Volkswagen ID.3: Electric drive. Charging unit for high-voltage battery

• Assembly overview – charging unit for high-voltage battery
• Assembly overview – charging unit for high-voltage battery
• Removing and installing charging unit 1 for high-voltage battery AX4
• Removing and installing charging unit 1 for high-voltage battery AX4

Assembly overview – charging unit for high-voltage battery

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 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]

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

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

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

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

Electric drive. Charging socket, with separate charging cableElectric drive. Charging unit for high-voltage battery, with integrated voltage converter