Removing and installing high-voltage wiring harness for high-voltage battery — VW

🧭 Before you start

Fits: VW Passat B8 (3G, 2014–)

• Renewed: safety cover with seal

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• To ensure complete accessibility of the bolts (3), the following measures are necessary.
• Renew safety cover with seal after each removal.

🔧 Engine codes this applies to

📋 Procedure

1. De-energise high-voltage system .
2. Separate high-voltage wire for high-voltage battery charging unit P25(1) from power and control electronics for electric driveJX1.
3. Pull out connector lock (3)(arrow A) to do this.
4. Push locking mechanism (4) in (direction of arrow B), and pull off connector (1) approx. 5 mm until it is engaged in second locking detent.
5. Push locking mechanism (5) in (direction of arrow D), and pull connector off connector mounting (2)(arrow C). [Note: To ensure complete accessibility of the bolts (3), the following measures are necessary.]

6. Only release plenum chamber cover in area of bolt (3); do not remove completely General body repairs, exterior50Bulkhead; Removing and installing plenum chamber cover.
7. Only release bulkhead in area of bolt (3); do not remove completely General body repairs, exterior50Bulkhead; Removing and installing bulkhead.
8. Unscrew bolts (2).
9. Release catch (arrow A).
10. Remove cover (1) in direction of (arrow B) from power and control electronics for electric driveJX1.
11. Release catches (arrows).
12. Remove safety cover (1).
13. Unscrew bolts (3, 4, 5).
14. Lay wiring harness (1) to one side.
15. Pull out high-voltage wiring harness for high-voltage batteryPX1(item 2), and lay it to one side.
16. Fit cover back in place on power and control electronics for electric driveJX1, and secure it with two bolts.
17. Remove left and right underbody cladding extension General body repairs, exterior66Underbody cladding; Removing and installing underbody cladding.
18. Detach underbody cover (2) at front left on the inside. To do this, unscrew nuts (1).
19. Remove nuts (arrows).
20. Lower rear silencer slightly using engine and gearbox jackVAS 6931.
21. Unscrew bolts (arrows), and place heat shield (2) for high-voltage battery on exhaust system (1).
22. Disconnect electrical connector (3).
23. Lay high-voltage cable (4) to one side.
24. Guide out high-voltage cable from between heat shield (1) for high-voltage battery and high-voltage battery (2).
25. Lay brake lines (1) to one side.
26. Remove clip (2).
27. Release catches (arrows), and detach guide (3).
28. Lower subframe Running gear, axles, steering40Subframe; Lowering subframe.
29. Remove guide for high-voltage cable from subframe.
30. Remove high-voltage cable downwards.
31. Installation is carried out in the reverse order; note the following: [Note: Renew safety cover with seal after each removal.]
32. Re-energise high-voltage system .

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