Volkswagen ID.4: Charging unit for high-voltage battery

• Assembly overview - charging unit for high-voltage battery, rear-wheel drive
• Assembly overview - charging unit for high-voltage battery, all-wheel drive
• Removing and installing charging unit 1 for high-voltage battery [AX4], rear-wheel drive
• Removing and installing charging unit 1 for high-voltage battery [AX4], all-wheel drive

Assembly overview - charging unit for high-voltage battery, rear-wheel drive

Assembly overview - charging unit for high-voltage battery

1. Bracket for charging unit 1 for high-voltage battery - AX4-
2. Bolt

• Qty. 2
• 20 Nm

3. Charging unit 1 for highvoltage battery - AX4-

• With control unit for high-voltage battery charger - J1050-
• ⇒ Rep. gr. 93 ; Removing and installing charging unit 1 for highvoltage battery [AX4]

4. Bolt

• 8 Nm

5. Potential equalisation line with additional external PE conductor
6. Bolt

• Qty. 4
• 8 Nm

7. High-voltage electrical connector
8. Bolt

• Qty. 2
• 20 Nm

9. Bracket for charging unit 1 for high-voltage battery - AX4-
10. Bolt

• Qty. 5
• 8 Nm

11. Electrical connector for electrical system
12. High-voltage electrical connector
13.  Coolant hose
14. Retaining clip for coolant hose

Assembly overview - charging unit for high-voltage battery, all-wheel drive

Assembly overview - charging unit for high-voltage battery

1. 12 V voltage supply

• Positive terminal

2. 12 V voltage supply

• Negative terminal

3. Bolt

• 20 Nm

4. Voltage converter - A19-

• ⇒ Rep. gr. 93 ; Removing and installing voltage converter [A19]

5. Bracket
6. Bolt

• Qty. 4
• 8 Nm

7. Bolt

• Qty. 4
• 20 Nm

8. Bolt

• Qty. 3
• 8 Nm

9. Bolt

• 8 Nm

10. Bolt

• Qty. 2
• 8 Nm

11. Potential equalisation line
12.  High-voltage electrical connector
13. Bolt

• Qty. 4
• 8 Nm

14. Electrical connector for electrical system
15. Bracket for charging unit 1 for high-voltage battery - AX4-
16. High-voltage electrical connector
17. Potential equalisation line
18. Coolant hose
19. Charging unit 1 for high-voltage battery - AX4-

• With control unit for high-voltage battery charger - J1050-
• ⇒ Rep. gr. 93 ; Removing and installing charging unit 1 for high-voltage battery [AX4]

20. Bracket for voltage converter - A19-
21. Electrical connector for electrical system
22. High-voltage electrical connector
23. Coolant hose

Removing and installing charging unit 1 for high-voltage battery [AX4], rear-wheel drive

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

Special tools and workshop equipment required

• drip tray - VAS 6208-
• hose clamps up to 25 mm - 3094-

Charging unit 1 for high-voltage battery - AX4- is referred to hereafter as charging unit.

Removing

DANGER

High voltage can cause fatal injury.

Danger of severe or fatal injuries from electric shock or electric arcs.

• Have a high-voltage technician (HVT) or a high-voltage expert (HVE) de-energise the high-voltage system.

• ⇒ Rep. gr. 93 ; De-energise high-voltage system .

If the charging unit is renewed, perform the test plan for renewal of the control unit:

• Carry out function "Renew control unit" using ⇒ Vehicle diagnostic tester ⇒ Rep. gr. 00 ; Access to diagnoses .

Continued

• Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Disconnecting and connecting battery .
• Remove rear underbody cladding ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody cladding; Removing and installing rear underbody cladding .
• Remove rear centre underbody cladding ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody cladding; Removing and installing rear centre underbody cladding .
• Remove skid plate ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody cladding; Removing and installing skid plate .
• Place drip tray - VAS 6208- under rear section of vehicle.
• Clamp off coolant hoses -2- and -4- using hose clamps up to 25 mm - 3094- .
• Open clamp -3-, and pull coolant hose off power and control electronics for electric drive - JX1- .
• Pull out retaining clip -arrow-, and pull coolant hose -4- off charge unit -1-.

• Loosen anti-roll bar ⇒ Running gear, axles, steering; Rep. gr. 42 ; Anti-roll bar; Removing and installing anti-roll bar .
• Disconnect electrical connector -1- from charging unit -2-.

• Disconnect electrical connector -2-, -3- and -4-.

• Unscrew potential equalisation line.
• Protect connector receiver and coolant connections to prevent the ingress of dirt.
• Unscrew bolts -arrows-.
• Remove charging unit -1- with bracket downwards.
• Place charging unit -1- on a clean surface.

• Unscrew bolts -arrows-.
• Remove bracket -4- from charging unit -1-.

• Unscrew bolts -arrows-.
• Remove bracket -2- from charging unit -1-.

Installing

Install in reverse order of removal, observing the following:

• ⇒ Rep. gr. 19 ; Cooling system/coolant; Filling cooling system

If the charging unit has been renewed, perform the test plan for renewal of the control unit:

• Carry out function "Renew control unit" using ⇒ Vehicle diagnostic tester ⇒ Rep. gr. 00 ; Access to diagnoses .

Continued

WARNING

High voltage can cause fatal injury.

Danger of severe or fatal injuries from electric shock or electric arcs.

•  Have a high-voltage technician (HVT) or a high-voltage expert (HVE) re-energise the high-voltage system.
• ⇒ Rep. gr. 93 ; Re-energise high-voltage system .

Tightening torques

• ⇒ Rep. gr. 93 ; Assembly overview - charging unit for high-voltage battery

Removing and installing charging unit 1 for high-voltage battery [AX4], all-wheel drive

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

Special tools and workshop equipment required

• drip tray - VAS 6208-

The charging unit 1 for high-voltage battery - AX4- will henceforth be referred to as "charging unit".

Removing

DANGER

High voltage can cause fatal injury.

Danger of severe or fatal injuries from electric shock or electric arcs.

• Have a high-voltage technician (HVT) or a high-voltage expert (HVE) de-energise the high-voltage system.

• ⇒ Rep. gr. 93 ; De-energise high-voltage system .

If the charging unit is renewed, perform the test plan for renewal of the control unit:

• Carry out function "Renew control unit" using ⇒ Vehicle diagnostic tester ⇒ Rep. gr. 00 ; Access to diagnoses .

Continued

•  Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Disconnecting and connecting battery .
• ⇒ Rep. gr. 19 ; Drain coolant .
• Remove rear underbody cladding ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody cladding; Removing and installing rear underbody cladding .
• Remove rear centre underbody cladding ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody cladding; Removing and installing rear centre underbody cladding .
• Remove skid plate ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody cladding; Removing and installing skid plate .
• Loosen anti-roll bar ⇒ Running gear, axles, steering; Rep. gr. 42 ; Anti-roll bar; Removing and installing anti-roll bar .
• Place drip tray - VAS 6208- under rear section of vehicle.
• Open clamps -3-, and pull coolant hoses -4- off battery charger -1- and coolant hose -6- off rear motor.
• Unscrew nut -5-.
• Unscrew nut -11-.
• Unscrew bolts -9-.
• Disconnect electrical connector -7-.

• Disconnect electrical connector -1-, -2- and -4-.

• Unscrew potential equalisation line.
• Protect connector receiver and coolant connections to prevent the ingress of dirt.
• Unscrew bolts -arrows-.
• Remove charging unit -1- with bracket downwards.
• Place charging unit -1- on a clean surface.

• Unscrew bolts -1-.
• Detach bracket -2- with voltage converter - A19- .

• Unscrew bolts -arrows-.
• Remove bracket -4- from charging unit -1-.

• Unscrew bolts -arrows-.
• Remove bracket -2- from charging unit -1-.

Installing

Install in reverse order of removal, observing the following:

• ⇒ Rep. gr. 19 ; Filling cooling system

If the charging unit has been renewed, perform the test plan for renewal of the control unit:

• Carry out function "Renew control unit" using ⇒ Vehicle diagnostic tester ⇒ Rep. gr. 00 ; Access to diagnoses .

Continued

WARNING

High voltage can cause fatal injury.

Danger of severe or fatal injuries from electric shock or electric arcs.

• Have a high-voltage technician (HVT) or a high-voltage expert (HVE) re-energise the high-voltage system.

• ⇒ Rep. gr. 93 ; Re-energise high-voltage system .

Tightening torques

• ⇒ Rep. gr. 93 ; Assembly overview - charging unit for high-voltage battery