How to Diagnose and Replace Battery on 2005 Vw Beetle Tdi

Step-by-Step Guide

1. 1

   Step 1: Place the gear selector in Park or First gear.

   Memory Keeper ,,,,, Removing Negative Cable ,,, Disengage Battery Tabs ,, Removing Battery Hold Down Bolt , Battery Hold-Down Bolt and Bracket ,,,,,, Battery Hydrometer Test ,,, Do not overfill.,,,, Charge the battery for seventy-two (72) hours to bring the battery to a full charge (Figure B-11).
   
   Charging Discharged Battery ,,,,,,, Battery OCV Test , A load tester evaluates the ability of the battery to operate the vehicle starter motor or accessories, and maintain the LOAD for fifteen (15) seconds with the voltage not going below
   9.6 volts.
   
   A battery incapable of holding that voltage LOAD is defective (Figure B-13) Checking Battery With Load Tester .
   
   The load test showed the Beetle storage battery to be defective.,,,,,,,,,
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   Step 2: Place wheel chocks behind the rear wheels.

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   Step 3: Pull the hood lever in the cabin compartment.

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   Step 4: Pull the outside hood cable toward you and raise hood.

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   Step 5: Place a memory keeper device in the accessory socket in the cabin compartment (Figure B-1).

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   Step 6: Press the tab on the top battery cover and remove.

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   Step 7: Press the tab on the fuse box and lift cover off (Figure B-2) Removing Fuse Cover

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   Step 8: Using a 1/4-inch square drive 10mm socket and 1/4-inch square drive ratchet

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   Step 9: remove POSITIVE cable to fuse box (Figure B-3)

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    Step 10: Remove Fuse Box Cover

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    Step 11: Using a 1/4-inch square drive 10mm socket and 1/4-inch square drive ratchet

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    Step 12: remove the NEGATIVE cable of the battery post (Figure B-4).

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    Step 13: Using a 1/4-inch square drive 10mm socket and 1/4-inch square drive ratchet

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    Step 14: remove the clamp to the POSITIVE cable of the battery post (Figure B-5).

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    Step 15: Detach the clamp on the battery cover (Figure B-6) Removing Clamp on Battery Cover

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    Step 16: Using a flat-blade screwdriver

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    Step 17: disengage the tabs that secure the battery cover to the battery tray (Figure B-7).

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    Step 18: Remove battery cover and set aside.

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    Step 19: Using a 3/8-inch square drive 13mm socket and 3/8-inch square drive ratchet

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    Step 20: and 18-inch 3/8-inch square drive extension remove the battery hold-down bolt and bracket (Figure B-8).

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    Step 21: The battery hold-down bolt and bracket removed as shown in Figure B-9.

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    Step 22: Using battery strap (attached to battery)

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    Step 23: remove the storage battery from vehicle and place on workbench for testing.

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    Step 24: The electrolyte level is tested in the cells of the battery before it is checked.

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    Step 25: Remove the battery filler caps (6) from their cells.

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    Step 26: Place a battery hydrometer in one (1) of the cells.

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    Step 27: The reading on the scale of the hydrometer should be approximately 1.270.

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    Step 28: This reading indicates the battery is fully charged (Figure B-10).

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    Step 29: A lower reading would indicate the battery needs to be charged before testing.

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    Step 30: Cells checked low are filled with distilled water only.

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    Step 31: Fill cells that are low to the filler line with distilled water above the top plate.

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    Step 32: Using a typical battery charger

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    Step 33: place the selector switch on the 2-amp or 10-amp setting.

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    Step 34: Place the POSITIVE (red) cable of the battery charger to the POSITIVE post of the battery.

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    Step 35: Place the NEGATIVE (black) cable of the battery charger to the NEGATIVE post of the battery.

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    Step 36: Set the battery charger to the 2-amp (slow charging) setting.

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    Step 37: Using a digital multi-meter (available at auto parts stores) set the selector switch to the VOLTS setting.

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    Step 38: Place the red test lead into the red jack of the multi-meter.

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    Step 39: Place the black test lead into the COM jack of the multi-meter.

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    Step 40: Place the other end of the red test lead and attach to POSITIVE post of the battery.

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    Step 41: Place the other end of the black test lead and attach to NEGATIVE post of the battery.

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    Step 42: The reading on the display of the multi-meter should range from 1.250 to 1.275 volts indicating the battery is fully charged.

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    Step 43: This test (open circuit voltage) only indicates that the battery can hold a charge (Figure B-12).

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    Step 44: A battery is accurately checked for capacity and strength with a battery load tester.

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    Step 45: The replacement battery should have the same specifications and dimensions as the the original or dead battery; namely

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    Step 46: amperage rating and cold cranking rating.

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    Step 47: Clean the battery POSITIVE and NEGATIVE posts and cables with a battery post brush (Figure B-14).

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    Step 48: Battery Post Brush

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    Step 49: Stubborn corrosion on the battery cables should be cleaned with baking soda and water.

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    Step 50: Place the replacement battery in the vehicle battery tray.

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    Step 51: Install the battery hold-down bolt and bracket

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    Step 52: fuse box bolt

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    Step 53: and top battery cover in the reverse order from which they were removed.

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    Step 54: Remove the battery memory keeper from the accessory socket.

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    Step 55: Remove the wheel chocks from under the rear wheels.

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    Step 56: Test drive the Beetle for proper operation.

Detailed Guide

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