Removing and installing power and control electronics for electric drive JX1 — AUDI

Removing and installing
power and control electronics for electric drive
JX1
WARNING
Working on vehicles with high-voltage wiring:
Do not support yourself or tools on high-voltage wiring or associated components --> this can damage the insulation.
High-voltage wiring must not be excessively bent or kinked --> this can damage the insulation.
The round high-voltage connectors are colour-coded with an external coloured ring and are provided with mechanical coding or guide lugs. It is important to observe this coding when joining up the round high-voltage connectors, otherwise the connectors can be damaged.
Special tools and workshop equipment required
Torque wrench
V.A.G 1331
Hose clamps up to 25 mm
3094
Release tool
T40258
Removing
De-energise high-voltage system.
The high-voltage system must be de-energised according to the
“Guided Fault Finding”
routine in the
Vehicle diagnostic tester
, and ONLY by this method.
DANGER!
High voltage can cause fatal injury
Danger of severe or fatal injuries from electric shock
The high-voltage system may only be de-energised by a suitably qualified person (Audi high-voltage technician).
It must be definitely confirmed that the high-voltage system is de-energised. The system may only be de-energised using the
vehicle diagnostic tester
via
“Guided Fault Finding”
.
The qualified person (Audi high-voltage technician) confirms that the system is de-energised and uses the
locking cap
T40262
to ensure that the system cannot be re-energised. The ignition key and the
maintenance connector for high-voltage system
TW
are then stored in a safe place by the qualified person.
The qualified person (Audi high-voltage technician) marks the vehicle by attaching the appropriate warning signs.
Note
De-energising high-voltage system:
Connect vehicle diagnostic tester
Select
Guided Fault Finding
mode
Using the
Go to
button, select the following menu options in succession:
Function/component selection
Body
Electrical system
Self-diagnosis-compatible systems
8C - Hybrid battery management -J840
8C - Hybrid battery management, functions
51 - De-energise high-voltage system (Rep. gr. 93)
Disconnect 12 V batteries
Electrical system
Rep. gr.
27
Disconnecting and connecting battery
.
Remove front left headlight
Electrical system
Rep. gr.
94
Removing and installing headlight housing
.
Remove bolts
arrows
on cover
1
and take cover off
power and control electronics for electric drive
JX1
2
.
Coolant expansion tank is secured on bracket (front) of
power and control electronics for electric drive
JX1
.
Remove bolts
arrows
on bracket (front)
2
, swivel coolant expansion tank
1
to one side and secure tank.
Take care not to damage the red warning label on the
power and control electronics for electric drive
JX1
.
Unplug connectors on
power and control electronics for electric drive
JX1
.
Push locking mechanism
5
in direction of
arrow
and, starting from the right, release and unplug
high-voltage wire for electrical air conditioner compressor
P3
3
using
release tool
T40258
.
Caution
Only unplug high-voltage connectors by pulling them upwards. Do NOT rotate or tilt them; this could damage the coding on the high-voltage wires.
Push locking mechanism
4
in direction of
arrow
.
Starting from left, release and unplug
high-voltage wiring harness for hybrid battery
PX1
/
high-voltage wiring harness for drive motor
PX2
1
and
2
using
release tool
T40258
.
Caution
Only unplug high-voltage connectors by pulling them upwards. Do NOT rotate or tilt them; this could damage the coding on the high-voltage wires.
Place the
high-voltage wiring harness for hybrid battery
PX1
1
and the
high-voltage wiring harness for drive motor
PX2
/
high-voltage wire for electrical air conditioner compressor
P3
2
on a cover on the engine.
Unscrew nuts
arrows
on
terminal 30 wiring junction 2
TV22
2
and move
terminal 30 wiring junction 2
TV22
2
to side.
Remove bolts
arrows
on bracket (front)
1
.
Remove bolts and nut
arrows
on bracket (rear)
1
.
Unfasten potential equalisation line
2
on body
3
.
Unscrew securing nut for B+ wire (9 Nm)
1
and pull B+ wire off threaded connection on
power and control electronics for electric drive
JX1
2
.
Clamp off both coolant lines
4 and 5
with
hose clamps up to 25 mm
3094
3 and 6
.
Open and pull off both hose connectors
2 and 5
.
Note
Catch escaping coolant using a suitable container.
Lift
power and control electronics for electric drive
JX1
1
upwards slightly.
Disconnect breather hose.
Lift
power and control electronics for electric drive
JX1
upwards out of vehicle.
Removing bracket
Remove bolts
2
and take bracket (front)
1
off
power and control electronics for electric drive
JX1
.
Remove bolts
2
and take bracket (rear)
1
off
power and control electronics for electric drive
JX1
.
Installing
Installation is carried out in reverse sequence; note the following:
Tightening torques
Chapter
WARNING
Pay very careful attention to the coding of the high-voltage wires. Mistakes lead to short circuits and irreparable damage to high-voltage components.
WARNING
Working on vehicles with high-voltage wiring:
Do not support yourself or tools on high-voltage wiring or associated components --> this can damage the insulation.
High-voltage wiring must not be excessively bent or kinked --> this can damage the insulation.
The round high-voltage connectors are colour-coded with an external coloured ring and are provided with mechanical coding or guide lugs. It is important to observe this coding when joining up the round high-voltage connectors, otherwise the connectors can be damaged.
Note
The contact surfaces of the potential equalisation line must be checked prior to installation.
The contact surfaces must be clean and free from rust and grease.
Otherwise, repair the contact surfaces using the
contact surface cleaning set
VAS 6410
Electrical system; General information
Rep. gr.
97
Cleaning contact surfaces with
contact surface cleaning set
VAS 6410
.
Connect high-voltage wires according to their coding
Fig.
.
Note
High-voltage wires can only be connected and secured in specified sequence.
Connect and lock high-voltage wire connectors in reverse sequence to removal.
Check that the red warning label is present and take care not to damage it.
Re-energise high-voltage system.
The high-voltage system must be re-energised according to the
“Guided Fault Finding”
routine in the
Vehicle diagnostic tester
, and ONLY by this method.
DANGER!
High voltage can cause fatal injury
Danger of severe or fatal injuries from electric shock.
The high-voltage system may only be re-energised by a suitably qualified person (Audi high-voltage technician).
The system may only be re-energised using the
vehicle diagnostic tester
via
“Guided Fault Finding”
.
The vehicle is then made ready for operation again by the qualified person (Audi high-voltage technician).
The qualified person (Audi high-voltage technician) marks the vehicle by attaching the appropriate warning signs.
Note
Re-energising high-voltage system:
Connect vehicle diagnostic tester
Select
Guided Fault Finding
mode
Using the
Go to
button, select the following menu options in succession:
Function/component selection
Body
Electrical system
Self-diagnosis-compatible systems
8C - Hybrid battery management -J840
8C - Hybrid battery management, functions
51 - Re-energise high-voltage system (Rep. gr. 93)
Bleed low-temperature cooling circuit
4-cylinder direct petrol injection engine (2.0 ltr. 4-valve turbo), mechanics
Rep. gr.
19
.
The following steps must always be performed if
power and control electronics for electric drive
JX1
is renewed:
Connect
Vehicle diagnostic tester
.
Select
Guided Fault Finding
mode.
Using the
Go to
button, select the following menu options in succession:
Function/component selection
Body
Electrical system
Self-diagnosis-compatible systems
51 - Electric drive control unit - J841
51 - Electric drive, functions
51 - Basic setting (Rep. gr. 93)