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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Volkswagen Passat B6 (from the year 2004)

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Volkswagen Passat B6
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Passat B6
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Accumulator battery



The modern maintenance-free battery
Fig. 7.5. The modern maintenance-free battery: 1 - a cover of the housing; 2 - a protective cover of terminals; 3 - interconnections; 4 - the final terminal; 5 - plug elements (beneath the cover); 6 - plate holder; 7 - the case; 8 - the bottom of the amplifier; 9 - positive plate, closed cage; 10 - negative plate



Viewed in this manual have the vehicle's electrical system, the voltage is 12 V. The mass of the body is connected to the negative terminal of the battery. The battery is located in the engine compartment or under the rear seat (models with air conditioning, as well as some diesel versions).
The battery has three major functions in the electrical system of a vehicle:
- Provides an electric current to start the engine;
- Stabilizes the voltage in the electrical system,
- May in a short time to provide a current when the power consumption exceeds the power output of the generator.
Sealed batteries are standard for all cars. They have on the body is not flooded traffic jams. The battery is completely sealed, except for two small lateral openings for ventilation. These holes allow air to escape formed gases.
Sealed batteries have the following advantages over conventional batteries:
- For the longevity of the batteries do not need to top up the water;
- The battery is protected from overcharging. If too much tension is supplied to the battery, it will not take as much power as conventional battery. Increasing the voltage continues to charge conventional battery, leading to gassing and loss of electrolyte;
- To be self-charging battery as a conventional battery. This is very important when the car is in one place for a long time;
- With smaller dimensions and weight of voltage and current are unchanged.
The battery has two indicators:
- An indicator of battery capacity determined at 27 ?� C, which when fully charged, provides 10.5 V or more;
- An indicator of the battery during cold start is determined by testing at -18 ?� C, which shows the battery power while cranking the engine when the engine is cold.
The backup battery capacity is defined as the maximum possible for a long time for traffic at night with the minimum electrical load without the use of the power output of the generator. Expressed in minutes, Reserve Capacity (or component E) is the necessary time to fully charged battery pack at 27 ?� C and the discharge current of 25 A at terminals to achieve voltage of 10.5 V.
Testing vultures current at cold start is carried out at -18 ?� C. The minimum rate of current which the battery must be maintained at a predetermined temperature, there is a minimum voltage of 7.2 V.
This indicator is measured at cold start.
Battery life is not unlimited. However, with proper care battery will last for many years.
If the battery has been tested well, but revealed malfunctions without apparent cause, the cause of failure or refusal may be the following factors:
- Any device was left on all night;
- In a short period the car was moving at low speed;
- The electrical load of a vehicle exceed the power output of the generator, often with the inclusion of non-standard equipment;
- A fault in the charging system: slipping generator belt, a malfunction or failure of the generator voltage regulator and so on. D;
- Incorrect use of batteries: failure to cleaning, fixing or loosening the terminal clamps;
- Mechanical failure of the electrical system: shorted or pinched wires.
Sealed batteries have built-in temperature compensated hydrometer in the upper part used for the following diagnosis:
- When you look at the hydrometer, make sure that the top of the battery clean;
- During normal operation must be received two indications:
Visible green dot-emergence of green called "green dot" means that the battery is ready for testing;
Dark green invisible point - if there are complaints about the start-ups, you need to test the battery. At the same time must be checked electrical systems and charging. Sometimes it may be a third condition:
Pure or light yellow color, the level is below the tip of the hydrometer. This can cause excessive or prolonged charging excessive or normal wear and tear of the battery. Therefore, charging and the electrical systems may need to check if there are complaints about the start-up of the cold engine. If the battery - the cause of the complaint for a bad start a cold engine, replace it.

Checking the state of charge of the battery
The density of the electrolyte in conjunction with the measurement of the voltage at the battery terminals allow us to make an accurate conclusion about the state of charge of the battery. To test serves as a hydrometer, which can be purchased in a specialty store. The greater the density of the electrolyte, the more rises (float) float hydrometer. On hydrometer scale values expressed in terms of density (g / cm3).
During the measurement of the density of the electrolyte follow so that the surface of the battery box and other details with the pipette hydrometer not falling droplets of electrolyte containing sulfuric acid, which causes corrosion and leakage.
When measuring the density of the electrolyte temperature of the electrolyte should be in the range of 20-30? C. The density of the electrolyte should be measured in each element (bank) battery. After measuring the density of the electrolyte can set the degree of discharge of the battery.
All the elements of the electrolyte should be of the same density.
The density of the electrolyte in a fully charged battery is 1.28 g / cm 3.
The density of the electrolyte secondary battery discharged by 25% is 1.24g / cm 3.
The density of the electrolyte secondary battery discharged by 50%, is 1.20 g / cm 3.
Battery, discharged more than 25% in winter and more than 50% in the summer, remove from the car and recharge.
In measuring the density of the electrolyte of the electrolyte temperature must be between 20-30 ?� C. The density of the electrolyte should be measured in each element (bank) battery. After measuring the density of the electrolyte can set the degree of discharge of the battery.
All the elements of the electrolyte should be of the same density.
The density of the electrolyte in a fully charged battery is 1.28 g / cm 3.
The density of the electrolyte secondary battery discharged by 25% is 1.24g / cm 3.
The density of the electrolyte secondary battery discharged by 50%, is 1.20 g / cm 3.
Battery, discharged more than 25% in winter and more than 50% in the summer, remove from the car and recharge.

Charging the battery
Battery with a green dot indicates that charging is not needed until the battery is discharged, for example, when starting a cold engine.
When charging the battery with sealed terminals outside the vehicle, install the adapter. Make sure all the charger connections are clean and secure. For best results, the battery should be charged when the electrolyte and the plates are at room temperature. Extremely cold battery can not be charged for several hours after the start of charging.
Charge the battery until the green dot. During charging, the battery should be checked every 30 minutes. Tilting or shaking may be necessary for the emergence of a green point.
After charging the battery should be tested.
The time required to recharge the battery depends on:
- The size of the battery - for a fully discharged battery high capacity, designed for heavy duty, it takes time 2 times longer than charging the battery of the car;
- Temperature - charging the battery at -18 ?� C will require more time than at 27 ?� C. When the charger is connected to a cold battery, first charge level is very low, but the growth temperature of the battery charge level rise;
- The ability of the charger - the charger to the charging current of 5 A will take longer to charge than the charger to the charging current of 30 A or more;
- The state of charge - to charge a completely discharged battery must be twice the size of the charge, than to charge the two half-discharged batteries, because the battery is fully discharged in the electrolyte composition is close to almost pure water is a poor conductor. Then, as the charging current increases the acid content in the electrolyte increases accordingly charge state.
Before charging, disconnect the battery positive cable and workpiece first weight cable.
Before charging, check the electrolyte level, if necessary add distilled water.
Frozen battery (the battery electrolyte is frozen) defrost before charging. A fully charged battery is frozen at -65 ?� C, a half-charged battery - at -30 ?� C, flat battery - at -12 ?� C.
Charge the battery in a well-ventilated area. When charging the battery installed, leave open the car's hood.
In normal charging, the charging current value is about 10% of the battery capacity. (ie battery capacity of 50 hours must be charged A current of approximately 5.0 A). As the charging time can take a value of 10 hours.
Connect the positive terminal of the battery to the positive wire terminals of the battery negative lead from the charger.
During charging, the electrolyte temperature must not exceed +55 ?� C, if necessary, interrupt or decrease the charging current charging.
Charge the battery as long as all elements of the battery will not start copious gas evolution and, as the next in succession after hour 3 dimensions not cease to increase the density of the electrolyte and voltage.
After charging, check the electrolyte level, if necessary add distilled water.

Charging the battery fully discharged
The following procedure is used to recharge a completely discharged battery:
- Measure the voltage at the battery terminals accurate voltmeter. If the measured value is below 10 V, charging current will be very low, and it may take some time before the battery will take a few milliamps redundant;
- Put the battery charger on the high place. Some chargers have a circuit reverse polarity protection that prevents improper charging when connecting to the battery terminals. Fully discharged battery does not have enough voltage to activate this circuitry, even if the wires are connected correctly. This will cause the battery will not charge. Therefore, follow the specific instructions of the manufacturer of chargers to the battery charger is turned on and start charging the battery with a low voltage;
- Chargers provide voltage regulators and current. The time required for charging the battery according to the different voltage values are given below.

The charging time of the battery depending on the initial battery voltage

If the resulting battery charge can not be measured after the time of charging, the battery should be replaced.
If the resulting charge measured during charging, the battery is working, it is necessary to complete the charging normally.
If the resulting battery charge can not be measured after the charging time calculated by the above method, the battery should be replaced.
If the resulting charge measured during the charging time, the battery is good, and charging should be completed in the usual way.

Battery care
From time to time you need to perform the following work to the battery lasts longer and its maximum power is maintained.
Always keep the battery and its surrounding components clean. The surface of the battery must always be dry, otherwise, between individual banks may have superficial leakage currents, which is why the battery will discharge itself.
The electrolyte level must always be at the ring located on the underside of the priming chamber. For the topping, use distilled water.
In cold weather, do not leave the battery in an uncharged state, as it is (or rather, the electrolyte therein) freeze. Weakly charged battery freezes at a temperature of about -10 ?� C.

Storage Battery
The batteries are not used for a long time, discharge by themselves and can be susceptible to sulfation plates. If such a battery Rapid charger charge, they do not accept the charging current and for so-called surface charge.
Before you reject the battery should check it out:
Check the density of the electrolyte. If the density of all elements differ by no more than 0.02 g / cm 3, the battery needs to be charged charger.
Check the battery after charging under load. If the values do not match the required, the battery is faulty.
Check the density of the electrolyte. If the density of the electrolyte in one or more banks is much lower than in the other (e.g., in five banks density is 1.16 g / cm 3, and a 1.08 g / cm 3), the battery is internal short-circuiting.
To avoid premature aging of the battery, you should charge the battery in storage, every 3 months.

Self-discharge of the battery
Depending on the modifications to the vehicle during normal battery self-discharge is added to the energy consumption of permanent consumers. Therefore, the battery is not to drive the vehicle must be charged once a month and a half. If you suspect the presence of surface leakage currents should check the onboard network of the vehicle.
To check, use a fully charged battery.
Set the ammeter (with a limit of measurement of 0-5 mA and 0-5 A) highest limit of measurement. Turn on the ammeter between the terminals of the battery and the cable weight. Connect the positive lead of the ammeter to the positive pole of the battery, negative cable ammeter - to the negative battery terminal.
Turn off all electrical consumers, close all doors and the trunk, turn off the ceiling illumination of a motor compartment.
Switch the measuring range of the ammeter to decrease until, until there any evidence (permissible value range of 1-3 mA). Taking out one after the other fuses from the fuse block, remove or tamper with any electrical circuit in series. If the opening of one of the chains readings will drop to 0, then the chain should look for the source of the fault. Troubleshooting: corroded or dirty contacts of electric sockets, frayed wires, the internal circuit in the electrical components.
If protected fuse circuit fault is detected, disconnect the wires from the fuse unprotected devices: the generator, starter, ignition system components.
If you disable one of the unprotected circuits ammeter will drop to 0, repair or replace the appropriate item. When leakage current in the starter or ignition system, always check (in accordance with the scheme) the ignition switch and starter.

Removing and installing the battery

Tightening the nuts battery terminals
Fig. 7.6. Tightening the nuts battery terminals



When disconnecting the battery from the memory unit of the central control system of the engine and gearbox, anti-lock braking systems, as well as the memory of other electrical appliances such as radios and watches erased data occurred failures. Once connected, re-program the appropriate instruments. Some of the radios are installed as standard security code. The security code prevents unauthorized use of the radio if its power is turned off. Power and clock radio is switched off if, for example, disconnected battery, lifted the receiver, or the fuse blows.
Unscrew the nuts and remove the "negative" terminal, and then "positive" terminal of the battery.
Remove the nut bracket supporting the battery.
Remove the bracket supporting the battery.
Remove the battery.
Before installing the Clean terminal of the battery, this will suit a brass wire brush. To prevent corrosion cover the battery terminals with special grease.
Battery installation spend to sequences, return to removal.
Tighten the nut of the bracket supporting the battery torque 6-8 Nm.
Tighten the nuts of the battery terminals torque 9-12 Nm.




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