Battery - Testing and Charging Procedure

Condition

Battery, Testing, Charging Using Midtronics MCR340V Battery Analyzer or InCharge 940 (INC-940) Battery Charging Station

27 06 08 Dec. 2, 2006, 2013458, Supersedes Technical Bulletin Group 27 number 04-01 dated Sept. 1, 2004 due to additional models and information.

Technical Background

The Midtronics MCR340V and InCharge 940 are the only approved VW battery testers and chargers that can be used to test and charge batteries in VW vehicles.The use of non-approved battery testers and chargers are not permitted since damage may occur to the battery internally.
The EOS 3.2L engine is equipped with 2-6V AGM batteries which are connected in series to achieve 12V.The 2-6V battery system must always be treated as a 12V battery system.Never attempt to charge only one 6V battery.If battery replacement is necessary, never replace one 6V battery; both batteries must be replaced as a pair! See photo below for reference.

WARNING:
Danger of injury! Prior to handling or servicing batteries, read, understand and observe the Warnings and Safety Measures for lead-acid and AGM batteries.Never attempt to test, charge, or replace one 6V battery.The 2-6V batteries must be treated as a 12V battery system.

Production Solution

No production change required.

Service

WARNING:
Danger of injury! Prior to handling or servicing batteries, read, understand and observe the Warnings and Safety Measures for lead-acid or AGM batteries.Never attempt to test, charge, or replace one 6V battery.The 2-6V batteries must be treated as a 12V battery system.

NOTE:
In order to prevent damage to the battery or vehicle, observe battery type descriptions and notes.

Tip: Switch off all electrical consumers.
Switch ignition OFF and remove ignition key.

Testing/charging directly at battery

Tip:
Do not remove batteries from the vehicle to test the batteries; always test batteries in the vehicle except for the following conditions:
- Battery was removed for a separate repair prior to performing the battery test.
- Over the counter parts.

Testing/Charging 6V batteries when out of vehicle:

If the batteries have been removed from the vehicle, never attempt to test/charge one 6V battery; as stated above, treat the batteries as a 12V system.To accomplish this, connect cable (part number 1Q0971226) to the inner battery terminals as follows (see photos below for clarification):

Tip:
Cable has + and - stamps on each terminal.The positive (+) terminal is a larger diameter than the negative (-) terminal.Do not attempt to force the wrong terminal of the harness onto the battery terminal if it does not fit.

1. Connect the cable with the positive (+) stamp to inner positive (+) terminal of the 1st battery.When doing so, assure that the other end of the cable (negative) does not make contact with ground or any object.Tighten to 6Nm.
2. Connect the negative (-) terminal of the cable to the inner negative (-) terminal of the 2nd battery.Tighten to 6Nm.
3. Connect Midtronics tester positive (+) clamp (red color) to outer positive (+) terminal of 2nd battery.
4. Connect Midtronics tester - (negative) clamp (black color) to outer negative (-) terminal of 1st battery.

When testing and/or charging has finished:
5. Remove Midtronics tester negative (-) clamp (black color).
6. Remove Midtronics tester positive (+) clamp (red color).
7. Remove battery cable negative (-) connection at 2nd battery negative (-) terminal.8.Remove battery cable positive (+) connection at 1st battery positive (+) terminal.

Testing/charging 2 - 6V batteries when in vehicle:

INC940

1. Connect Midtronics tester + (positive) clamp (red color) to outer + (positive) terminal of battery.
2. Connect Midtronics tester - (negative) clamp (black color) to outer - (negative) terminal of other battery.

When testing or charging battery either installed or removed from vehicle:
- Select AGM (Absorbed Glass Mat) for 3.2L engine (located in the trunk - one 6V battery on each side of the ski-chute).380 DIN*

* Always verify using DIN rating as shown on battery label.

Always use actual DIN rating as shown on battery label -arrow-.

Tip:
- Label shown is for example only.DIN or SAE specifications may vary from battery to battery.

- Since the 2-6V batteries are connected in series to achieve 12V, the same current value will flow through each battery.As a result, only use a DIN value of 380A, do not double or halve this value when entering into the Midtronics tester.

If DIN rating is not shown:
- Use SAE value as printed on the battery label.

If using the SAE value rating:
- The Midtronics tester menu option must be changed to achieve accurate results.
- The change from DIN to SAE can be made from the "Other" menu option on the Midtronics tester.

Testing/charging from remote location (3.2L)

- (3.2L) DO NOT use remote location (+) -arrow-, as shown.

- (3.2L) DO NOT use engine bracket (-) -arrow-, as shown.

- (3.2L) Test/charge (AGM) battery located in trunk
- one 6V battery located on each side of ski chute.
- as shown.

MCR 340V and INC-940 displays "System Noise" at beginning of battery test
The MCR 340V and INC-940 may display "System Noise" at beginning of battery test when testing directly at battery.

This is an infrequent and a normal message which may be caused by:
- Ignition left in "ON" position.
- Accessories or loads turned ON in vehicle with key in "ON" position.
- Loads running with the ignition in the "OFF" position such as: the cooling fan or after-run coolant pump.
- Aftermarket equipment (iPod (due to improper installation), Lojack(R), remote starters, televisions, lighting, etc.)

This may be overcome by verifying:
- Ignition is in "OFF" position.
- All loads (cooling fan or after-run coolant pump) are OFF prior to testing.
- Any aftermarket equipment is disconnected from the vehicle's electrical system.Wait a few minutes, retest battery again.

Battery testing results: Midtronics MCR340V Battery Analyzer vs. INC-940 Battery Charging Station
In some cases, when testing a battery using the MCR340V tester:

Test results may be "Good Battery - Recharge".

However, when attempting to charge the same battery with INC-940 Charger:

Results may be to "Replace Battery" either after testing or during the charging process.

Tip: This is normal since both MCR 340V and INC-940 use a conductance test, but the INC-940 also incorporates the use of a 150A load test and "sophisticated" charging algorithm which monitors the charging state of the battery.

In this case, the results of INC-940 should always be used instead of MCR340V.

Charging system test results at battery: " Low Charging Voltage" using the Midtronics MCR 340V Battery Analyzer
If performing a charging system test with Midtronics MCR340V tester directly at the battery:

Test results may be "Problem - Low Charging Voltage".

This result may be due to a faulty generator, however, do not automatically assume that the generator is faulty.Since the MCR340V is connected at the battery, the low charging voltage could be due to excessive voltage drop on the generator-battery cable, poor connections, contaminated or faulty grounds in the charging system.

To deem the generator faulty:
- Verify charging voltage and current output, directly at generator, using the 5051 measurement tools functions.

Tip:
- Test generator at the back or as close as possible to achieve accurate results.
- Failure to properly diagnose the issue may lead to the replacement of unnecessary parts which could result in a denied warranty claim.

Charging system test result at battery: "Excess Ripple Detected" using the Midtronics MCR340V Battery Analyzer
If performing a charging system test with Midtronics MCR340V tester directly at the battery:

Test results may be "Problem - Excess Ripple Detected".

Tip:
This result may be due to periodic "system noise" in the vehicle's electronics system or possible low battery voltage.

To ensure test results are accurate:
- Always retest directly at battery and perform any action as directed by Midtronics tester (good, recharge or replace).
- Perform charging system test again at battery.

Battery testing/charging: INC-940 Battery Charging Station -Automatic Mode-
When using INC-940 Battery Charging Station in "Automatic Mode" and testing or charging a deeply discharged battery:

INC-940 may continuously display a message "Are clamps connected?"

In order to test battery:
- Manually charge battery for 30 minutes and perform test again.

Battery testing/charging: INC-940 Battery Charging Station -Manual Mode-
When using INC-940 Battery Charging Station in "Manual Mode" and testing or charging a deeply discharged battery:

INC-940 may display a message "Are clamps connected?" twice.

This is not a result of defective INC-940 test equipment, but is a safety feature of the INC-940 to ensure cables are connected to the battery before power is turned ON.

INC-940 Battery Charging Station - always displays " Check Connections"
The INC-940 may always display the message to " Check Connections" after cables are connected to the battery terminals.

This is most likely due to the sensing probe making contact with the clamp.

Tip: There is one sensing probe on each clamp, (+) and (-), make sure to check both!

- There must be no contact between the inside connection and the outside jaw of the clamp, -arrows- as shown.

- Inside connection is bent and touching the outside of the clamp, -arrows- as shown.

If the clamp is incorrect:
- Use a small flat tool and gently bend the sensing probe so it does not make contact with the clamp.If this does not resolve the issue:
- Contact Midtronics Corporation Customer Service Department at 1-800-776-1995 for assistance.

Warranty
Information only.

Required Parts and Tools
No Special Tools required.