Removing and installing charging unit 1 for high-voltage battery AX4 — VW

Removing and installing
charging unit 1 for high-voltage battery
AX4
Note
Charging unit 1 for high-voltage battery
AX4
contains
control unit for high-voltage battery charging unit
J1050
Special tools and workshop equipment required
Torque wrench
V.A.G 1331
Hose clamps up to 25 mm.
3094
Drip tray for workshop hoist
VAS 6208
Removing
DANGER
Risk of death due to high voltage.
Electrical shocks will cause serious injuries or death.
Have a qualified technician de-energise the high-voltage system.
De-energise high-voltage system
Chapter
.
If necessary, remove motor cover panel
Chapter
.
Place
drip tray
VAS 6208
beneath vehicle.
Clamp off coolant hoses with
hose clamps up to 25 mm
3094
.
Disconnecting 12-V connector on
charging unit 1 for high-voltage battery
AX4
Note
The connector on
charging unit 1 for high-voltage battery
AX4
and the connector on the
power and control electronics for electric drive
JX1
are identical. If both connectors are disconnected, there is a risk of interchanging them when reconnecting. Mark connectors accordingly before disconnecting them.
Release connector in
direction of arrow A
.
Pull off connector in
direction of arrow B
.
Note
The high-voltage cables are secured with cable retainers. The cable retainers must be detached before disconnecting connectors in order to allow for pulling off the connectors.
Insert a small screwdriver
2
in
direction of arrow A
into high-voltage connector
1
in order to release it.
Push screwdriver
2
in
direction of arrow B
. This will release high-voltage connector
1
.
Pull off high-voltage connector
1
.
Release high-voltage connector
1
by pressing locking mechanism
2
.
Pull off high-voltage connector
1
.
Release and pull off high-voltage connectors
1
and
2
. To do this, follow the work procedure below
Fig.
.
Releasing high-voltage connector:
Pull locking mechanism
3
in
direction of arrow A
.
Push detent
4
in
direction of arrow B
. At the same time, pull high-voltage connector
1
in
direction of arrow C
off connector mounting
2
.
The high-voltage connector
1
can be pulled out of connector mounting
2
by approx. 5 mm.
Push detent
5
in
direction of arrow D
. At the same time, pull high-voltage connector
1
in
direction of arrow C
completely off connector mounting
2
.
Remove bolt
1
.
Remove potential equalisation line
2
.
Loosen clamps
3
.
Pull coolant hoses
2
off
charging unit 1 for high-voltage battery
AX4
1
.
Remove bolts
2
.
Remove
charging unit 1 for high-voltage battery
AX4
1
upwards.
Installing
Install in the reverse order of removal, observing the following:
WARNING
Risk of death due to high voltage.
Electrical shocks will cause serious injuries or death.
Have a qualified technician commission the high-voltage system.
Commission high-voltage system
Chapter
.
Specified torques
Chapter
“
Assembly overview - charging unit for high-voltage battery
”