No Start, Generator (Gen) Control Light On Or Flashing, Electrical Consumers Not Functioning Properly (GROUP 27, NO. 06-01)

TEST PLAN A - BATTERY CHECK

1. - Verify vehicle has no start condition due to a discharged battery or battery related issue (generator control light on, or flashing). If yes, go to step 2. If no, do not complete this TB.
2. - Test battery using Midtronics tester. Perform action as directed by Midtronics tester to remedy battery condition. This step must be completed before proceeding to step 3! Go to step 3.
3. - Determine Test plan based on servicing dealer location.

• For servicing dealerships located in any of the following states: Alabama, Arizona, California, Florida, Georgia, Hawaii, Louisiana, Mississippi, Nevada, New Mexico, Oklahoma, and Texas, perform Test Plan B. 
• For servicing dealerships located in all other US states or Canada, perform Test Plan C. 

TEST PLAN B - ONLY PERTAINS TO THE 12 US STATES LISTED ABOVE. ALL OTHER STATES AND CANADA, USE TEST PLAN C.

1. - Verify vehicle is equipped with a 90A Bosch or 90A Valeo generator. If yes, go to step 2. If no, do not complete this technical bulletin.
2. - Locate 90A generator part number installed in vehicle. Using Generator Reference Table, verify generator part number is listed in table. Locate replacement generator part number using same table. Go to step 3.
   NOTE: If generator part number is not listed, contact VW Helpline for further assistance.
3. - Replace generator with replacement part number from Generator Reference Table, see Repair Manual Group 27 - Starter, Generator, Cruise control. Do not perform any diagnosis on existing 90A generator in vehicle. Go to step 4.

   TIP:  If generator replacement part does not fit properly in vehicle, contact VW Helpline for further assistance.

   DO NOT use any other part number as a substitute other than the part number indicated in Table.

   DO NOT use remanufactured part number, otherwise warranty claim may be denied.

4. - After generator has been replaced:
   • Restore electrical power
   • Clear DTCs

TEST PLAN C - ONLY PERTAINS TO ALL OTHER US STATES NOT LISTED ABOVE AND CANADA.

1. - Verify vehicle is equipped with a 90A Bosch or 90A Valeo generator. If yes, go to step 2. If no, do not complete this TB.

   TIP:  Connect the URDI test probe and the 500 amp current probe to the VAS 5051 tool to measure voltage and amperage output as follows:

2. - Vehicle must be at normal operating temperature and ambient temperature should be greater than 24°C/75°F. Using a VAS 5051 select Test Instruments from display screen
   • Connect red test lead to B+ terminal on back of generator.
   • Connect black test lead to battery negative (-) terminal.
   • Connect 500A current clamp probe to measure (amperage) output of generator.
   • Lower hood so that heat can build up in engine compartment. Failure to perform this step may result in erroneous readings.
   NOTE: If servicing dealership has an air conditioned shop area, it my be necessary to take the vehicle outside when taking voltage and current measurements; otherwise the resulting outcome may be erroneous readings.
   • Monitor charging voltage and current during the next steps:
     1. - Start engine and turn on (at a minimum) the following consumers (headlights, radio (at half volume or more), A/C, and rear defrost.
     2. - Allow vehicle to idle for 15 minutes. Charging voltage should have dropped to less than 12.5V
     3. - After 15 engine idling minutes, increase the engine RPM to 2000 while monitoring charging voltage and current for 20 seconds

        Did the charging voltage increase to a value of 12.9V or higher within 20 seconds?

   • If YES, Did output current increase to a value greater than 75 amps?
   • If YES, Charging system operating properly, no further action required.
   • If No, Generator is not functioning properly, continue to step 3.
3. Locate 90 amp generator part number installed on vehicle.
   • Using Generator Reference Table, verify generator part number is listed in the table.
   • Locate replacement generator part number using same table, then Go to Step 4.

     TIP:  If generator part number is not listed in Table, contact VW Helpline for further assistance.

4. Replace generator with replacement part number from Generator Reference Table, see Repair Manual Group 27 - Starter, Generator, Cruise control, and restore electrical power.

• Restore electrical power & Clear DTCs