Removing and installing high-voltage battery: VW Golf VI

🧭 Before you start

De-energise the high-voltage system and disconnect the 12V battery. Clear the luggage compartment, remove the bonding conductor, covers, high-voltage plug, fan and air duct, mask the ducts and remove the gaskets and battery bolts. Underneath, set up the assembly platform with the supporting frame, remove the underbody panel, disconnect plugs, earth conductor and coolant hoses, bolt the frame to the battery and lower it. Clean the bonding contact surfaces before installation, then re-energise and document.

Fits: VW Golf VI (5K, 2008–2013)

• Special tools named: VAS 6410

Don't miss

• Only an electrically skilled person with live-working qualification may carry out this work.
• Mask the battery air ducts with tape; nothing may fall into them.
• Use the release tool on the high-voltage plugs rather than forcing them.
• Bonding conductor contact surfaces must be clean, rust- and grease-free before installation.
• Re-energise the high-voltage system and complete the documentation after refitting.

Written for this job from the workshop steps below · TorqFix editorial.

📋 Procedure

1. ⚠ Removal of the high-voltage battery may only carried out by an electrically skilled person who has gained the "Live Working" qualification. — De-energise high-voltage system
2. Disconnect 12V battery.
3. Remove luggage compartment floor General body repairs, interior70Load and luggage compartment trim; Removing and installing load floor.
4. Remove breakdown kit and vehicle tools from luggage compartment.
5. Unscrew securing nuts (arrows A) from high-voltage battery and remove equipotential bonding conductor (earth cable) from battery.

6. Unscrew bolts (arrows) and remove cover (1).
7. Unclip plug (1) from bracket in (direction of arrow) and unplug.
8. Release high-voltage plug (1) using release tool (A) and unplug from battery.
9. ⚠ High voltage in high-voltage battery's high-voltage system despite being de-energisedDanger of electric shock!Work may only be carried out by an electrically skilled person with "live working" qualification. — Unscrew bolts (1) and nuts (2) and then remove cover (A).
10. Unscrew 4 bolts from fan and lay fan to one side.
11. ⚠ Danger of battery short-circuitNo objects must be allowed to fall into the battery air duct.Mask air ducts with adhesive tape. — Unscrew nuts (arrows) and remove air duct (1).
12. Mask air duct with adhesive tape.
13. Unscrew 12 nuts (1 and 2).
14. Remove air duct gaskets (1 and 2) from studs and place on ground.
15. Unscrew 4 bolts (1) for battery.
16. Lift battery out of vehicle boot using engine hoist and hoist attachment.
17. Set up scissor-type assembly platformVAS 6131 A.
18. Secure supporting frame for high-voltage battery AX6 on scissor-type assembly platformVAS 6131 A.
19. Unscrew bolts (arrows) and remove underbody panel (1).
20. Release and detach plug (1) using release tool (2).
21. Release and detach plug (2) using release tool (A).
22. Unscrew cap nut (arrow) and remove equipotential bonding conductor (1) from stud.
23. Disconnect coolant hoses (1) from high-voltage batteryAX2.
24. Unplug connector (2).
25. Screw battery supporting frame to high-voltage battery 1AX2.
26. Unscrew bolts (arrows) of high-voltage battery 1AX2 from vehicle underbody.
27. Lower high-voltage battery 1AX2 using scissor-type assembly platform. [Note: The contact surfaces of the equipotential bonding conductor must be checked prior to installation.The contact surfaces must be clean, rust- and grease-free.Otherwise, repair the contact surfaces using the contact surface cleaning setVAS 6410Electrical system; General information97Contact surface cleaning set VAS 6410.]
28. Re-energising the high-voltage system and documentation .

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