Volkswagen ID.4: High-voltage battery components, edge of upper part of battery housing with wax

• Overview of fitting locations - battery modules, 48, 55 kWh
• Overview of fitting locations - battery modules, 62 kWh
• Overview of fitting locations - battery modules, 82 kWh
• Assembly overview - high-voltage battery, removed, 48, 55, 62 kWh
• Assembly overview - high-voltage battery, removed, 82 kWh
• Assembly overview - battery modules
• Assembly overview - switching unit for high-voltage battery, 48, 55, 62 kWh
• Assembly overview - switching unit for high-voltage battery, 82 kWh
• Assembly overview - high-voltage battery, connecting element, 48, 55, 62 kWh
• Assembly overview - high-voltage battery, connecting element, 82 kWh
• Removing battery module
• Installing battery module
• Removing and installing battery modules control unit
• Removing and installing connecting element, 48, 55 kWh
• Removing and installing connecting element, 62 kWh
• Removing and installing connecting element, 82 kWh

Overview of fitting locations - battery modules, 48, 55 kWh

1. Battery module 1 - J991-

• ⇒ Rep. gr. 93 ; Removing battery module
• ⇒ Rep. gr. 93 ; Installing battery module

2. Battery module 2 - J992-

• ⇒ Rep. gr. 93 ; Removing battery module
• ⇒ Rep. gr. 93 ; Installing battery module

3. Battery module 3 - J993-

• ⇒ Rep. gr. 93 ; Removing battery module
• ⇒ Rep. gr. 93 ; Installing battery module

4. Battery module 4 - J994-

• ⇒ Rep. gr. 93 ; Removing battery module
• ⇒ Rep. gr. 93 ; Installing battery module

5. Battery module 5 - J995-

• ⇒ Rep. gr. 93 ; Removing battery module
• ⇒ Rep. gr. 93 ; Installing battery module

6. Battery module 6 - J996-

• ⇒ Rep. gr. 93 ; Removing battery module
• ⇒ Rep. gr. 93 ; Installing battery module

7. Battery module 7 - J997-

• ⇒ Rep. gr. 93 ; Removing battery module
•  Rep. gr. 93 ; Installing battery module

8. Battery module 8 - J998-

• ⇒ Rep. gr. 93 ; Removing battery module
• ⇒ Rep. gr. 93 ; Installing battery module

9. Battery modules control unit - J1208-

•  ⇒ Rep. gr. 93 ; Removing and installing battery modules control unit

10. Battery modules control unit 5 - J1212-

• ⇒ Rep. gr. 93 ; Removing and installing battery modules control unit

Overview of fitting locations - battery modules, 62 kWh

Overview of fitting locations - battery modules

1. Battery module 1 - J991-

• ⇒ Rep. gr. 93 ; Removing battery module
• ⇒ Rep. gr. 93 ; Installing battery module

2. Not fitted
3. Not fitted
4. Not fitted
5.  Battery module 5 - J995-

• ⇒ Rep. gr. 93 ; Removing battery module
• ⇒ Rep. gr. 93 ; Installing battery module

6. Battery module 6 - J996-

• ⇒ Rep. gr. 93 ; Removing battery module
• ⇒ Rep. gr. 93 ; Installing battery module

7. Battery module 7 - J997-

• ⇒ Rep. gr. 93 ; Removing battery module
• ⇒ Rep. gr. 93 ; Installing battery module

8. Battery module 8 - J998-

• ⇒ Rep. gr. 93 ; Removing battery module
• ⇒ Rep. gr. 93 ; Installing battery module

9. Battery module 9 - J999-

• ⇒ Rep. gr. 93 ; Removing battery module
• ⇒ Rep. gr. 93 ; Installing battery module

10. Battery module 10 - J1000-

• ⇒ Rep. gr. 93 ; Removing battery module
• ⇒ Rep. gr. 93 ; Installing battery module

11. Battery module 11 - J1001-

• ⇒ Rep. gr. 93 ; Removing battery module
• ⇒ Rep. gr. 93 ; Installing battery module

12. Battery module 12 - J1002-

• ⇒ Rep. gr. 93 ; Removing battery module
• ⇒ Rep. gr. 93 ; Installing battery module

13. Battery modules control unit 9 - J1216-

• ⇒ Rep. gr. 93 ; Removing and installing battery modules control unit

14. Battery modules control unit 5 - J1212-

• ⇒ Rep. gr. 93 ; Removing and installing battery modules control unit

15. Battery modules control unit - J1208-

• ⇒ Rep. gr. 93 ; Removing and installing battery modules control unit

Overview of fitting locations - battery modules, 82 kWh

Overview of fitting locations - battery modules

1. Battery module 1 - J991-

• ⇒ Rep. gr. 93 ; Removing battery module
• ⇒ Rep. gr. 93 ; Installing battery module

2. Battery module 2 - J992-

• ⇒ Rep. gr. 93 ; Installing battery module
• ⇒ Rep. gr. 93 ; Removing battery module

3. Battery module 3 - J993-

• ⇒ Rep. gr. 93 ; Installing battery module
• ⇒ Rep. gr. 93 ; Removing battery module

4. Battery module 4 - J994-

• ⇒ Rep. gr. 93 ; Installing battery module
• ⇒ Rep. gr. 93 ; Removing battery module

5. Battery module 5 - J995-

• ⇒ Rep. gr. 93 ; Installing battery module
• ⇒ Rep. gr. 93 ; Removing battery module

6. Battery module 6 - J996-

• ⇒ Rep. gr. 93 ; Installing battery module
• ⇒ Rep. gr. 93 ; Removing battery module

7. Battery module 7 - J997-

• ⇒ Rep. gr. 93 ; Installing battery module
• ⇒ Rep. gr. 93 ; Removing battery module

8. Battery module 8 - J998-

• ⇒ Rep. gr. 93 ; Installing battery module
• ⇒ Rep. gr. 93 ; Removing battery module

9. Battery module 9 - J999-

• ⇒ Rep. gr. 93 ; Installing battery module
• ⇒ Rep. gr. 93 ; Removing battery module

10. Battery module 10 - J1000-

• ⇒ Rep. gr. 93 ; Installing battery module
• ⇒ Rep. gr. 93 ; Removing battery module

11. Battery module 11 - J1001-

• ⇒ Rep. gr. 93 ; Installing battery module
• ⇒ Rep. gr. 93 ; Removing battery module

12. Battery module 12 - J1002-

• ⇒ Rep. gr. 93 ; Installing battery module
• ⇒ Rep. gr. 93 ; Removing battery module

13. Battery modules control unit - J1208-

• Rep. gr. 93 ; Removing and installing battery modules control unit

14. Battery modules control unit 5 - J1212-

• ⇒ Rep. gr. 93 ; Removing and installing battery modules control unit

15. Battery modules control unit 9 - J1216-

• ⇒ Rep. gr. 93 ; Removing and installing battery modules control unit

Overview of fitting locations - battery connectors

Overview shows high-voltage battery, 82 kWh as an example

1. Battery module 1 - J991-
2. Battery module 2 - J992-
3. Battery module 3 - J993-
4. Battery module 4 - J994-
5. Battery module 5 - J995-
6. Battery module 6 - J996-
7. Battery module 7 - J997-
8. Battery module 8 - J998-
9. Battery module 9 - J999-
10. Battery module 10 - J1000-
11. Battery module 11 - J1001-
12. Battery module 12 - J1002-

Assembly overview - high-voltage battery, removed, 48, 55, 62 kWh

Assembly overview - high-voltage battery (removed)

1. Upper part of battery housing

• ⇒ Rep. gr. 93 ; Opening high-voltage battery 1 AX2
• ⇒ Rep. gr. 93 ; Checking whether upper part of battery housing can be reused
• ⇒ Rep. gr. 93 ; Closing high-voltage battery 1 AX2

2. Bolt

• Qty. 14
• Renew after removing
• M5×18

3. Small fastener

• Qty. 2
• Renew after removing

4. Large fastener

• Qty. 2
• Renew after removing

5. Spacer

• Qty. 8

6. Bolt

• Qty. 72
• Renew after removing

7. Separating film

• Renew after removal of high-voltage battery 1 - AX2-
• Qty. 14

8. Lower part of battery housing
9. Bolt

• Qty. 16
• Renew after removing
• M5×25
• 4.5 Nm

10. Pressure relief valve

• Renew after removing

11. Potential equalisation
12. Nut

• M6×10
• 8 Nm

Upper part of battery housing - specified torque and tightening sequence 1

Upper part of battery housing - specified torque and tightening sequence 2 for production condition and repair bolt stage 2

Upper part of battery housing - specified torque and tightening sequence 2 for repair bolt stage 1

Assembly overview - high-voltage battery, removed, 82 kWh

Assembly overview - high-voltage battery (removed)

1. Upper part of battery housing

• ⇒ Rep. gr. 93 ; Opening high-voltage battery 1 AX2
• ⇒ Rep. gr. 93 ; Checking whether upper part of battery housing can be reused
• ⇒ Rep. gr. 93 ; Closing high-voltage battery 1 AX2

2. Bolt

• Qty. 22
• Renew after removing
• M5×18

3. Small fastener

• Qty. 2
• Renew after removing

4. Large fastener

• Qty. 2
• Renew after removing

5. Spacer

• Qty. 8

6. Bolt

• Qty. 82
• Renew after removing

7. Separating film

• Renew after removal of high-voltage battery 1 - AX2-
• Qty. 22

8. Lower part of battery housing
9. Bolt

• Qty. 16
• Renew after removing
• M5×25
• 4.5 Nm

10. Pressure relief valve

• Renew after removing

11. Potential equalisation line
12. Nut

• M6×10
• 8 Nm

Upper part of battery housing - specified torque and tightening sequence 1

Upper part of battery housing - specified torque and tightening sequence 2 for production condition and repair bolt stage 2

Upper part of battery housing - specified torque and tightening sequence 2 for repair bolt stage 1

Assembly overview - battery modules

1. Battery modules control unit

• ⇒ Rep. gr. 93 ; Removing and installing battery modules control unit

2. Bolt

• Qty. 2
• M5 x 25
• 4.5 Nm

3. Bolt

• Qty. 4
• Renew after removing
• M8 x 72
• 16 Nm + 180º

4. Battery module

• ⇒ Rep. gr. 93 ; Removing battery module
• ⇒ Rep. gr. 93 ; Installing battery module

5. Bolt

• Qty. 2
• M6 x 20
• 8 Nm

6. High-voltage connector
7. Bolt

• Qty. 3
• M8 x 25
• 20 Nm

8. Reinforcement for highvoltage battery body aperture

• Depending on equipment/version

Assembly overview - switching unit for high-voltage battery, 48, 55, 62 kWh

Assembly overview - switching unit for high-voltage battery

1. Cover

• 2x

2. Bolt

• 7x
• Renew after removing
• M6 x 20
• 8 Nm

3. Bridge
4. Bolt

• 9x
• M6 x 52
• 8 Nm

5. Switching unit for highvoltage battery, positive terminal - SX8-

• ⇒ Rep. gr. 93 ; Removing and installing switching unit for highvoltage battery, positive terminal SX8

6. Bolt

• Renew after removing
• M6 x 20
• 8 Nm

7. Switching unit for highvoltage battery, negative terminal - SX7-

• With high-voltage battery isolation igniter - N563-
• ⇒ Rep. gr. 93 ; Removing and installing switching unit for high-voltage battery, negative terminal SX7

8. Bolt

• M6 x 20
• 8 Nm

9. Electrical wire
10. Battery regulation control unit - J840-

• ⇒ Rep. gr. 93 ; Removing and installing battery regulation control unit J840

11. Electrical wire

Assembly overview - switching unit for high-voltage battery, 82 kWh

Assembly overview - switching unit for high-voltage battery

1. Cover

• 2x

2. Bolt

• 2x
• Renew after removing
• M6 x 20
• 8 Nm

3. Bolt

• 5x
• Renew after removing
• M6 x 20
• 8 Nm

4. Bridge
5. Bolt

• 9x
• M6 x 52
• 8 Nm

6. Switching unit for highvoltage battery, negative terminal - SX7-

• With high-voltage battery isolation igniter - N563-
• ⇒ Rep. gr. 93 ; Removing and installing switching unit for highvoltage battery, negative terminal SX7

7.  Electrical wire
8. Switching unit for highvoltage battery, positive terminal - SX8-

• ⇒ Rep. gr. 93 ; Removing and installing switching unit for high-voltage battery, positive terminal SX8

9. Bolt for high-voltage connecting bracket

• M6 x 20
• 8 Nm

10. Electrical wire
11. Battery regulation control unit - J840-

• ⇒ Rep. gr. 93 ; Removing and installing battery regulation control unit J840

Assembly overview - high-voltage battery, connecting element, 48, 55, 62 kWh

Assembly overview - high-voltage battery, connector strip

1. Connector strip

• ⇒ Rep. gr. 93 ; Removing and installing connector strip

2. Bolt

• Qty. 5
• Renew after removing
• Specified torque and tightening sequence
• M6×20

3. Bolt

• Qty. 16
• Renew after removing
• Specified torque and tightening sequence
• M5×25

Connector strip - specified torque and tightening sequence

Assembly overview - high-voltage battery, connecting element, 82 kWh

Assembly overview - high-voltage battery, connector strip

1. Connector strip

• ⇒ Rep. gr. 93 ; Removing and installing connector strip

2. Bolt

• Qty. 5
• Renew after removing
• Specified torque and tightening sequence
• M6×20

3. Bolt

• Qty. 16
• Renew after removing
• Specified torque and tightening sequence
• M5×25

Connection strip - specified torque and tightening sequence

Removing battery module

Special tools and workshop equipment required

• Contact protection - T10608-
• High-voltage tool kit - VAS 6762-
• High-voltage tool kit - VAS 6883A-
• adapter - 10-222A/14-
• contact protection - T10628-
• hook - 10-222A/10-
• lifting tackle - 3033-
• lifting tackle - T10619-
• removal wedge set - VAS 895 015-
• shackle - 10-222A/12-
• support bracket - 10-222B-
• workshop hoist - VAS 6100-

DANGER

High voltage can cause fatal injury.

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

• Suitable personal protective equipment (PPE) must be worn for the following work.
• The following steps require a second suitably qualified person to be present to supervise.
• Outside the danger zone, the second person may assist the high-voltage expert where required to the extent of his/her qualification.
• The personal protective equipment (PPE) must be dry and undamaged.

Put on protective equipment ⇒ Electronic parts catalogue (ETKA) before performing the following work steps:

• Clothing approved for working with electric arcs (minimum protection class 2, at least 318 kJ)
• Helmet with visor approved for working with electric arcs (minimum protection class 2, at least 318 kJ)
• Gloves approved for working with electric arcs with nitrile glove liners (minimum protection class 2, at least 318 kJ), minimum insulating effect up to 500 V
• Safety shoes with ESD protection
• ⇒ Rep. gr. 93 ; Open high-voltage battery 1 AX2 .
• ⇒ Rep. gr. 93 ; Interrupt electrical circuit .
• ⇒ Rep. gr. 93 ; Charging and discharging battery modules
• Mark installation position of electrical connectors and highvoltage connecting brackets.
• Unplug electrical connector -2-.
• Fit contact protection - T10628- -A- on battery module -1-.
• Remove bolts -3-.
• Remove high-voltage connecting bracket -4-.
• Fit contact protection - T10608- on open high-voltage connection at battery module.

Important

•  Contact protection - T10608- -B- must be fitted.
• Fit contact protection - T10628- -A-.
• Remove bolts -2-.
• Remove high-voltage connecting bracket -3-.
• Fit contact protection - T10608- on open high-voltage connection at battery module.

Important

• Contact protection - T10608- -2- must be fitted on open highvoltage connections.
• Remove bolts -3-.

NOTICE

Mechanical forces on connector housing of battery modules control unit Risk of damage to battery modules control unit

• Unplug electrical connector of battery modules control unit in vicinity of battery module that is to be removed.
• Prepare support bracket - 10-222B- -1- and adapter - 10-222A/14- -2- and position over centre of battery module.
• Connect battery module to lifting tackle - T10619- -3-, shackle - 10-222A/12- -4- and hook - 10-222A/10- -5-.

• Lift battery module off lower part of battery housing at outside in direction of -arrow- until battery module is released.

• Remove support bracket - 10-222B- -1- and adapter - 10-222A/14- -2-.
• Attach lifting tackle - 3033- -B- to workshop hoist - VAS 6100- -A-.
• Lift battery module -1- using workshop hoist - VAS 6100- -A-, lifting tackle - T10619- -D-, shackle - 10-222A/12- -Cand lifting tackle - 3033- -B-.
• Set battery module down on a clean surface.

Important

• After the module has been lifted, the 2-component thermal grease must be renewed.

NOTICE

Risk of leaks in high-voltage battery 1 - AX2- .

• Do not remove 2-component thermal grease from sealant on inner edge of lower part of battery housing. If 2-component thermal grease is touching sealant, leave approx. 3 mm of 2-component thermal grease on sealant.
• Carefully remove 2-component thermal grease residue from lower part of battery housing using a suitable scraper from removal wedge set - VAS 895 015- .

If reusing battery module

• Remove 2-component thermal grease from battery module, making sure no residue is left.

Installing battery module

Special tools and workshop equipment required

• High-voltage tool kit - VAS 6762-
• High-voltage tool kit - VAS 6883A-
• Torque wrench - VAS 6883/1A-
• accidental contact protection - T10608-
• accidental contact protection insert - T10628-
• cartridge opener - VAS 221 005-
• double cartridge gun - VAS 5237-
• lifting bracket - T10619-
• lifting tackle - 3033-
• reversible ratchet - VAS 6762/29-
• shackle - 10-222A/12-
• template - T10606-
• workshop hoist - VAS 6100-

DANGER

High voltage can cause fatal injury.

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

• Suitable personal protective equipment (PPE) must be worn for the following work.
• The following steps require a second suitably qualified person to be present to supervise.
• Outside the danger zone, the second person may assist the high-voltage expert where required to the extent of his/her qualification.
•  The personal protective equipment (PPE) must be dry and undamaged.

Put on the required protective equipment for the subsequent work steps ⇒ Electronic parts catalogue (ETKA) :

•  Arc flash resistant clothing (at least APC 2, at least 318 kJ)
• Helmet with arc flash resistant visor (at least APC 2, at least 318 kJ)
• Arc flash resistant gloves with nitrile glove liners (at least APC 2, at least 318 kJ), insulating up to at least 500 V
• Safety shoes with ESD protection

Installing

• On removed battery module, check if separating film of lower part of battery housing -2- is present and undamaged.
• Only affix separating film -2- on inner edges of lower part of battery housing -1-.

Important

• Removed battery modules must be inserted in lower part of battery housing with 2-pack thermal grease ⇒ Electronic parts catalogue (ETKA) .
• Before installing, adhere to cleaning solution flash-off time of 10 minutes.
• Bonding surfaces are dry.
• Clean surfaces onto which 2-pack thermal compound is to be applied using cleaning solution ⇒ Electronic parts catalogue (ETKA) .
• Insert template - T10606- -A- into lower part of battery housing.

  Push in direction of -arrows- up to position shown.

NOTICE

• 2-pack thermal grease application insufficient.

  Thermal conductivity impaired.

• Apply 2-pack thermal grease in one pass and without bubbles.

Important

• Use cartridge opener - VAS 221 005- to open cartridge.
• Fill 2-pack thermal grease -A- using double cartridge gun - VAS 5237- -C- up to edge of template - T10606- -B-.
• Remove template - T10606- -B- from lower part of battery housing.

• Attach lifting tackle - 3033- -B- to workshop hoist - VAS 6100- -A-.
• Position battery module -1- with workshop hoist - VAS 6100- -A-, lifting bracket - T10619- -D-, shackle - 10-222A/12- -Cand lifting tackle - 3033- -B- above lower part of battery housing.
• Screw in bolts of battery module by hand to continue guiding battery module.
• Lower battery module -1- into lower part of battery housing up to 3 cm before end position. Screw in bolts 3 to 4 turns of thread.
• Lower battery module -1- to final position.

Important

• Torque must be monitored by a 2nd person.
• Tighten bolts of battery module in diagonal sequence using torque wrench - VAS 6883/1A- .
• Tighten bolts of battery module to turning further angle in diagonal sequence using reversible ratchet - VAS 6762/29- .

Installing

Important

• Torque must be monitored by a 2nd person.
• Remove accidental contact protection - T10608- from battery module -1-.
• Fit accidental contact protection insert - T10628- -A-.
• Install battery connector -4-.
• Tighten bolts -3-.
• Test battery connector against housing for short circuit.
• Connect electrical connector -2-.

Important

• Torque must be monitored by a 2nd person.

• Remove accidental contact protection - T10608- -B- from battery module -1-.
• Fit accidental contact protection insert - T10628- -A-.
• Install battery connector -3-.
• Tighten bolts -2-.
• Test battery connector against housing for short circuit.

Tightening torques

• ⇒ Rep. gr. 93 ; Assembly overview - high-voltage battery, battery modules

Removing and installing battery modules control unit

Special tools and workshop equipment required

• High-voltage tool kit - VAS 6762-
• Torque wrench, insulated - VAS 691 001-

DANGER

High voltage can cause fatal injury.

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

• Suitable personal protective equipment (PPE) must be worn for the following work.
• The following steps require a second suitably qualified person to be present to supervise.
• Outside the danger zone, the second person may assist the high-voltage expert where required to the extent of his/her qualification.
• The personal protective equipment (PPE) must be dry and undamaged.

Put on protective equipment ⇒ Electronic parts catalogue (ETKA) before performing the following work steps:

• Clothing approved for working with electric arcs (minimum protection class 2, at least 318 kJ)
• Helmet with visor approved for working with electric arcs (minimum protection class 2, at least 318 kJ)
• Gloves approved for working with electric arcs with nitrile glove liners (minimum protection class 2, at least 318 kJ), minimum insulating effect up to 500 V
• Safety shoes with ESD protection Battery modules control unit - J1208- is referred to as battery modules control unit below.

Battery modules control unit 5 - J1212- is referred to as battery modules control unit below.

Battery modules control unit 9 - J1216- is referred to as battery modules control unit below.

Removing

• ⇒ Rep. gr. 93 ; Open high-voltage battery 1 AX2 .
• ⇒ Rep. gr. 93 ; Interrupt electrical circuit .

NOTICE

Risk of damage to high-voltage battery 1 - AX2- if components are interchanged.

• Mark installation position of electrical connectors, cable routing and installation position of battery modules control unit.

• Unplug electrical connectors -3- and -4- and move electrical wire to one side.
• Remove bolts -2-.
• Remove battery modules control unit -1-.

Installing

Installation is carried out in reverse order; note the following:

• Perform "Controller configuration" function with ⇒ Vehicle diagnostic tester ⇒ Rep. gr. 00 ; Starting diagnosis .

Tightening torques

• ⇒ Rep. gr. 93 ; Assembly overview - high-voltage battery, battery modules

Removing and installing connecting element, 48, 55 kWh

Removing and installing connector strip

Special tools and workshop equipment required

• High-voltage tool kit - VAS 6762-
• High-voltage tool kit - VAS 6883A-
• Torque wrench - VAS 6883/1A-
• contact protection - T10608-
• contact protection - T10628-

DANGER

High voltage can cause fatal injury.

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

• Suitable personal protective equipment (PPE) must be worn for the following work.
• The following steps require a second suitably qualified person to be present to supervise.
• Outside the danger zone, the second person may assist the high-voltage expert where required to the extent of his/her qualification.
• The personal protective equipment (PPE) must be dry and undamaged.

Put on protective equipment ⇒ Electronic parts catalogue (ETKA) before performing the following work steps:

• Clothing approved for working with electric arcs (minimum protection class 2, at least 318 kJ)
• Helmet with visor approved for working with electric arcs (minimum protection class 2, at least 318 kJ)
• Gloves approved for working with electric arcs with nitrile glove liners (minimum protection class 2, at least 318 kJ), minimum insulating effect up to 500 V
• Safety shoes with ESD protection Switching unit for high-voltage battery, negative terminal - SX7- is referred to below as switching unit, negative terminal.

Removing

• ⇒ Rep. gr. 93 ; Open high-voltage battery 1 AX2 .
• ⇒ Rep. gr. 93 ; Interrupt electrical circuit .
• Fit contact protection - T10628- on battery module 2 - J992- .
• Unscrew bolts -2- from high-voltage connecting brackets -1- on switching unit, negative terminal -3- and battery module 2 - J992- .
• Remove high-voltage connecting bracket -1-.
• Fit contact protection - T10608- on open high-voltage connection at battery module 2 - J992- .
• Detach cap for switching unit, negative terminal -3-.

• Remove bolts -2-.
• Remove bolts -3-.
• Remove connector strip -1-.

Installing

Installation is carried out in reverse order; note the following:

Important

• Have a second person check all torques.
• Check that seal is not damaged.
• Clean sealing surface with cleaning solution ⇒ Electronic parts catalogue (ETKA) .
• Apply sealant ⇒ Electronic parts catalogue (ETKA) all around outside of connector strip next to existing seal.
• Ensure lower part of battery housing makes contact with seal.
• Install high-voltage connecting bracket and check it for short circuit to lower part of battery housing.

Tightening torques

• ⇒ Rep. gr. 93 ; Assembly overview - switching unit for high-voltage battery
• ⇒ Rep. gr. 93 ; Assembly overview - high-voltage battery, connector strip

Removing and installing connecting element, 62 kWh

Removing and installing connector strip

Special tools and workshop equipment required

• High-voltage tool kit - VAS 6762-
• High-voltage tool kit - VAS 6883A-
• Torque wrench - VAS 6883/1A-
• accidental contact protection - T10608-
• accidental contact protection insert - T10628-

DANGER

High voltage can cause fatal injury.

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

• Suitable personal protective equipment (PPE) must be worn for the following work.
• The following steps require a second suitably qualified person to be present to supervise.
• Outside the danger zone, the second person may assist the high-voltage expert where required to the extent of his/her qualification.
• The personal protective equipment (PPE) must be dry and undamaged.

Put on the required protective equipment for the subsequent work steps ⇒ Electronic parts catalogue (ETKA) :

• Arc flash resistant clothing (at least APC 2, at least 318 kJ)
• Helmet with arc flash resistant visor (at least APC 2, at least 318 kJ)
• Arc flash resistant gloves with nitrile glove liners (at least APC 2, at least 318 kJ), insulating up to at least 500 V
• Safety shoes with ESD protection Switching unit for high-voltage battery, negative terminal - SX7- is referred to hereafter as switching unit, negative terminal.

Removing

• ⇒ Rep. gr. 93 ; Open high-voltage battery 1 [AX2] .
• ⇒ Rep. gr. 93 ; Open electrical circuit .
• Fit accidental contact protection insert - T10628- onto battery module 1 - J991- .
• Unscrew bolts -3- from high-voltage connector -2- on switching unit, negative terminal -1- and battery module 1 - J991- .
• Remove high-voltage connector -2-.
• Fit accidental contact protection - T10608- onto exposed high-voltage connection on battery module 1 - J991- .
• Detach cap for switching unit, negative terminal -1-.

• Unscrew bolts -2-.
• Unscrew bolts -3-.
• Remove connector strip -1-

Installing

Install in reverse order of removal, observing the following:

Important

•  Have an additional person observe all torque settings.
• Make sure not to damage seal.
• Clean sealing surface with cleaning solution ⇒ Electronic parts catalogue (ETKA) .

• Apply sealant ⇒ Electronic parts catalogue (ETKA) all around on outer side of connector strip, next to existing seal.
• Make sure that seal makes contact with lower part of battery housing.
• Install high-voltage connector and check for short circuit to lower part of battery housing.

Tightening torques

• ⇒ Rep. gr. 93 ; Assembly overview - switching unit for high-voltage battery
• ⇒ Rep. gr. 93 ; Assembly overview - high-voltage battery, connector strip

Removing and installing connecting element, 82 kWh

Removing and installing connector strip

Special tools and workshop equipment required

• High-voltage tool kit - VAS 6762-
• High-voltage tool kit - VAS 6883A-
• Torque wrench - VAS 6883/1A-
• contact protection - T10608-
• contact protection - T10628-

DANGER

High voltage can cause fatal injury.

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

• Suitable personal protective equipment (PPE) must be worn for the following work.
• The following steps require a second suitably qualified person to be present to supervise.
• Outside the danger zone, the second person may assist the high-voltage expert where required to the extent of his/her qualification.
• The personal protective equipment (PPE) must be dry and undamaged.

Put on protective equipment ⇒ Electronic parts catalogue (ETKA) before performing the following work steps:

• Clothing approved for working with electric arcs (minimum protection class 2, at least 318 kJ)
• Helmet with visor approved for working with electric arcs (minimum protection class 2, at least 318 kJ)
• Gloves approved for working with electric arcs with nitrile glove liners (minimum protection class 2, at least 318 kJ), minimum insulating effect up to 500 V
• Safety shoes with ESD protection

Switching unit for high-voltage battery, negative terminal - SX7- is referred to below as switching unit, negative terminal.

Switching unit for high-voltage battery, positive terminal - SX8- is referred to below as switching unit, positive terminal.

Removing

• ⇒ Rep. gr. 93 ; Open high-voltage battery 1 AX2 .
• ⇒ Rep. gr. 93 ; Interrupt electrical circuit .
• Fit contact protection - T10628- on battery module 1 - J991- and battery module 2 - J992- .
• Unscrew bolts -2- from high-voltage connecting brackets -1- on switching unit, negative terminal -3-, switching unit, positive terminal -3-, battery module 1 - J991- and battery module 2 - J992- .
• Remove high-voltage connecting bracket -1-.
• Fit contact protection - T10608- on open high-voltage connection on battery module 1 - J991- and battery module 2 - J992- .
• Detach caps for switching unit, negative terminal -3- and switching unit, positive terminal -3-.

• Remove bolts -2-.
• Remove bolts -3-.
• Remove connector strip -1-.

Installing

Installation is carried out in reverse order; note the following:

Important

• Have a second person check all torques.
• Check that seal is not damaged.
• Clean sealing surface with cleaning solution ⇒ Electronic parts catalogue (ETKA) .
• Apply sealant ⇒ Electronic parts catalogue (ETKA) all around outside of connector strip next to existing seal.
• Ensure lower part of battery housing makes contact with seal.
• Install high-voltage connecting bracket and check it for short circuit to lower part of battery housing.

Tightening torques

• ⇒ Rep. gr. 93 ; Assembly overview - switching unit for high-voltage battery
• ⇒ Rep. gr. 93 ; Assembly overview - high-voltage battery, connector strip

Removing and installing switching unit for high-voltage battery, negative terminal SX7

Installing

• Battery regulation control unit - J840- , switching unit for high-voltage battery, negative terminal - SX7- and switching unit for high-voltage battery, positive terminal - SX8- must be renewed together ⇒ Rep. gr. 93 ; Removing and installing battery regulation control unit [J840] .

Removing and installing switching unit for high-voltage battery, positive terminal SX8

Installing

• Battery regulation control unit - J840- , switching unit for high-voltage battery, negative terminal - SX7- and switching unit for high-voltage battery, positive terminal - SX8- must be renewed together ⇒ Rep. gr. 93 ; Removing and installing battery regulation control unit [J840] .