Volkswagen ID.4: High-voltage cables, all-wheel drive

• Overview of fitting locations - high-voltage wires, charging unit, high-voltage battery, charging socket
•  Overview of fitting locations - high-voltage wiring, electric drive control units, high-voltage battery
• Overview of fitting locations - high-voltage wires, voltage converter, high-voltage heater, air conditioner compressor, all-wheel drive
• Removing and installing high-voltage wiring harness for power and control electronics for electric drive
• Removing and installing high-voltage wiring harness for high-voltage heater
• Removing and installing high-voltage wiring harness for voltage converter, high-voltage heater, air conditioner compressor
• Unplugging high-voltage connectors

Overview of fitting locations - high-voltage wires, charging unit, high-voltage battery, charging socket

1. High-voltage battery 1 - AX2-

• Depending on equipment
• ⇒ High-voltage battery; Rep. gr. 93 ; High-voltage battery unit; Exploded view - installed high-voltage battery

2. High-voltage wiring harness with high-voltage battery charging socket 1 - UX4-

• To charging unit 1 for high-voltage battery - AX4- / high-voltage battery 1 - AX2-
• ⇒ Rep. gr. 93 ; Removing and installing high-voltage battery charging socket 1 UX4

3. Charging unit 1 for highvoltage battery - AX4-

• ⇒ Electric drive motor 0EH, 0EJ; Rep. gr. 93 ; Charging unit for high-voltage battery; Removing and installing charging unit 1 for high-voltage battery AX4

 Overview of fitting locations - high-voltage wiring, electric drive control units, high-voltage battery

1. Power and control electronics 2 for electric drive - JX4-

• Depending on vehicle equipment: vehicles with all-wheel drive
• ⇒ Rep. gr. 93 ; Removing and installing power and control electronics 2 for electric drive JX4

2. High-voltage battery 1 - AX2-

• Depending on equipment
• ⇒ High-voltage battery; Rep. gr. 93 ; Highvoltage battery unit; Assembly overview - installed high-voltage battery

3. Power and control electronics for electric drive - JX1-

• ⇒ Rep. gr. 93 ; Removing and installing power and control electronics for electric drive JX1

4. High-voltage wiring harness for power and control electronics for electric drive - JX1-

• Depending on equipment
• ⇒ Rep. gr. 93 ; Removing and installing high-voltage wiring harness for power and control electronics, rear-wheel drive

5. High-voltage wiring harness for power and control electronics for electric drive - JX1- and power and control electronics 2 for electric drive - JX4-

• Depending on vehicle equipment: vehicles with all-wheel drive
• ⇒ Rep. gr. 93 ; Removing and installing high-voltage wiring harness for power and control electronics, all-wheel drive

6. Passage

Overview of fitting locations - high-voltage wires, voltage converter, high-voltage heater, air conditioner compressor, all-wheel drive

1. Charging unit 1 for highvoltage battery - AX4-

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

2. High-voltage wiring harness for ancillaries

• ⇒ "23.7 Removing and installing high-voltage wiring harness for voltage converter, highvoltage heater, air conditioner compressor"

3. Passage

• ⇒ "23.4 Assembly overview - passage", page 430

4. High-voltage battery 1 - AX2-

• Depending on equipment
• ⇒ High-voltage battery; Rep. gr. 93 ; Highvoltage battery unit; Assembly overview - installed high-voltage battery

5. PTC heater element 3 - Z132-

• ⇒ Heating, air conditioning; Rep. gr. 87 ; Coolant circuit; Removing and installing heater element 3 Z132

6. Electrical air conditioner compressor - V470-

• ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Removing and installing air conditioner compressor VX81

7. High-voltage wire to high-voltage heater (PTC) - ZX17-

• ⇒ "23.6 Removing and installing high-voltage wiring harness for high-voltage heater"

8. High-voltage heater (PTC) - ZX17-

• ⇒ Heating, air conditioning; Rep. gr. 87 ; Front heater and air conditioning unit; Removing and installing high-voltage heater (PTC) ZX17

9. Voltage converter - A19-

• ⇒ Rep. gr. 93 ; Assembly overview - voltage converter

Assembly overview - passage

1. Bolt

• 2x
• 50 Nm + 90º

2. Passage

• Front section

3. Passage

• Rear section

4. Bolt

• 2x
• 8 Nm

5. Bolt

• 2x
• 20 Nm

6. Bolt

• 20 Nm

7. Bracket

• For passage

Removing and installing high-voltage wiring harness for power and control electronics for electric drive

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 .
• Remove air intake box of heater and air conditioning unit ⇒ Heating, air conditioning system; Rep. gr. 87 ; Front heater and air conditioning unit; Removing and installing air intake box of heater and air conditioning unit .
• Remove PTC heater element 3 - Z132- ⇒ ; Rep. gr. ; Removing and installing PTC heater element 3 [Z132] .
• Unscrew bolts -4- for retainer -3- of high-voltage cable -2-.

• Push locking element -4- in direction of -arrow B-.
• Open locking bracket -3- in direction of -arrow A-, and pull off high-voltage connector -2-.

• Remove front underbody cladding ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody cladding; Removing and installing front underbody cladding .
• Unscrew bolts -1- for coolant pump bracket.
• Pull corresponding high-voltage cables -arrow- off retainer.
• Move aside high-voltage cables, and guide them through towards rear.

• Remove high-voltage battery; do not reattach passage ⇒ High-voltage battery; Rep. gr. 93 ; High-voltage battery unit; Removing and installing high-voltage battery 1 [AX2] .
• Unscrew bolts -4- and -5-.
• Remove support plate -3-.
• Unscrew bolts -2- and -6-.
• Remove support plate -1-.

• Open spreader rivet -2-, and release high-voltage cable retainer -3-.
• Unscrew bolts -arrows-, and pull passage -1- downwards slightly.
• Unclip high-voltage cable -4-, and guide it through towards rear.

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

• Remove electric drive motor for rear axle ⇒ Rep. gr. 10 ; Removing rear motor .
• Lower rear axle ⇒ Running gear, axles, steering; Rep. gr. 42 ; Rear axle; Lowering rear axle .
• Move aside high-voltage cable of electric drive motor -1-, and guide it through towards front.
• Detach high-voltage cable -1-.

Installing

Install in reverse order of removal, observing the following:

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

• ⇒ "23.4 Assembly overview - passage"
• ⇒ Rep. gr. 19 ; Assembly overview - electric coolant pump

Removing and installing high-voltage wiring harness for high-voltage heater

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 .
•  Remove bulkhead ⇒ General body repairs, exterior; Rep.gr. 50 ;  Bulkhead; Removing and installing bulkhead .
• Remove air intake box of heater and air conditioning unit ⇒ Heating, air conditioning system; Rep. gr. 87 ; Front heater and air conditioning unit; Removing and installing air intake box of heater and air conditioning unit .
• Disconnect high-voltage connectors -3- ⇒ Rep. gr. 93 ; Disconnecting high-voltage connectors .
• Loosen cable holders -arrows- on bulkhead.
• Expose high-voltage cable -2- as far as leadthrough -1-.

• Remove front right footwell vent ⇒ Heating, air conditioning system; Rep. gr. 87 ; Air duct; Assembly overview - air duct and air distribution in passenger compartment .
• Disconnect electrical connector -7-, and loosen retaining clip -5-.
• Expose high-voltage cable as far as leadthrough.

• Release fasteners -6- of grommet -5-.
• Guide high-voltage cable -7- out of air intake cowling -4-.
• Unscrew bolts -1- and -3-.

• Remove high-voltage cable -2- upwards.

Installing

Install in reverse order of removal, observing the following:

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 .

Removing and installing high-voltage wiring harness for voltage converter, high-voltage heater, air conditioner compressor

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 .
• Remove air intake box of heater and air conditioning unit ⇒ Heating, air conditioning system; Rep. gr. 87 ; Front heater and air conditioning unit; Removing and installing air intake box of heater and air conditioning unit .
• Remove PTC heater element 3 - Z132- ⇒ ; Rep. gr. ; Removing and installing PTC heater element 3 [Z132] .
• Disconnect upper of electrical connectors indicated by -2-, and move aside cable ⇒ Electric drive motor; Rep. gr. 93 ; High-voltage cables; Disconnecting high-voltage connectors .

• Disconnect high-voltage connectors -3- ⇒ Rep. gr. 93 ; Disconnecting high-voltage connectors .

• Move aside high-voltage cable -1- at cable duct -2- -arrow-, and guide it through towards rear.

• Remove front underbody cladding ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody cladding; Removing and installing front underbody cladding .
• Unscrew bolts -1- for coolant pump bracket.
• Pull corresponding electrical wire -arrow- off retainer.

• Remove high-voltage battery; do not reattach passage ⇒ High-voltage battery; Rep. gr. 93 ; High-voltage battery unit; Removing and installing high-voltage battery 1 [AX2] .
• Unscrew bolts -4- and -5-.
• Remove support plate -3-.
• Unscrew bolts -2- and -6-.
• Remove support plate -1-.

• Open spreader rivet -2-, and release high-voltage cable retainer -3-.
• Unscrew bolts -arrows-, and pull passage -1- downwards slightly.
• Unclip high-voltage cable -5-, and guide it through towards rear.

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

• Remove electric drive motor for rear axle ⇒ Rep. gr. 10 ; Removing rear motor .
• Lower rear axle ⇒ Running gear, axles, steering; Rep. gr. 42 ; Rear axle; Lowering rear axle .
• Push high-voltage cable of electric drive motor -1- to one side.
• Unscrew nuts -arrows-, and push wiring duct -3- to one side.
• Move aside high-voltage cable -2-.

• Loosen cable clips -arrows-.
• Push electrical wire -1- to one side.
• Move aside high-voltage cable -2-, and guide it through towards front.
• Remove high-voltage cable for ancillaries.

Installing

Install in reverse order of removal, observing the following:

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

• ⇒ "23.4 Assembly overview - passage"
• ⇒ Rep. gr. 19 ; Assembly overview - electric coolant pump

Unplugging high-voltage connectors

Version 1 for electrical connector of auxiliary consumers

• Release locking element -1- in direction of -arrow A-.
• Insert a suitable screwdriver -5- between locking element -1- and electrical connector for auxiliary consumers -3- to release and disconnect electrical connector in direction of -arrow B-.

All vehicles (continued)

Version 2 for electrical connector of auxiliary consumer

• Release locking element -1- in direction of -arrow A-.
• Using a suitable screwdriver -5-, release electrical connector for auxiliary consumers -2- in direction of -arrow B- and disconnect.

All vehicles (continued)

Version 1 for electrical connector of high-voltage system connection/ DC charging connection

• Release locking element -3- by turning it in direction of -arrow A-.
• Press locking bracket -4- in direction of -arrow B-, and disconnect high-voltage system connection -1- and DC charging connection -1-.

All vehicles (continued)

Version 2 for electrical connector of high-voltage system connection/ DC charging connection

• Use suitable screwdriver to release locking element -2- by pushing it upwards.
• Release locking element -2- in direction of -arrow A-.
• Press locking bracket -4- in direction of -arrow B-, and disconnect high-voltage system connection -1- and DC charging connection -1-.