Battery (With Fastener Secured Fuse Holder)
Battery (with Fastener Secured Fuse Holder), Removing And Installing
CAUTION!
Before beginning repairs on the electrical system:
- Obtain the anti-theft radio security code.
- Switch the ignition off.
- Disconnect the battery Ground (GND) strap.
- After reconnecting battery, re-code and check operation of anti-theft radio. Also check operation of clock and power windows.
Special tools, testers and auxiliary items needed
- VAG 1331 Torque wrench (or equivalent 5 - 50 N.m)
Battery, removing
First remove fuse holder on top of battery:
- Switch off ignition.
CAUTION!
Do not loosen or remove ground strap from body. Disconnect from battery only.
- Disconnect battery Ground (GND) strap from battery negative post.
- Press locking lugs together -arrows- and remove cover.
- Remove positive bus securing bolt-1-on (+) positive terminal clamp.
- Remove securing bolts -A- and remove cables to fuses.
- Pull off connections -2-.
- Relieve tension on fuse holder mounting in direction of -arrow A- and release clip with screwdriver in direction of -arrow B-.
- Lift fuse holder from battery.
- Remove screws -arrows- and remove cover -1-.
- Release battery positive terminal clamp securing bolt -arrow-.
- Battery insulation jacket can only be opened and removed (where applicable) after first loosening and removing battery positive terminal clamp from battery.
- Remove M8 x 25 hex bolt -arrow-.
- Remove battery hold-down bracket.
- If present, disconnect central gas vent hose from top cover.
- Carefully lift battery from engine compartment.
Battery, installing
To ensure battery seats securely, only install batteries with a 10.5 mm battery foot strip and adhere to the following work sequences:
- Install battery so battery carrier lug -arrow- engages in battery foot strip cut-out -1-.
It must not be possible to move a battery to the left or to the right.
Battery is inserted correctly when center cut-out in battery foot strip aligns with threaded hole in battery carrier -arrows-
- On batteries with a hose for central venting ensure that the hose is not squashed. Only then can the battery vent freely.
- On batteries without a hose for central venting ensure that the opening on the upper side of the battery cover is not blocked.
NOTE: New generation batteries are equipped with a central gas venting system and integrated flame trap. Function: Gases produced during charging escape through a central opening on the side of the upper cover. The integrated flame trap prevents flammable gases in the battery from igniting. The flame trap is comprised of a small round fiberglass mat with a diameter of 15 mm and a thickness of 2 mm. Working as a one-way-valve, it allows gases produced during charging to vent.
- Fit battery hold-down bracket and tighten M8 x 25 securing bolt to 22 Nm.
- Reinstall insulation jacket where applicable.
- Install positive clamp onto battery positive terminal.
NOTE:
- Battery terminal clamps must only be fitted by hand without force, this prevents damage to battery housing.
- Battery terminals must no longer be greased.
- Tighten battery positive terminal clamp securing screw to 6 Nm.
- Fit fuse holder onto battery and install positive bus onto securing pins on battery positive terminal.
- Engage fuse holder clip in battery.
- Tighten securing bolt -1- for positive bus on (+) positive terminal clamp.
- Connect cables to strip fuses again and tighten securing bolts -A-.
- Fit connections -2-.
- Only after the fuse holder and positive terminal have been secured should the negative terminal clamp be installed.
- Tighten securing bolt to 6 Nm.
- Reinstall cover -1 - with screws -arrows-.
CAUTION!
If battery is not secured properly, the following will result:
- Shortened battery service life due to vibration damage.
- Battery cell and plate damage.
- Electrolyte leakage due to battery case damage.
- Poor collision safety.