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

• Assembly overview - high-voltage battery, installed, 48, 55, 62 kWh
• Assembly overview - high-voltage battery, installed, 82 kWh
• Inspecting and classifying high-voltage battery 1 AX2
• Checking high-voltage battery for leaks
• Removing and installing high-voltage battery 1 [AX2], 48, 55, 62 kWh
• Removing and installing high-voltage battery 1 [AX2], 82 kWh
• h3 {color: blue;} h4 {color: #FF00FF;}
• Raising high-voltage battery 1 [AX2]
• Opening high-voltage battery 1 AX2
• Sealing high-voltage battery 1 [AX2], 48, 55, 62 kWh
• Sealing high-voltage battery 1 [AX2], 82 kWh
• Voltage and insulation measurement, 48, 55, 62 kWh
• Voltage and insulation measurement, 82 kWh
• Opening electrical circuit, 48, 55 kWh
• Opening electrical circuit, 62 kWh
• Opening electrical circuit, 82 kWh
• Removing and installing battery regulation control unit J840
• Checking whether upper part of battery housing can be reused
• Renewing lower part of battery housing

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

Assembly overview - high-voltage battery, installed

1. High-voltage battery 1 - AX2-

• ⇒ Rep. gr. 93 ; Removing and installing high-voltage battery 1 [AX2]

2. Bolt

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

3. Skid plate for high-voltage battery

•  ⇒ General body repairs, exterior; Rep.

  gr. 66 ; Underbody cladding; Removing and installing high-voltage battery skid plate

4. Reinforcement for highvoltage battery body aperture
5. Centre underbody cladding

• ⇒ General body repairs, exterior; Rep.

  gr. 66 ; Underbody cladding; Removing and installing centre underbody cladding

6. Bolt

• Qty. 14
• Renew after removing
• Specified torque and tightening sequence

7. Bolt

• Qty. 4
• Renew after removing
• Specified torque and tightening sequence

8. Banjo bolt

• Qty. 4
• Renew after removing
• 150 Nm

High-voltage battery - specified torque and tightening sequence

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

Assembly overview - high-voltage battery, installed

1. High-voltage battery 1 - AX2-

• ⇒ Rep. gr. 93 ; Removing and installing high-voltage battery 1 [AX2]

2. Bolt

• Qty. 24
• Renew after removing
• Specified torque and tightening sequence

3. Skid plate for high-voltage battery

• ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody cladding; Removing and installing high-voltage battery skid plate

4. Bolt

• Qty. 4
• Renew after removing
• Specified torque and tightening sequence

5. Banjo bolt

• Qty. 4
• Renew after removing
• 150 Nm

High-voltage battery - specified torque and tightening sequence

Inspecting and classifying high-voltage battery 1 AX2

Special tools and workshop equipment required

• diagnosis box - VAS 5581A-
• diagnostic cable - VAS 5581A/11-
• vehicle diagnostic tester

CAUTION

The high-voltage battery can become extremely hot. This can cause injuries.

Take care not to burn your hands.

• Put on protective gloves.

Note

Inform the high-voltage expert if any problems arise or entries in the event memory appear.

Visual inspection of high-voltage battery 1 [AX2]

Inspect the high-voltage battery 1 - AX2- for the following:

• Cracks in upper or lower parts of battery housing
• Deformations in upper or lower parts of battery housing
• Colour changes due to temperature impact and tarnishing of battery housing
• Escaping electrolyte
• Damage to high-voltage contacts
• Legible information and warning stickers properly in place
• Fitted potential equalisation line
• Corrosion damage
• If abnormalities are detected during the visual inspection, a classification of the high-voltage battery 1 - AX2- must be carries out.

Preparatory work on removed high-voltage battery:

•  Connect diagnosis box - VAS 5581A- via diagnostic cable - VAS 5581A/11- to vehicle diagnostic tester .

Important

• Before commencing the diagnosis, Gateway (GW) operating mode must be selected on the diagnosis box - VAS 5581A- .

• Connect diagnostic cable - VAS 5581A/11- to 12V-connector -1- of high-voltage battery 1 - AX2- .
• Connect black earth terminal of diagnostic cable - VAS 5581A/11- to earth of battery housing -arrow-.

Classification of high-voltage battery:

• Carry out classification of high-voltage battery using ⇒ Vehicle diagnostic tester ⇒ Rep. gr. 00 ; Access to diagnoses .

Diagnosis of high-voltage battery 1 [AX2]

Special tools and workshop equipment required

• diagnosis box - VAS 5581A-
• diagnostic cable - VAS 5581A/11-
• vehicle diagnostic tester

High-voltage battery installed

Important

• The high-voltage battery 1 remains installed in the vehicle during the diagnosis.

• Carry out diagnosis of high-voltage battery using ⇒ Vehicle diagnostic tester ⇒ Rep. gr. 00 ; Access to diagnosis .

High-voltage battery removed

• Connect diagnosis box - VAS 5581A- via diagnostic cable - VAS 5581A/11- to vehicle diagnostic tester .

Important

• Before commencing the diagnosis, Gateway (GW) operating mode must be selected on the diagnosis box - VAS 5581A- .

• Connect diagnostic cable - VAS 5581A/11- to 12V-connector -1- of high-voltage battery 1 - AX2- .
•  Connect black earth terminal of diagnostic cable - VAS 5581A/11- to earth of battery housing -arrow-.
• Carry out diagnosis of high-voltage battery using ⇒ Vehicle diagnostic tester ⇒ Rep. gr. 00 ; Access to diagnosis .

For further measures on high-voltage battery:

• Disconnect diagnosis box - VAS 5581A- .

Checking high-voltage battery for leaks

Special tools and workshop equipment required

• pressure and vacuum pump - VAS 671 005-
• sealing plugs - T10607-

Note

Searching for leaks from the high-voltage battery 1 - AX2- is only required if the leak test under pressure failed.

Note

Leaks are indicated by bubbles.

Note

Leaks can potentially be traced to the banjo bolts on the underside of high-voltage battery 1 - AX2- .

• Seal connections of high-voltage battery 1 - AX2- using sealing plugs - T10607- .
• Build up pressure using pressure and vacuum pump - VAS 671 005- .
• Using commercially available leak detection spray

• Spray contact surfaces of upper part of battery housing and lower part of battery housing.
• Spray banjo bolts on underside

Leakage test of high-voltage battery 1 [AX2]

Special tools and workshop equipment required

• Distributor - VAS 691 005/1-
• Pressure and vacuum pump - VAS 671 005-
• Pressure sensor - V.A.G 1397B-
• Pressure sensor - VAS 611 013-
• Sealing plug - T10607-
• Test connector set - VAS 6911/3B
• Sealing plug - T10607-
• Test connector set - VAS 6911/3B

Important

• A leak test must always be carried out with vacuum before removing and after installing the high-voltage battery 1 - AX2- .
• High-voltage battery 1 - AX2- is acclimatised.
• The leakage test and acclimatisation must be carried out at a steady ambient temperature.

• Check that gasket -arrows- is correctly seated.
• Check connector strip for moisture. Carefully wipe with lintfree cleaning cloth

• Carry out "Leak test" function with ⇒ Vehicle diagnostic tester ⇒ Rep. gr. 00 ; Access to diagnoses .

Removing and installing high-voltage battery 1 [AX2], 48, 55, 62 kWh

Removing and installing high-voltage battery 1 [AX2]

Special tools and workshop equipment required

• drip tray - VAS 6208-
• engine bung set - VAS 6122-
• hose clamps, up to 25 mm - 3094-
• insulating mat - VAS 6762/44-
• scissor-type assembly platform - VAS 6131BID

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.

CAUTION

The high-voltage battery can become extremely hot. This can cause injuries.

Take care not to burn your hands.

• Put on protective gloves.

NOTICE

Potential damage to vehicle

• Make sure that nobody is inside the vehicle after the highvoltage battery has been removed

The high-voltage battery 1 - AX2- will subsequently be referred to as "high-voltage battery".

Removing

• ⇒ Rep. gr. 93 ; Visual inspection of high-voltage battery 1 [AX2] .

NOTICE

Potential damage to vehicle from slipping.

• The dimensions of the vehicle support plates and their spindles must be sufficient to ensure that the load that is imparted centrally between the outer edge and centre of the vehicle support plates can be supported. If the dimensions are not sufficient, different vehicle support plates must be used that meet this requirement.

Note

Not every lifting platform is suitable for the removal of the highvoltage battery. Ensure that there is sufficient clearance. When lifting, ensure that there is sufficient clearance -a- around the high-voltage battery so that it can be placed on the scissor-type assembly platform - VAS 6131B- .

• Swivel lifting platform arm with vehicle support plate -1- up to frame of high-voltage battery -2-. Then swivel back lifting platform arm with vehicle support plate -1- far enough -ato allow for lowering high-voltage battery -2- in the following step.

• Remove front underbody cladding ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody cladding; Removing and installing front underbody cladding .
• Detach front right wheel housing liners in area of threaded connection of high-voltage battery ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing liner; Removing and installing front wheel housing liner .
• Remove side underbody cladding ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody cladding; Removing and installing side underbody cladding .
• Remove centre underbody cladding.
• Remove rear centre underbody cladding ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody cladding; Removing and installing rear centre underbody cladding .
• Remove rear underbody cladding ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody cladding; Removing and installing rear underbody cladding .
• Loosen and unscrew bolts -2- by hand.
• Pull out reinforcement for high-voltage battery body aperture -1-.
• ⇒ Rep. gr. 93 ; De-energising high-voltage system

• Unscrew nut for potential equalisation line -1-. Counterhold on centre hex stud, when doing this.
• Disconnect electrical connector of high-voltage battery -2-.
• Disconnect electrical connector for auxiliary consumers -5-
• ⇒ Rep. gr. 93 ; Disconnecting high-voltage connectors .
• Remove pressure relief valve -3-.

• Perform ⇒ Rep. gr. 93 ; leakage test of high-voltage battery 1 [AX2] .
• Disconnect high-voltage system connection -4- ⇒ Rep. gr. 93 ; Disconnecting high-voltage connectors .
• Disconnect DC charging connection -6-.

• Check that gasket -arrows- is correctly seated.
• Check connector strip for moisture, and carefully wipe it dry with a lint-free cloth.

• Fit cap -2- on connector strip -1-.

• Unscrew bolts -1- from coolant pump for high-voltage battery - V590- .
• Open clip -2-.

• Pull coolant pump in direction of -arrow-, and disconnect electrical connector -1-.

• Loosen bolts -2- and -3- by hand.
• Unscrew bolts -2- and -3- from high-voltage battery -1-.

NOTICE

Risk of damage to the high-voltage battery.

• The high-voltage battery must lie flat against the scissortype assembly platform - VAS 6131B- . Remove any kind of soiling.

Important

• Scissor-type assembly platform and front side of high-voltage battery must be flush -arrow-.
• Lay insulating mat - VAS 6762/44- -2- centrally on scissortype assembly platform - VAS 6131B- -3-.

• Align scissor-type assembly platform - VAS 6131B- -1- so that it is flush with front side of high-voltage battery; highvoltage battery must lie flat against the platform.

CAUTION

Risk of injury from moving parts.

Body parts could suffer contusions.

• Never reach or step into the hazard zone.

NOTICE

Risk of damage to components caused by moving scissortype assembly platform.

• Ensure sufficient clearance to body.
• Ensure sufficient clearance to electrical wiring and electrical connectors.

• Raise scissor-type assembly platform - VAS 6131B- -3- far enough to take up weight of high-voltage battery -1-.
• Loosen and unscrew bolts -2- from high-voltage battery -1- by hand.

• Carefully lower high-voltage battery until coolant connections become accessible.
• Place drip tray - VAS 6208- under coolant connections.
• Clamp off coolant hoses -1- and -2- using hose clamps, up to 25 mm - 3094- -A-.

• Pull out retaining clips for coolant connections -1- in direction of -arrow-, and pull coolant hoses off high-voltage battery.
• Seal coolant connections with plugs from engine bung set - VAS 6122- .

• Carefully lower high-voltage battery.

Secure media duct -1- with screws -2- ⇒ Electronic parts catalogue (ETKA)

Installing

Install in reverse order of removal, observing the following:

New high-voltage battery

• Perform procedure for renewal of high-voltage battery ⇒ Rep. gr. 93 ; Renewing high-voltage battery 1 [AX2] .

All vehicles (continued)

Removed high-voltage battery

• Remove separating film -2- from lower part of battery housing -1-.
• Clean area of separating film -2- with cleaning solution ⇒ Electronic parts catalogue (ETKA) .
• Renew separating film -2-.

All vehicles (continued)

CAUTION

Risk of injury from moving parts.

Body parts could suffer contusions.

• Never reach or step into the hazard zone.

NOTICE

Risk of damage to components caused by moving scissortype assembly platform.

• Ensure sufficient clearance to body.
• Ensure sufficient clearance to electrical wiring and electrical connectors.

• Align high-voltage battery on scissor-type assembly platform - VAS 6131B- under vehicle.
• Raise high-voltage battery on scissor-type assembly platform - VAS 6131B- to 5 cm before end position.
• Connect coolant hoses.
• Raise high-voltage battery on scissor-type assembly platform - VAS 6131B- to end position.

• Tighten bolts -2- to specified torque according to specified tightening sequence.

• Tighten bolts -2- and -3- to specified torque according to specified tightening sequence.

• Connect high-voltage system connection -4-.
• Connect DC charging connection -6-.

• Perform ⇒ Rep. gr. 93 ; leakage test of high-voltage battery 1 [AX2] .
• Connect electrical connector of high-voltage battery -2-.
• Connect electrical connector for auxiliary consumers -5-.
• Install pressure relief valve -3-.

• Install body aperture reinforcement for high-voltage battery -1-. To do this, tighten bolts -2- in specified tightening sequence to specified torque.

• Tighten nut for potential equalisation line to specified torque.

  Counterhold on centre hex stud when doing this.

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

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 - high-voltage battery (installed)
• ⇒ Rep. gr. 93 ; Overview of fitting locations - potential equalisation lines

Removing and installing high-voltage battery 1 [AX2], 82 kWh

Removing and installing high-voltage battery 1 [AX2]

Special tools and workshop equipment required

• drip tray - VAS 6208-
• engine bung set - VAS 6122-
• hose clamps, up to 25 mm - 3094-
• insulating mat - VAS 6762/44-
• scissor-type assembly platform - VAS 6131B

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.

CAUTION

The high-voltage battery can become extremely hot. This can cause injuries.

Take care not to burn your hands.

• Put on protective gloves.

NOTICE

Potential damage to vehicle

• Make sure that nobody is inside the vehicle after the highvoltage battery has been removed.

The high-voltage battery 1 - AX2- will subsequently be referred to as "high-voltage battery".

Removing

• ⇒ Rep. gr. 93 ; Visual inspection of high-voltage battery 1 [AX2] .

NOTICE

Potential damage to vehicle from slipping.

•  The dimensions of the vehicle support plates and their spindles must be sufficient to ensure that the load that is imparted centrally between the outer edge and centre of the vehicle support plates can be supported. If the dimensions are not sufficient, different vehicle support plates must be used that meet this requirement

Note

Not every lifting platform is suitable for the removal of the highvoltage battery. Ensure that there is sufficient clearance. When lifting, ensure that there is sufficient clearance -a- around the high-voltage battery so that the high-voltage battery can be placed on the scissor-type assembly platform - VAS 6131B- .

• Swivel lifting platform arm with vehicle support plate -1- up to frame of high-voltage battery -2-. Then swivel back lifting platform arm with vehicle support plate -1- far enough -ato allow for lowering high-voltage battery -2- in the following step.

• Remove front underbody cladding ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody cladding; Removing and installing front underbody cladding .
• Detach front right wheel housing liners in area of threaded connection of high-voltage battery ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing liner; Removing and installing front wheel housing liner .
• Remove side underbody cladding ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody cladding; Removing and installing side underbody cladding .
• Remove rear centre underbody cladding ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody cladding; Removing and installing rear centre underbody cladding .
• Remove rear underbody cladding ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody cladding; Removing and installing rear underbody cladding .
• ⇒ Rep. gr. 93 ; De-energise high-voltage system .

NOTICE

Potential leakage of the high-voltage battery due to impurities in the seal area of the electrical plug connectors.

• Sealing surfaces on the connector strip must be free of impurities.

• Remove coarse soiling in area of electrical connectors.
• Unscrew nut for potential equalisation line -1-. Counterhold on centre hex stud, when doing this.
• Disconnect electrical connector of high-voltage battery -2-.
• Disconnect electrical connector for auxiliary consumers -5- ⇒ Rep. gr. 93 ; Disconnecting high-voltage connectors .
• Remove pressure relief valve -3-.

• Perform ⇒ Rep. gr. 93 ; leakage test of high-voltage battery 1 [AX2] .

Note

For better disconnection of the high-voltage system connector, the guide of the high-voltage system connection cable must be removed.

• Unclip locking devices -arrow-.
• Separate lower part of cable duct -1- from cable duct cover -2-.

• Disconnect high-voltage system connection -4- ⇒ Rep. gr. 93 ; Disconnecting high-voltage connectors .
• Disconnect DC charging connection -6-.

• Check that gasket -arrows- is correctly seated.
• Carefully absorb moisture from connector strip using lint-free cleaning cloth.

NOTICE

Potential leakage of the high-voltage battery due to impurities in the seal area of the electrical plug connectors.

• Sealing surfaces on the connector strip must be free of impurities.

• Remove soiling from connector strip using lint-free cleaning cloth and cleaning solution ⇒ Electronic parts catalogue (ETKA) .

• Fit cap -2- on connector strip -1-.

• Unscrew bolts -1- from coolant pump for high-voltage battery - V590- .
• Open clip -2-.

• Pull coolant pump in direction of -arrow-, and disconnect electrical connector -1-.

• Loosen bolts -2- and -3- by hand.
• Unscrew bolts -2- and -3- from high-voltage battery -1-.

NOTICE

Risk of damage to the high-voltage battery.

• The high-voltage battery must lie flat against the scissortype assembly platform - VAS 6131B- . Remove any kind of soiling.
• Note position of the spirit level -3- on the scissor-type assembly platform - VAS 6131B- .

• Lay insulating mat - VAS 6762/44- centrally on scissor-type assembly platform - VAS 6131B- -1-.
• Place scissor-type assembly platform - VAS 6131B- -1- underneath, and align it so that high-voltage battery -2- can lie flat against it.

CAUTION

Risk of injury from moving parts.

Body parts could suffer contusions.

• Never reach or step into the hazard zone.

NOTICE

Risk of damage to components caused by moving scissortype assembly platform.

• Ensure sufficient clearance to body.
•  Ensure sufficient clearance to electrical wiring and electrical connectors.
• Raise scissor-type assembly platform - VAS 6131B- -1- far enough to take weight off high-voltage battery.

• Loosen and unscrew bolts -2- from high-voltage battery -1- by hand.

• Carefully lower high-voltage battery until coolant connections become accessible.
• Place drip tray - VAS 6208- under coolant connections

• Clamp off coolant hoses -1- and -2- using hose clamps, up to 25 mm - 3094- -A-.

• Pull out retaining clips for coolant connections -1- in direction of -arrow-, and pull coolant hoses off high-voltage battery.
• Seal coolant connections with plugs from engine bung set - VAS 6122- .
• Carefully lower high-voltage battery.
• Secure media duct -1- with screws -2- ⇒ Electronic parts catalogue (ETKA) .

Installing

Install in reverse order of removal, observing the following:

New high-voltage battery:

• Perform procedure for renewal of high-voltage battery ⇒ Rep. gr. 93 ; Renewing high-voltage battery 1 [AX2] .

All vehicles (continued)

Removed high-voltage battery

• Remove separating film -2- from lower part of battery housing -1-.
• Clean area of separating film -2- with cleaning solution ⇒ Electronic parts catalogue (ETKA) .
• Renew separating film -2-.

All vehicles (continued)

CAUTION

Risk of injury from moving parts.

Body parts could suffer contusions.

• Never reach or step into the hazard zone.

NOTICE

Risk of damage to components caused by moving scissortype assembly platform.

• Ensure sufficient clearance to body.
• Ensure sufficient clearance to electrical wiring and electrical connectors.

• Align high-voltage battery on scissor-type assembly platform
• VAS 6131B- under vehicle.
• Raise high-voltage battery on scissor-type assembly platform - VAS 6131B- to 5 cm before end position.
• Connect coolant hoses.
• Raise high-voltage battery on scissor-type assembly platform - VAS 6131B- to end position.
• Tighten bolts -2- to specified torque according to specified tightening sequence.

• Tighten bolts -2- and -3- to specified torque according to specified tightening sequence.

• Connect high-voltage system connection -4-.
• Connect DC charging connection -6-.

• Perform ⇒ Rep. gr. 93 ; leakage test of high-voltage battery 1 [AX2] .
• Connect electrical connector of high-voltage battery -2-.
• Connect electrical connector for auxiliary consumers -5-.
• Install pressure relief valve -3-.

• Tighten nut for potential equalisation line to specified torque, counterholding at centre hex stud while doing so.
• ⇒ Rep. gr. 19 ; Cooling system/coolant; Filling cooling system

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 - high-voltage battery (installed)
• ⇒ Rep. gr. 93 ; Overview of fitting locations - potential equalisation lines