Removing and installing high-voltage wiring harness for hybrid battery PX1 — VW

Removing and installing
high-voltage wiring harness for hybrid battery
PX1
High-voltage wiring harness for hybrid battery
PX1
consists of the following lines:
High-voltage wire for hybrid battery, positive terminal
P1
High-voltage wire for hybrid battery, negative terminal
P2
WARNING
Observe general warning instructions for work on the high-voltage system
Chapter
Note
Observe instructions on handling high-voltage cables
Chapter
.
Special tools and workshop equipment required
Torque wrench
V.A.G 1331
Removing:
WARNING
High-voltage in the hybrid vehicle's high-voltage system. Danger of electric shock! Work on the high-voltage system is also necessary for the following work sequence. Now de-energise the high-voltage system
Chapter
.
De-energising the high-voltage system
Chapter
Removing front and rear noise insulation
General body repairs, exterior
Rep. gr.
50
Noise insulation
.
Removing left underbody trim
General body repairs, exterior
Rep. gr.
50
Underbody trim
.
Loosen heat shield fasteners.
Pull off both high-voltage cable retainers
arrow
from housing rib of
power and control electronics for electric drive
JX1
.
Unscrew 3 nuts (9 Nm)
1
for line trim.
Separate cable ties, open line trim
arrows
and remove
high-voltage wiring harness for hybrid battery
PX1
from line trim.
Remove line trim upwards out of engine compartment.
Thread high-voltage wiring harness downwards out of engine compartment.
Open both corrugated tube clips
2
, separate cable tie
arrow
and unclip high-voltage wiring harness.
Caution
If the fuel tank is more than one-quarter full, empty it
Rep. gr.
20
Fuel tank; Emptying fuel tank
.
Remove lower protective cover and securing straps on left side of tank
Rep. gr.
20
Fuel tank; Assembly overview - fuel tank
.
Lower fuel tank
Rep. gr.
20
Fuel tank; Assembly overview - fuel tank
.
Note
Due to reasons of clarity, the following illustrations show the high-voltage cable with the fuel tank removed.
The fuel tank does not have to be removed in order to remove and install the high-voltage cable.
Open 2 expanding rivets
3
on line trim and pull off.
Release 2 expanding anchors
arrows
on front line trim from holes in body.
Release 2 expanding anchors
arrows
on rear line trim from holes in body.
Open both corrugated tube clips
2
and unclip high-voltage wiring harness.
Removing luggage compartment floor
General body repairs, interior
Rep. gr.
70
Load and luggage compartment trim; Removing and installing load floor
.
Unscrew 3 nuts (4 Nm)
4
and remove line shield upwards from studs
arrow 1
.
Unclip line passage and guide downwards through body floor
arrow 2
.
Guide both connectors for
hybrid battery unit
AX1
through opening in body floor
arrow 3
and remove
high-voltage wiring harness for hybrid battery
PX1
downwards from vehicle.
Installing:
Install in the reverse order of removal. When doing this, note the following:
For correct longitudinal positioning in vehicle, a plastic eyelet is mounted on
high-voltage wiring harness for hybrid battery
PX1
in area of line shield in luggage compartment. On installation, this plastic eyelet must be mounted on centre stud of line shield in luggage compartment.
Note
All cable ties which have been released or separated during removal must be reattached in the same position on installation.
Tighten all threaded connections to specified torques.
When installing line passage in luggage compartment floor, make sure that it engages and seals securely.
Re-energising the high-voltage system and documentation
Chapter
.