply: S504_123

• Battery charger VAS 5900 Battery charger VAS 5903
In vehicles with a second battery, ensure that

the correct battery is connected to the backup
power supply.
S504_125
46
Jump starting
If the battery is discharged and the vehicle will not start, the vehicle can be started with the aid of an external
power source. A battery starter or a battery in a jump starting vehicle can be used as an external power source.
Battery starter VAS 5098

lkswage es n
Vo ot g
The compact, portable battery starter y ua
d VAS 5098 with
b ran
ir se tee
its two-meter long jump leads cant o
h be used for jump
u or
s a ac
starting. s
ce
le
un
pt
an
d
itte
y li
The battery starter provides non-mains jump starting
erm
ab
ility
ot p
power for vehicles with discharged/weak batteries.
wit
is n
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ole,
spec
Depending on the outside temperature and the
battery capacity, between 15 and 30 starts can be
t to the co
performed. The device is protected from total
S504_129
discharge and it functions without voltage peaks.
rrectne
Once the jump starting process has finished, the de-
s
energised terminal clamps can be removed from the
s o
cial p
f
vehicle battery.
inform
mer
atio
m
The safety electronics in the battery starter • Observe the operating manual for
o
n
c
VAS 5098.
i
or
automatically check the vehicle for a short circuit once

thi
e
• Observe the instructions in ElsaPro

t
sd
a
the jump leads have been connected. If there is a

iv
o
r
(electronic service information system

p
cum
r
short circuit, jump starting will be blocked. The

fo
professional).
en
ng
t.
yi
electronic system can also detect jump leads which Cop •
Co
On vehicles featuring a start/stop system
py
t. rig
have been connected to the incorrect terminal. If the yri
gh by or an energy recovery function, the black
ht
op Vo
jump leads have been connected to the incorrect
c by lksw terminal clamp (–) must be clamped on the
cted agen
Prote AG. earth connection. The cylinder block, for
terminal, then the device switches to fault mode. This
example, or a metal component firmly
prevents any subsequent damage.
bolted to the cylinder block, can be used as
an earth connection.
The starting process can be monitored via integrated • Do not use jump starting on batteries with
LEDs. an insufficient acid level.
• Never use jump starting on damaged,
frozen or thawed batteries. Risk of
explosion! The battery must be replaced.
47
AG. Volkswagen AG d
agen oes
olksw not
yV gu
Service d b ara
ise nte
or eo
h
aut ra
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ce
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un
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an
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ab
pe
ility
Battery in a jump starting vehicle
ot
wit
, is n
h re
hole
spec
A battery in another vehicle (jump starting vehicle) can also be used for jump starting. Suitable jumps leads are
es, in part or in w
t to the co
required for this type of jump starting. The cables are used to connect the positive battery terminal/jump starting
point (+) and the negative battery terminal/jump starting point (–) of the jump starting vehicle to the positive
rrectness of i
battery terminal/jump starting point (+) and a suitable earth connection in the vehicle being jump started, in the
specified order.
l purpos
The cylinder block or a metal component firmly bolted to the cylinder block, or a jump starting point (–) can be used
nform
as an earth connection.
ercia
Vehicles in which the battery is installed in the interior feature a jump starting point or two jump starting points in
m
a
com
tio
the engine compartment.
n in
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te o
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fo
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Co py
Connecting the jump leads rig
ht. Jump starting point (positive battery
by
rig
ht
terminal) in the engine compartment,
copy Vo
by lksw
cted agen
To avoid any damage from occurring during jump Prote e.g. in the Passat Variant with V6
AG.
starting, the following basic rules must be observed:
• Jump starting may only be performed using jump

leads with a sufficiently large cross section, and
insulated terminal clamps.
• There must be no contact between the two
vehicles, as otherwise current could flow as soon
as the positive terminals are connected.
• Place the wires of the jump leads in a way that
they cannot be touched by rotating parts in the S504_092
engine compartment.
• The discharged battery must be properly
connected to the vehicle electrical system. Jump starting point in the engine
• Both batteries must feature the same nominal compartment, e.g. in the Phaeton
voltage.
• The capacity of the battery providing the current
must have around the same capacity as the
discharged battery.
• The order in which connections are made and the
position of the jump starting point, or the jump
starting points on vehicles with a battery in the
interior, can be found in the respective operating
manual.
S504_093
48
Starting the engine and disconnecting the jump leads
• When the engine of the vehicle with the discharged battery is started, wait two to three minutes until the engine
is “running smoothly”.
• Before disconnecting the jump leads, switch off the dipped beam headlights, should these be switched on.
• Switch on the heating fan and the heated rear window in the vehicle with the discharged battery so that no
voltage peaks occur when the starter battery is disconnected.
• Disconnect the jump leads with the engine running and in exactly the reverse order, i.e. start with the negative
terminal and only then disconnect the positive terminal.
Jump leads agen

AG. Volkswagen AG d
oes
olksw not
byV gu
ara
ed
is
The jump leadshor(also referred to as bridging cables) nte
eo
aut ra
consist of two
ss insulated wires. There is an insulated c
ce
e
nl
terminal clamp at the end of each wire. The wires and

pt
du
an
itte
the terminal clamps are distinguished by their colour.

y li
erm
ab
The red wire is for the positive battery terminal. The

ility
ot p
wit
black wire is provided for the negative battery

, is n
h re
hole
terminal or the earth connection. Jump leads must

spec
es, in part or in w
comply with the standard DIN 72553. The wire cross

t to the co
section must be at least 25 mm2 (0.038 in2) for

vehicles with a petrol engine, and for vehicles with a
rrectness of i
diesel engine, they must be at least 35 mm2 (0.054

S504_091
in2). A wire with a sufficiently large cross section
l purpos
prevents overheating.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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Improperly performed jump starting may cause a battery explosion and severe injuries. To reduce the risk of an
o
m
f
en
ng
t.
exploding battery, the instructions in ElsaPro (electronic service information system professional) must be obser-
py
i Co
t. Co
ved, along with the following:
py
rig
h ht
rig by
copy Vo
by lksw
•
cted On vehicles with a start/stop system or energy recovery function, the black terminal clamp (–) must be
agen
Prote AG.
clamped onto a suitable earth connection, a solid metal component firmly bolted to the cylinder block or to
the cylinder block itself.
• Never use jump starting on damaged, frozen or thawed batteries. Risk of explosion! The battery must be
replaced.
• Do not use jump starting on batteries with an insufficient acid level.
• Connect the jump leads in the correct order – the positive cable first, and then the negative cable.
• Never clamp the negative cable to fuel system components or to the brake lines.
• Avoid any electrostatic discharge near the battery.
• Always wear suitable eye protection and never lean over the battery.
49
Service
Battery – operation
Replacing the battery
The procedure used to replace the battery differs according to vehicle type, equipment level, and market. For
example, the battery may be installed in either the engine compartment or the luggage compartment. Independent
of this, there are a number of important basic rules which must be adhered to when replacing a battery.
Removing the battery
• Unlock the vehicle.

• Switch off all electrical consumers.
• Switch off ignition.
• Open the battery heat shield. AG. Volkswagen AG d
agen oes
olksw no
• Undo the clamp connection for the by Vnegative battery terminal clamp tand gu pull off the earth cable battery clamp.
ara
ed
ris nte
• Undo the clamp connectionthfor o the positive battery terminal clamp and pull eoff
or
the positive cable battery clamp.
au ac
• Unscrew the securing bolts ss and remove the clamping plate or the mounting bar.
ce
e
nl
• To prevent a voltage drop in the vehicle electrical system, the vehicle voltage should be maintained by means
pt
du
an
itte
y li
of a backup power supply, as described on page 46.
erm
ab
ility
• When installing the battery outside the engine compartment, pay particular attention to the gas venting hose.
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Never remove the battery positive terminal clamp when the negative terminal clamp is still connected.
l purpos
There is a risk of short circuit.

Risk of injury. Observe the warnings and safety regulations.
nf
ercia
orm
m
atio
om
n in
or c
thi
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sd
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Installing the battery

o
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f
en
ng
i t.
py Co
t. Co py
rig
• Ensure that only a VOLKSWAGEN genuine rig
h • To guarantee that the battery is securely seated, a
by
ht
opy Vo
battery with the same dimensions is used. cted
by c
battery with a low base bar must be installed in all
lksw
agen
Prote AG.
• To ensure that the battery can be fastened by the current vehicles. If applicable, the base bar
base of its housing, all starter batteries feature adapter must be removed.
base bars on the long side in accordance with EN • Do not grease the battery terminals, as otherwise
(European standards). The base bars are an the battery clamps could become loose.
integral part of the battery housing. Some • Pay particular attention to the position of the
batteries also feature additional base bars on the battery on the bracket and, if applicable, the ribs
narrow sides. on the front and rear.
50
• Tighten the battery clamping plate to the specified • When installing batteries with a central gas
torque in accordance with ElsaPro (electronic venting hose, make sure that the hose is not
service information system professional). crushed.
• Only attach battery terminal clamps by hand and • When installing batteries with a protective cap for
without using force to avoid damaging the battery the positive battery terminal (see page 18)
housing. Before applying the battery clamps, any featuring a sprayed on plug, it must be pressed
heat shield provided with the battery must be into the corresponding vent opening in
installed. accordance with the usage table in the
• Tighten the screw connections for the battery information brochure (see page 20).
clamps using the specified torque (information can • After making the connection, vehicle equipment
be found in ElsaPro (electronic service information such as the radio, clock, and electric windows must
system professional)). be checked in accordance with the information in
• Always start by screwing on the positive battery ElsaPro (electronic service information system
terminal clamp and only then attach the negative professional) and activated accordingly.
terminal clamp to the negative terminal on the • Read the event memories and erase if necessary.
battery. n AG. Volkswagen AG do
wage es n
• Install any add-on parts, such as a battery heat y Volks ot g
ua
d b ran
shield, terminal caps or gas venting hoses, oris e
tee
th or
properly. au ac
s s
ce
le
un
pt
an
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ab
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ility
ot
wit
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Base bar Base bar adapter
hole
spec
(Part number: 000 915 413)
es, in part or in w
t to the co
rrectness of i
l purpos
S504_090
S504_089
nform
mercia
Base bar (long side) Base bar (short side)

a
com
tion in
r
te o
thi
a = 10.5 mm → low base bar

s
iva
do
a = 19.0 mm → high base bar

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rp
cum
fo
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ng
i t.
py Co
t. Co py
rig
h ht
rig by
copy Vo
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cted agen
Observe the fitting instructions for the battery. Prote AG.
Detailed information on the base bar adapter and inserting the sealing plugs can be found in the fitting
instructions for the spare battery in the information brochure (see page 20).
51
Service
Storage
The permissible storage period for all current
VOLKSWAGEN batteries is limited to 15 months.
Although this storage period is three months longer
than the one for the older batteries, it is necessary to
organise battery storage so that the permissible
storage period is not exceeded. This is why the FiFo
principle must be used for battery storage. FiFo
stands for First in – First out.
The FiFo principle refers to all storage processes in

which those elements which were put into storage first
are the first ones to be taken out of storage. This
storage principle ensures that the batteries which . Volkswagen AG
gen AG does
lkswa not
have been stored for longest (or are oldest) are the y V o gu
d b ara
ones taken from the warehouse first. ise nte
or e th or
au ac
ss
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un
pt
S504_072
an
d
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erm
Placed in storage
ab
ility
ot p
II Storage
wit
is n
III
h re
Delivery
ole,
spec
1 Stored first
2, 3, 4, 5 Batteries subsequently placed in storage
t to the co
rrectnes
Each battery features a manufacturing date code on
s o
cial p
f
or near the negative battery terminal in addition to
inform
the production date code. This means it is possible to
mer
atio
m
tell when a battery was manufactured at a glance.

o
n
c
i
or
n thi
te
sd
a
The manufacturing date code is a black capital letter

iv
o
pr
cum
r
on a coloured sticker. The sticker is applied to the

fo
en
ng
t.
yi
front of the battery cover. The letter refers to the
Co
Cop py
ht. rig
quarter and the colour of the sticker signalises the py
rig by
ht
co Vo
year of manufacture. For example, a black D on a cted
by lksw
agen S504_073
Prote AG.
white sticker indicates that the date of manufacture
was the 4th quarter, 2013.
The sequence of colours starts again after six years.

Batteries which have been in storage for more
than 15 months may no longer be sold as new
parts.
52
Avoiding short circuits
Batteries must be stored so that no short circuits or

sparks can be produced. The pre-fitted protective cap
on the positive battery terminal may only be removed
shortly before installation. agen AG. Volkswagen AG do
ksw es n
Vol ot g
d by ua
ran
e
ris tee
utho or
a ac
ss
Store in a cool place No-load voltage dependency
ce
e
nl
pt
du
on temperature and time
an
itte
y li
erm
ab
Batteries must be stored in a cool and dark place,
No-load voltage [V]
ility
ot p
when possible with a room temperature of
wit
, is n
h re
max. 20 °C. The decrease in the no-load voltage (and
hole
spec
therefore the charge level) of the battery along the
es, in part or in w
8 °C
t to the co
time axis will depend on the storage temperature. The
cooler the storage place, the lower the self-discharge
and decrease in the charge level will be.
rrectness of i
13 °C
l purpos
18 °C
Recharging
nform
mercia
at
22 °C
om
The charge level of the battery must be monitored

on
c
in t
or
over the permissible storage period of 15 months to Time [s]

his
ate
do
riv
ensure that the customer always receives a fully-

p
cum
or
charged, “new” battery. The no-load voltage of the S504_074

f
en
ng
t.
yi Co
battery must not be less than 12.5 volts when it is t. Cop py
rig
gh
handed over. Batteries with a charge level between
ht
pyri by
Vo
co lksw
by
12.3 V and 12.5 V must be charged for at least one Prote
cted AG.
agen
hour before being handed over to a customer.
Transportation
Securing batteries
Batteries must be secured in a way that they cannot slide, tip over or be damaged.

Batteries must be secured against short circuits. When being transported on pallets, covering the batteries on the
top pallet with cardboard guarantees they will be secured against short circuits.
No traces of electrolyte
No traces of electrolyte must be visible on the outer surfaces of the battery.
53
AG. Volkswagen AG d
agen oes
olksw not
byV gu
Service
d ara
ise nte
or eo
uth ra
s a c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Info sheet on handling starter batteries
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
Notes on handling filled starter batteries
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
o Vo
Safety by c lksw
cted agen
Prote AG.
Warnings and safety guidelines for filled lead-calcium batteries.
First aid: Warning:

• If battery acid is splashed in the eyes, rinse • Do not leave unprotected batteries in direct
immediately for several minutes with clear sunlight.
water! Then consult a doctor without delay. • Discharged batteries can freeze, so store
• If battery acid is splashed on the skin or clothing, under frost-free conditions.
neutralise immediately with acid neutraliser or
soapy water and rinse with plenty of water. Disposal:
• If battery acid is consumed, consult a doctor • Turn over old batteries only to approved
immediately! collectors or collection points.
• Old batteries are hazardous waste.
Danger of caustic burns: Please conform to local law!
Battery acid is severely caustic, so: • When transporting batteries, observe in-
• Wear safety gloves and eye protection. structions on reverse side under “Transport”.
• Do not tip battery because battery acid can • Never dispose of old batteries in household
leak out of vent holes. trash!
Danger of explosion:
• When batteries are charged, a highly explosive
mixture of hydrogen and oxygen is created. Follow instructions on the battery, in the direc-
Therefore: tions for use and in the automobile owner’s
Fire, sparks, naked lights and smoking are manual.
prohibited.
• Avoid making sparks with cables, electrical If battery acid should escape?
devices or electrostatic discharges. In case of loss of battery acid (e.g. damage to
• Avoid short circuits battery case):
• Scatter binding agent over escaped battery
acid.
Wear eye protection.
• If appropriate, treat with acid neutraliser
or soapy water.
Keep children away from acid and batteries.
54
© Volkswagen AG
K-VO-SO/1
Subject to amendment.
For internal use only
within the Volkswagen organisation.
As of: 03/2012
Storage and handling • In order to sell customers fresh, fully charged batteries, the open-circuit
voltage of each battery may not be below 12.5 V upon delivery/installation.
Those batteries with an open-circuit voltage of between 12.3 and
12.5 V must be charged for at least one hour prior to delivery/installation.
The shelf life of batteries is 15 months from the date of manufacture. (The • When charging batteries, always carefully follow the instructions
calendar week and year of this date are stamped on the negative pole.) Bat- provided with the battery-charging device.
teries that have exceeded their shelf life may not be sold as new batteries. Ensure good ventilation and avoid the possibility of short-circuiting.
From a technical point of view and assuming proper storage maintenance,
such batteries may still be installed up to 24 months after their date of Acid indicator
manufacture, but not as new batteries and without warranty. Batteries The acid-level indicator (a round inspection window)
which have been stored over 15 months without having been properly built into each battery indicates remaining service life:
maintained in storage (i.e. recharged) must be scrapped and must not be • Black: acid level OK Black
used under any circumstances, due to the risk of explosion. • From clear to light yellow: Replace battery! Acid level is OK.
Never attempt to open the battery in order to
fill it with distilled water! By doing so, you
assume liability in the event of any subsequent
fault or malfunction!
Clear (light yellow)
Replace battery.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
b ara
th orise
d
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eo
Transport
FiFo (First in First out) u ra
s a Pursuant to “UN 2794 / Wet Batteries Filled with Acid”c and “UN 2800 /
• To avoid storing batteries beyond their shelf life, they must
s be stored and
ce
Leak-Proof Wet Batteries”, filled batteries are not subject to the provi-
e
installed (or shipped) according to the FIFO principle. To facilitate this

nl
pt
du
storage method, each battery features a dot whose color indicates the sions of ADR and RiD, if the conditions of Special Provision 598 are met:
an
itte
quarter in which it was manufactured . You fi nd an updated overview

y li
erm
about this in the ServiceNet.

ab
ility
The safe handling of batteries

ot p

• Batteries must be secured in such a manner as to prevent them from
wit
• Batteries must be stored in such a manner as to prevent any short

, is n
slipping, falling or sustaining any damage (leaks).

h re
circuits or sparks from occurring. Pre-installed pole caps are only

hole
to be removed immediately before installation.

spec

es, in part or in w
Cool storage • Batteries must be protected against short circuits.

t to the co
• Batteries must be stored in a cool environment (max. 20° C or 68° F)

and protected from direct sunlight. Traces of acid
• No trace of acid may be found on the batteries’ outer surfaces under
Open-circuit voltage (V) The degree of decline in a bat- any circumstances.
rrectness of i
tery’s open-circuit voltage (and

thus its state of charge) during In addition to complying with these conditions, the following points
l purpos
the storage period depends on are to be observed:

storage temperature. • Batteries and vehicles may not be labeled in accordance with ADR
• When transporting batteries in passenger vehicles (incl. station wagons),
nform
ercia
The cooler the storage they are to be stored in the trunk or rear storage compartment in a
temperature, the less a manner consistent with the above conditions.
• No transport document is required.
m
battery will self-discharge.

at
om
• In the interest of clarity, the following notation should be included in the

ion
delivery order: “Transport to be carried out in accordance with Rn 2801,

c
in t
months
r
Section 4a.”
o
his
ate
Recharging batteries
do
riv
In order that customers always receive a “new” battery, every battery’s

p
cum
or
state of charge must be monitored during the allowed storage period The shipping of warranty batteries:
f
en
g
of 15 months. Since the state of charge is strongly dependent on storage

n
• Since starter batteries are by definition filled with acid, it is mandatory

t.
yi Co
temperature, the following rule applies: Cop that they be safely packed for shipping and delivery. py
t. The particular regulations of applicable countries must be observed!
rig
• If it is not possible to maintain a storage temperature of 20° C (68° F) or gh ht
yri by
less, battery voltage must be checked every 4 months. If voltage is found op Vo
c For further information, please refer to “Handling Complaints”
by lksw
to be equal to or less than 12.3 V, the battery must be recharged according cted
in the ServiceNet.
agen
to instructions, i.e. for 24 hours to a maximum of 14.8 V. Prote AG.
• If the storage temperature is maintained at or below 20° C (68° F),
battery voltage must be checked every 6 months.
If voltage is found to be equal to or less than 12.3 V, the battery must
be recharged according to instructions, i.e. charged for 24 hours to
a maximum of 14.8 V.
55
Service
Dangers when handling batteries

Knowing and avoiding dangers
Although batteries do involve a degree of danger, hazardous situations are easy to avoid when the warnings on
the battery, in the operating instructions and in ElsaPro (electronic service information system professional) are
observed.
Warning notices
• Those entrusted to the care of the company, e.g. AG. Volkswagen AG d

agen oes
olksw not
trainees, may only perform work on batteries y V gu
d b ara
rise nte
when instructed by experts (e.g. automotive tho eo
au ra
mechatronics technician/master technician).ss c
ce
S504_088
le
un
• Battery acid has a highly caustic effect, and
pt
an
d
itte
y li
suitable counteragents need to be kept to hand.
erm
ab
ility
Suitable counteragents include soapy water and
ot p
wit
is n
protective equipment.
h re
ole,
• If acid escapes from the battery, it can cause skin
spec
burns, acid corrosion and corrosion of the vehicle.
t to the co
This could cause damage to vehicle components
relevant to safety.
rrectne
• When charging the battery and regassing,
oxyhydrogen gas may be produced. In extreme
ss o
cases, the escaping gases can cause the battery to
cial p
f inform
explode if not handled properly.
mer
atio
• Any work which could produce sparks (grinding,
m
S504_087
o
n
c
cutting) is forbidden near batteries. Working with i

or
n thi
te
naked flames and smoking are also forbidden.

sd
iva
o
pr
The same restrictions apply near to the end of

um
r
fo
en
ng
t.
hoses when discharging battery gases using gas op
yi Co
py
C
venting hoses (which is always the case when the gh
t. rig
ht
pyri by
battery has been installed outside the engine co
by
Vo
lksw
cted agen
compartment). Prote AG.
• Sparks due to electrostatic charging must be

avoided. The vehicle body must therefore be
touched before touching the battery.
• Work may only be performed on batteries in well
ventilated and suitable rooms.
• Use personal protective equipment (goggles,
gloves).
56
Glossary
Acid density Battery

See density. Used here in the sense of a rechargeable battery or
"accumulator".
Acid level
Level of the electrolytes in wet batteries, identical to Block box
the electrolyte level. A vessel for several battery cells. The block box is
divided by partition walls.
ADR
Accord européen relatif au transport international Capacity
des marchandises Dangereuses par Route; European The amount of current which can be drawn from a
Agreement concerning the International Carriage of battery, measured in ampere-hours (Ah).
Dangerous Goods by Road
n AG. Volkswagen AG do Charge current

swage es n
Alternator y Volk ot g
ua Current with which
db ran the battery is being charged.
rise tee
This refers to thethpower generator for electrical
o
or
au ac
ss
consumers powered by the vehicle engine and used
ce
e
Charge level
nl
pt
for charging the battery in the vehicle (alternator with

du
an
itte
y li
rectifier). Indicates how much the battery has been charged.

erm
ab
ility
ot p
wit
, is n
h re
Ampere (A) Charge voltage

hole
spec
es, in part or in w
Unit of measurement used for the rated current. Voltage when charging the battery.
t to the co
Ampere hour (Ah) Charging

rrectness of i
l purpos
The product of rated current and time. Conversion of electrical energy into chemical energy
by a current flowing through the battery in a certain
nform
ercia
direction.
Arrhenius
m
at
om
io
Svante August Arrhenius (1859-1927) was a Swedish

n
c
in t
Cell plugs
or
physicist and chemist, who won the Nobel prize for

his
ate
do
riv
chemistry. He proved that there are salts in water The cell plugs are used to seal the cell openings in the
p
cum
for
which are ions. battery cover

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Backup power supply co Vo
by lksw
cted agen
Prote AG.
In backup power mode, the battery is connected to
the electrical consumers and to a charging unit at the
same time. This means that while charging, energy is
also be drawn from the battery by electrical
consumers. Backup power mode is, for example,
required for diagnostic processes to prevent battery
discharge.
57
Glossary
Cold test current (A) as per EN and DIN DUNS

olkswagen AG
. Vthe
n AGto
A high discharge current rating assigned wage does Data Universal Numbering System. The nine-digit
olks not
battery type, which allows the by Vstart response at low DUNSgu
aranumber is an internationally standardised
d
rise nte
temperatures to be assessed.
tho supplier eo
number which allows the company to be
au ra
ss c
Example for a 60 Ah battery: clearly identified all over the world.
ce
e
nl
pt
du
an
itte
When subject to the EN current load of 480 A at -
y li
erm
ab
18 °C, the battery voltage must not fall below 7.5 V Electrolyte
ility
ot p
wit
after 10 seconds.
, is n
Ionic conductor which connects electrodes with each
h re
hole
other. In lead batteries, the conductor is sulphuric
spec
After a subsequent pause of 10 seconds, the battery
es, in part or in w
is subject to the DIN current load of 280 A at -18°C. acid which has been diluted with distilled water.
t to the co
After being subject to the DIN current load for 133
seconds, the battery voltage must not fall below 6 V.
rrectness of i
Electrolyte level
l purpos
Level of the electrolytes in wet batteries, identical to

Cover the acid level.
nf
ercia
Used to cover all the cells in a block box. The cover is
orm
m
atio
fixed to the block box by a plastic weld.
m
End terminal
o
n in
or c
thi
e
Used for discharging the total voltage in a battery

t
sd
iva
Current charge factor o

r
and for supplying the charge voltage.

rp
cu
o
m
f
en
ng
Ratio of the amount of current required for full yi

t.
Co
op py
charging to the amount of current drawn from the t. C rig
yri
gh by End-of-discharge voltage
ht
battery beforehand. cop
by
Vo
lksw
Prote
cted AG. A defined voltage under which the specified power
agen
level must not fall when discharging. Once the end-

Density of-discharge voltage is reached, the battery is
Ratio of mass to volume, for example expressed in g/ discharged.
cm3 or as kg/l.
Flashing
Discharging Reprogramming; overwriting a program, along with
Conversion of chemical energy into electrical energy the data, which is embedded in an electronic device.
(current flows in the opposite direction to charging).
Full charge
Dissociation Charging which completes the chemical conversion.
Decay of molecules into more elementary Lead batteries are fully charged when the acid
components. density and voltage stop increasing once charging is
completed.
58
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
Gas discharge/venting Mass, active
ce
e
nl
pt
du
an
itte
Batteries with a gas discharge vent allow the gas The component of the plates (electrodes) which is
y li
erm
ab
mixture produced during gassing to be discharged in subject to chemical reactions when current passes
ility
ot p
wit
a safe place away from the battery using a plastic through it.
, is n
h re
hose (gas venting hose).
hole
spec
es, in part or in w
Negative plate
t to the co
Gassing Negative plate with an effective mass (when the
rrectness of i
Gas formation on the electrodes in a lead battery. In battery is charged) comprised of metallic lead (Pb)
particular, when charging finishes, more oxyhydrogen and, when the battery is discharged, lead sulphate
l purpos
forms due to the water contained in the electrolyte (PbSO4).
nf
ercia
decaying into hydrogen and oxygen.
orm
m
atio
No.
om
n in
c
Gassing voltage
or
"No." refers to the sequential numbers in bold type
thi
te
sd
iva
Charging voltage above which the battery starts listed in the margin of a text segment, which are used
o
r
rp
cu
o
m
gassing considerably. to refer to an exact passage in the text or to quote this
f
en
ng
t.
yi Co
passage respectively.
t. Cop py
rig
gh ht
yri by
Grid cop Vo
by lksw
cted agen
The grids carry the active mass of the battery. (Lead No-load voltage Prote AG.
grid as a mass carrier) Voltage on the terminals of a battery when the

charge and discharge current is shut off after
reaching a final value.
Ion
An ion is an electrically charged atom or molecule.
Atoms or molecules have exactly the same number of Oxyhydrogen
electrons and protons in a neutral state. Electrical Explosive mixture of hydrogen and oxygen.
charges, and therefore the ion, are produced when
an atom or molecule has one or more additional or
Plate connector
fewer electrons than when in a neutral state. Ions are
positive when there are fewer electrons, and Conductive connection between plates of the same
negatively charged when there are excess electrons. polarity in a cell.
Ionisation Plate block
Adding an electrical charge to atoms or molecules. Combined unit of positive and negative plate sets in a
cell, including the plate isolators (separators).
Lead battery
Positive plate
A battery with electrodes (effective mass) comprised
of lead dioxide (positive electrodes) and of lead Positive plate with an effective mass (when the battery
(negative electrodes) when charged. is charged) comprised of lead dioxide (PbO2) and,
The electrolyte is comprised of diluted sulphuric acid. when the battery is discharged, lead sulphate
(PbSO4).
59
Glossary
Quick charging Rectifier

Charging in a shorter time using a multiple of the The rectifier converts AC current into DC current. All
charge current. Quick charging only results in partial 12-volt alternators have an integrated rectifier.
charging of the battery.
Note: batteries must not be quick-charged, as quick RiD
charging damages them.
Règlement concernant le transport international
ferroviaire de marchandises Dangereuses, English:
Recombination Regulation concerning the International Carriage of
Dangerous Goods by Rail.
Reunifying the electrically opposing, charged
elements of a molecule or a positive ion, formed by
dissociation or ionisation, with an electron to form a Sealing plugs
neutral structure.
Sealing plugs for the central gas vent opening in the
battery cover. The sealing plugs must be used on one
Recombination battery side.
This is an absorbent glass matnbattery AG. Volks(AGM battery).
wagen A (Do not confuse them with the cell plugs!)
G do
wage e
It is distinguished from Vothe wet batteries not only bys not g
lks
by ua
being leak-proof ed ran
ris due to the the non-oversaturated tee
utho SDor card
glass mat separator,
a but also by an important ac
ss
The SD card is a digital storage device. The term is the
ce
le
characteristic – the AGM battery is sealed. Sealed

un
pt
an
d
means that each cell is separated from the abbreviation for “Secure Digital Memory Card”.
itte
y li
erm
ab
atmosphere by a valve. In normal AGM battery

ility
ot p
operation, the oxygen produced when the positive

wit
is n
Self-discharge
h re
ole,
plate is charged will migrate to the negative plate via

spec
Discharge due to chemical processes in the battery

fine gas capillaries in the glass mat, compounding

t to the co
back into water with the hydrogen produced there without using the battery to power electrical
during charging. consumers.
rrectne
This process is also referred to as recombination. To

prevent the battery exploding due to overpressure, Separator
ss
e.g. due to excessive charge voltages or extremely

o
cial p
A separator is permeable to ions and is found

in
high battery temperatures should any faults occur

form
between plates of different polarity.

mer
during the recombination process, the pressure relief

atio
m
This is polyethylene for wet batteries, glass fleece for

o
valve opens (see cell plugs, page 16) once a certain

n
c
i
or
AGM batteries.
thi
overpressure is reached in the battery cell.

te
sd
iva
o
pr
cum
r
fo
Series connection
en
ng
Recuperation yi
t.
Co
Cop py
Successive connection, or series connection. When
. rig
Recovery of the energy which is released upon
t
gh ht
pyri by
connected in series (e.g. by 6 lead cells to a 12 V
o Vo
braking is referred to as recuperation. The energy c
cted
by lksw
agen
Prote
battery), the respective opposite poles of adjacent
AG.
released when braking or driving in overrun mode is
converted into electrical energy by the alternator cells are connected to each other.
using recuperation. This energy is stored in the battery
and is available the next time the driver accelerates.
The battery can then supply the electrical consumers
and the engine does not have to power the alternator.
60
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
Starter battery aut Viscosity ra
ss c
ce
le
un
pt
This is primarily used for starting the engine. Viscosity is a measure of a fluid's resistance to
an
d
itte
y li
flowing.
rm
ab
pe
ility
ot
Starting power
wit
, is n
h re
Volt (V)
hole
The power required by the engine to start.
spec
es, in part or in w
Unit of measurement used for voltage.
t to the co
Sulphating
Water
rrectness of i
Conversion of effective mass of a battery into coarse,
l purpos
crystalline lead sulphate (PbSO4). Water refers to distilled water in this SSP.
nform
ercia
Sulphuric acid
m
a
com
tio
Sulphuric acid (H2SO4) is, when diluted with distilled
n in
r
te o
thi
water, used as an electrolyte in batteries.
s
iva
do
r
rp
cum
fo
en
ng
t.
Terminal voltage
i
py Co
t. Co py
rig
h
Voltage between the two end terminals of a battery. opy
rig by
Vo
ht
by c lksw
cted agen
Prote AG.
Total discharge
Current discharge until the battery is completely
exhausted. A battery is considered to be totally
discharged when the acid density falls below 1.14 g/
cm3 and the no-load voltage is less than 11.9 volts.
UN
United Nations. The four-digit UN number, also
known as the hazard identifier, is an ID number which
is defined for all hazardous substances and goods
(hazardous goods).
Service life
Operating time until a battery fails.
61
Test your knowledge
Which answers are correct?
One or several of the given answers may be correct.
1. What do you understand by the term ‘terminal voltage’?
❒ a) A different term for cell voltage.
❒ b) The voltage between the two end terminals of a battery.
❒ c) The identifier on the battery housing.
2. What do you understand by the term nominal capacity C20?
❒ a) A voltage of 12 volts.
❒ b) A current of 175 amperes.
❒ c) A battery capacity specified by the manufacturer in ampere hours.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
3. What is found in a battery cell? oris nte
eo
h
aut ra
ss c
❒
ce
le
a) The base bars and the block box.

un
pt
an
d
itte
y li
erm
ab
❒ b) The end terminals.
ility
ot p
wit
is n
h re
❒
ole,
c) The plate block with the positive and negative plate sets and the sulphuric acid.
spec
t to the co
4. What do you understand by the term ‘ALI’?

rrectne
❒ a) A colour indicator for the battery acid level.

ss o
cial p
f i
❒
n
b) A colour indicator for the battery charge level.

form
mer
atio
m
❒
o
c) A display element in the dash panel insert.

c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
i t.
py Co
t. Co py
rig
h ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
62
5. Which of the colours used for the two-colour acid level indicator shows that the acid level is OK?
❒ a) Green.
AG. Volkswagen AG d
❒ b) Black. lksw
agen oes
not
o
byV gu
ara
ed
ris nte
❒ c) Light yellow.utho eo
ra
s a c
s
ce
le
un
pt
an
d
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6. How is a technically correct battery inspection performed?
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❒ b) By measuring the internal resistance using the VAS 6161.
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❒ c) By measuring the no-load voltage using the VAS 5900.
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7. How can a battery with a damaged housing be repaired?

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8. What is the battery casing (box/sleeve) used for?
❒ a) To protect the battery from freezing.
❒ b) To protect the battery from becoming too hot.
❒ c) To protect other mechanical units from the battery acid.
9. What is the no-load voltage?
❒ a) The battery voltage when no load is connected and after reaching a final value. 9.) a)
8.) b)
❒ b) The voltage after charging. 7.) c)
6.) b)
5.) b)
❒ c) The voltage following a cold start. 4.) a)
3.) c)
2.) c)
1.) b)
Answers:
63
504
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© VOLKSWAGEN AG, Wolfsburg

All rights and rights to make technical alterations reserved.
000.2812.61.20 Technical status 12/2012
Volkswagen AG
After Sales Qualifizierung
Service Training VSQ/2
Brieffach 1995
D-38436 Wolfsburg
❀ This paper was manufactured from pulp that was bleached without the use of chlorine.

VAG Vehicle Batteries Self Study

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VAG Vehicle Batteries Self Study

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Service Training

Self-study Programme 504

1. the engine starts

information on the correct, service-oriented handling of batteries.

Charging and discharging processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Technical variables and terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Good value batteries (economy batteries) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Battery installation locations in the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Energy management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ion 30

Effects on energy management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Vehicle electrical system concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Battery and alternator interaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Test your knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

electrical voltage was named the Volt.

Primary advantages of the lead battery are:

• Good price-performance ratio

The evolution of the battery has not, however, come

The battery is assuming an increasingly important role

polarities. The electrodes or "plate blocks" are

immersed in a 38-percent sulphuric acid solution

(electrolyte) when fully charged.

The terminals, the cells and the plate connectors are

is always thicker than the negative battery terminal.

Central gas vent opening

The following types of battery are used at

Positive plate set

Positive lead plate

Complete plate block

Negative lead grid

Positive lead plate

Positive lead grid

sulphuric acid is able to conduct an electric current of damage to the housing.

The density of the sulphuric acid changes according

Acid density Charge level No-load voltage

to the charge level of the battery; see table.

The designations used in the table apply only for

Charging and discharging processes

Hydrogen Oxygen Sulphate ions Lead Electrolyte

The result is -> the acid density increases.

The chemical energy required for discharging electric

Caution, risk of explosion! Oxyhydrogen gas is produced when a battery is charged.

Technical variables and terms

Nominal capacity C20

When charging, the amount of energy fed into the

voltage (U) falling below 10.5 V. discharge.

This means that a new and fully charged 80 Ah

The nominal capacity is important when, for example,

at a value of 2 volts for vehicle batteries.

The nominal voltage of the entire battery is the

product of the nominal voltage of a cell multiplied by

Clamping voltage rrectness of i

The clamping voltage is the voltage between the two

The gassing voltage is the charge voltage above

which the battery starts gassing significantly. This

6 x 2.4 [V] = 14.4 [V].

• Black cover and transparent housing

• High performance capacity • Not leak-proof

• Electrolyte (battery acid) indicator

Advantages Disadvantages t to the co

• Maintenance-free • Slightly poorer cold start performance

• Low self-discharge rate over the entire service life

• No increase in self-discharge despite increasing

• Suitable for immediate use; filled and charged