Service

Workshop Manual
e-tron GT 2022 ➤
Electric drive motor 0EG
Edition 01.2023

Service Department. Technical Information

 Service
List of Workshop Manual Repair Groups

Repair Group
00 - Technical data
10 - Removing and installing engine
19 - Cooling
93 - Electric drive systems

Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness
and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as
a matter of course, be observed.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2023 Audi AG, Ingolstadt D4D8081B0ED

 e-tron GT 2022 ➤
Electric drive motor 0EG - Edition 01.2023

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Assessing high-voltage system risk level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 Work that requires high-voltage system to be de-energised . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Starting diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1 Safety and repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 Removing and installing motor (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1 Exploded view - motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2 Assembly overview - motor and transmission unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3 Removing motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4 Installing motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.5 Securing motor to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.6 Separating motor and transmission unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.7 Assembling motor and transmission unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.8 Determining thickness of shim for transmission unit gear cluster . . . . . . . . . . . . . . . . . . . . 26
3 Removing and installing motor (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.1 Exploded view - motor (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.2 Assembly overview - motor and transmission unit (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.3 Removing rear motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.4 Installing rear motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.5 Securing motor to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.6 Separating motor and transmission unit - motor (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.7 Assembling motor and transmission unit - motor (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4 Assembly mountings (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.1 Exploded view - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.2 Removing and installing motor carriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.3 Supporting motor in installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5 Assembly mountings (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.1 Exploded view - assembly mountings (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.2 Removing and installing motor carriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1 Safety and repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1.1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1.2 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.1 Exploded view - coolant expansion tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.2 Removing and installing coolant expansion tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.3 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.4 Draining coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.5 Filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.6 Bleeding cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Contents i
 e-tron GT 2022 ➤
Electric drive motor 0EG - Edition 01.2023

2.7 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

3 Coolant pump/thermostat assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.1 Overview of fitting locations - coolant pump/thermostat assembly . . . . . . . . . . . . . . . . . . . . 75
3.2 Exploded view - electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.3 Exploded view - coolant valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.4 Exploded view - coolant temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.5 Removing and installing coolant pump for high-voltage battery V590 . . . . . . . . . . . . . . . . 83
3.6 Removing and installing thermal management coolant pump 2 V618 . . . . . . . . . . . . . . . . 83
3.7 Removing and installing thermal management coolant pump 4 V620 . . . . . . . . . . . . . . . . 84
3.8 Removing and installing coolant changeover valve 1 N632 . . . . . . . . . . . . . . . . . . . . . . . . 85
3.9 Removing and installing coolant changeover valve 2 N633 . . . . . . . . . . . . . . . . . . . . . . . . 86
3.10 Removing and installing changeover and mixing valve for thermal management V650 . . 86
3.11 Removing and installing changeover and mixing valve 2 for thermal management V651 . . 87
3.12 Removing and installing changeover and mixing valve 4 for thermal management V653 . . 88
3.13 Removing and installing changeover and mixing valve 7 for thermal management V656 . . 89
3.14 Removing and installing coolant shortage indicator sender 2 G837 . . . . . . . . . . . . . . . . . . 89
3.15 Removing and installing coolant temperature sender 1 for thermal management G902 . . 89
3.16 Removing and installing coolant temperature sender 2 for thermal management G903 . . 90
3.17 Removing and installing coolant temperature sender 3 for thermal management G904 . . 91
3.18 Removing and installing coolant temperature sender 4 for thermal management G905 . . 91
3.19 Removing and installing coolant temperature sender 5 for thermal management G906 . . 92
3.20 Removing and installing coolant temperature sender 7 for thermal management G908 . . 93
3.21 Removing and installing coolant temperature sender 8 for thermal management G968 . . 93
3.22 Removing and installing coolant temperature sender 9 for thermal management G1017 . . 94
3.23 Removing and installing coolant temperature sender 1 for high-voltage battery G898 . . . . 95
3.24 Removing and installing coolant temperature sender 2 for high-voltage battery G899 . . . . 95
4 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
4.1 Exploded view - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
4.2 Removing and installing coolant distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.3 Removing and installing coolant manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5 Radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5.1 Exploded view - radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5.2 Exploded view - radiator blind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5.3 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
5.4 Removing and installing radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5.5 Removing and installing radiator fan V177 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
5.6 Removing and installing radiator blind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
5.7 Removing and installing radiator blind control motor V544 . . . . . . . . . . . . . . . . . . . . . . . . 107
5.8 Removing and installing radiator blind control motor 2 V550 . . . . . . . . . . . . . . . . . . . . . . . . 107
5.9 Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

93 - Electric drive systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

1 Safety and repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.2 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
2 High-voltage components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2.1 Overview of fitting locations - high-voltage components . . . . . . . . . . . . . . . . . . . . . . . . . . 111
3 Warning labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3.1 Checking warning labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
4 High-voltage battery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4.1 Assembly overview - high-voltage battery 1 AX2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4.2 Determining mean cell voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.3 Charging and discharging battery modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.4 Leak test for high-voltage battery 1 AX2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.5 Checking high-voltage battery 1 AX2 for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

ii Contents
 e-tron GT 2022 ➤
Electric drive motor 0EG - Edition 01.2023

4.6 Removing and installing high-voltage battery 1 AX2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

4.7 Lifting high-voltage battery 1 AX2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
4.8 Removing and installing skid plate for high-voltage battery . . . . . . . . . . . . . . . . . . . . . . . . 139
4.9 Removing and installing battery regulation control unit J840 . . . . . . . . . . . . . . . . . . . . . . . . 143
4.10 Removing and installing switching unit for high-voltage battery SX6 . . . . . . . . . . . . . . . . . . 145
5 High-voltage battery components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
5.1 Assembly overview - high-voltage battery 1 AX2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
5.2 Assembly overview - switching unit for high-voltage battery SX6 . . . . . . . . . . . . . . . . . . . . 162
5.3 Assembly overview - battery modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
5.4 Overview of fitting locations - battery connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
5.5 Inspecting and classifying high-voltage battery 1 AX2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
5.6 Marking battery modules and battery connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
5.7 Handling replacement bolts for cover for battery housing . . . . . . . . . . . . . . . . . . . . . . . . . . 172
5.8 Removing and installing cover for battery housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
5.9 Removing and installing battery housing (level 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
5.10 Removing battery module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
5.11 Installing battery module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
5.12 Visually inspecting and classifying battery module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
5.13 Provisional energisation of high-voltage battery 1 AX2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
5.14 Removing and installing communication wiring harness on high-voltage battery 1 AX2 . . 220
6 Power and control electronics for electric drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
6.1 Exploded view - power and control electronics for electric drive . . . . . . . . . . . . . . . . . . . . 232
6.2 Removing and installing power and control electronics for electric drive . . . . . . . . . . . . . . 234
7 Electric drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
7.1 Removing and installing drive motor rotor position sender 1 G713 . . . . . . . . . . . . . . . . . . 241
7.2 Removing and installing rear drive motor rotor position sender G1095 . . . . . . . . . . . . . . . . 241
8 Motor control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
8.1 Removing and installing motor control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
9 High-voltage wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
9.1 Overview of fitting locations - high-voltage wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
9.2 Removing and installing high-voltage wiring harness for drive motor . . . . . . . . . . . . . . . . 247
9.3 Removing and installing high-voltage wiring harness for switching unit for high-voltage
battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
9.4 Removing and installing high-voltage wire for voltage converter . . . . . . . . . . . . . . . . . . . . 252
9.5 Removing and installing high-voltage wire for electrical air conditioner compressor . . . . . . 253
9.6 Unplugging high-voltage connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
9.7 Removing and installing high-voltage wire for high-voltage heater . . . . . . . . . . . . . . . . . . 257
9.8 Removing and installing high-voltage wire for charging unit 1 for high-voltage battery . . . . 259
10 De-energising high-voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
10.1 De-energising high-voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
11 Re-energising high-voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
11.1 Re-energising high-voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
12 Potential equalisation lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
12.1 General notes - potential equalisation lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
12.2 Potential equalisation measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
12.3 Overview of fitting locations - potential equalisation lines . . . . . . . . . . . . . . . . . . . . . . . . . . 265
13 Charging socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
13.1 Exploded view - charging socket, left-hand drive vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . 268
13.2 Exploded view - charging socket, right-hand drive vehicles . . . . . . . . . . . . . . . . . . . . . . . . 268
13.3 Exploded view - charging socket 2, left-hand drive vehicles . . . . . . . . . . . . . . . . . . . . . . . . 269
13.4 Exploded view - charging socket 2, right-hand drive vehicles . . . . . . . . . . . . . . . . . . . . . . 270
13.5 Removing and installing high-voltage battery charging socket 1 UX4 - left-hand drive
vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
13.6 Removing and installing high-voltage battery charging socket 1 UX4 - right-hand drive
vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

Contents iii
 e-tron GT 2022 ➤
Electric drive motor 0EG - Edition 01.2023

13.7 Removing and installing high-voltage battery charging socket 2 UX5 - left-hand drive
vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
13.8 Removing and installing high-voltage battery charging socket 2 UX5 - right-hand drive
vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
13.9 e-tron charging system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
13.10 Diagnosis of e-tron charging system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
13.11 Removing and installing actuator for high-voltage charging socket lock . . . . . . . . . . . . . . 287
14 Charging unit for high-voltage battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
14.1 Exploded view - charging unit 1 for high-voltage battery . . . . . . . . . . . . . . . . . . . . . . . . . . 294
14.2 Removing and installing charging unit 1 for high-voltage battery AX4 . . . . . . . . . . . . . . . . 296
14.3 Removing and installing bracket for charging unit for high-voltage battery . . . . . . . . . . . . 298
14.4 Removing and installing charging process display unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
15 Voltage converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
15.1 Exploded view - voltage converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
15.2 Removing and installing voltage converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
15.3 Removing and installing power contactor with boost function . . . . . . . . . . . . . . . . . . . . . . 306
15.4 Removing and installing bracket for power contactor with boost function . . . . . . . . . . . . . . 312
16 Engine sound generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
16.1 Overview of fitting locations - vehicle noise/engine sound . . . . . . . . . . . . . . . . . . . . . . . . . . 315
16.2 Removing and installing engine sound generator control unit (GM4) . . . . . . . . . . . . . . . . 317
16.3 Removing and installing engine sound generator control unit (GM3) . . . . . . . . . . . . . . . . 319
16.4 Removing and installing actuator for engine sound generator (GM4) . . . . . . . . . . . . . . . . 322
16.5 Removing and installing actuator for engine sound generator (GM3) . . . . . . . . . . . . . . . . 323
16.6 Removing and installing internal loudspeaker for engine sound generator (GM3) . . . . . . 325
17 Accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
17.1 Exploded view - accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
17.2 Removing and installing accelerator pedal module GX2 . . . . . . . . . . . . . . . . . . . . . . . . . . 327

iv Contents
 e-tron GT 2022 ➤
Electric drive motor 0EG - Edition 01.2023

00 – Technical data
1 Safety precautions
10004LLL6843.007.1 - 01.2023

1.1 Safety information

Observe safety information ⇒ Safety information and repair
notes; Rep. gr. 00; Safety information.

1. Safety precautions 1
 e-tron GT 2022 ➤
Electric drive motor 0EG - Edition 01.2023

2 Repair instructions

2.1 Repair instructions

Observe repair instructions ⇒ Safety and repair instructions;
Rep. gr. 00; Repair instructions.

2 Rep. gr.00 - Technical data

 e-tron GT 2022 ➤
Electric drive motor 0EG - Edition 01.2023

3 Assessing high-voltage system risk

level

3.1 Work that requires high-voltage system

to be de-energised
The high-voltage system must be de-energised to perform the
following work.
Important
• De-energise high-voltage system ⇒ Motor; Rep. gr. 93; De-
energising high-voltage system.
Component Operation Qualification
Welding, grinding ⇒ Body Repairs; Rep. De-energisa‐
or cutting work gr. 00; Notes for vehicles tion and re-
near high-voltage with hybrid drive energisation
components by HVT, work
when system
is de-ener‐
gised by EIP
Body repairs (with ⇒ Body Repairs; Rep. De-energisa‐
straightening jig) gr. 00; Straightening jig tion and re-
energisation
by HVT, work
when system
is de-ener‐
gised by EIP
Electric drive con‐ ⇒ a6.2.1 nd installing HVT
trol unit for front electric drive control unit
axle -J1234- for front axle J1234”,
page 234
Electric drive motor ⇒ Motor; Rep. gr. 10; Re‐ De-energisa‐
for front axle -V662- moving and installing mo‐ tion and re-
tor (front); Removing mo‐ energisation
tor by HVT, work
when system
is de-ener‐
gised by EIP
Electric drive con‐ ⇒ a6.2.2 nd installing HVT
trol unit for rear electric drive control unit
axle -J1235- for rear axle J1235”,
page 238
Electric drive motor ⇒ Rep. gr. 10; Removing De-energisa‐
for rear axle -V663- motor (rear) tion and re-
energisation
by HVT, work
when system
is de-ener‐
gised by EIP
High-voltage bat‐ ⇒ Motor; Rep. gr. 93; De-energisa‐
tery 1 -AX2- High-voltage battery unit; tion and re-
Removing and installing energisation
high-voltage battery 1 by HVT, work
AX2 when system
is de-ener‐
gised by EIP

3. Assessing high-voltage system risk level 3

 e-tron GT 2022 ➤
Electric drive motor 0EG - Edition 01.2023

Component Operation Qualification

High-voltage bat‐ ⇒ Motor; Rep. gr. 93; HVE
tery 1 -AX2- High-voltage battery with addition‐
components; Removing al “HV battery
battery module, ⇒ Motor; repair” qualifi‐
Rep. gr. 93; High-voltage cation
battery components; Re‐
moving battery module
Voltage converter ⇒ Motor; Rep. gr. 93; De-energisa‐
for 800 V, 400 V, Voltage converter; Re‐ tion and re-
48 V, 12 V -A48- moving and installing energisation
voltage converter by HVT, work
when system
is de-ener‐
gised by EIP
Power contactor ⇒ a15.3 nd installing De-energisa‐
with boost function power contactor with tion and re-
-J1178- boost function”, page 306 energisation
by HVT, work
when system
is de-ener‐
gised by EIP
Charging unit 1 for ⇒ Motor; Rep. gr. 93; De-energisa‐
high-voltage battery Charging unit for high- tion and re-
-AX4- voltage battery; Remov‐ energisation
ing and installing charg‐ by HVT, work
ing unit 1 for high-voltage when system
battery AX4 is de-ener‐
gised by EIP
High-voltage bat‐ ⇒ Motor; Rep. gr. 93; De-energisa‐
tery charging sock‐ Charging socket; Remov‐ tion and re-
et 1 -UX4- ing and installing high- energisation
voltage battery charging by HVT, work
socket 1 UX4 when system
is de-ener‐
gised by EIP
High-voltage bat‐ ⇒ Motor; Rep. gr. 93; De-energisa‐
tery charging sock‐ Charging socket; Remov‐ tion and re-
et 2 -UX5- ing and installing high- energisation
voltage battery charging by HVT, work
socket 2 UX5 when system
is de-ener‐
gised by EIP
Actuator for high- ⇒ Rep. gr. 93; Remov‐ De-energisa‐
voltage charging ing and installing actuator tion and re-
socket lock 1 - for high-voltage charging energisation
F498-/actuator for socket lock by HVT, work
high-voltage charg‐ when system
ing socket lock 2 - is de-ener‐
F499- gised by EIP
Electrical air condi‐ ⇒ Heating, air condition‐ De-energisa‐
tioner compressor - ing; Rep. gr. 87; Air con‐ tion and re-
V470- ditioner compressor; Re‐ energisation
moving and installing air by HVT, work
conditioner compressor when system
is de-ener‐
gised by EIP
High-voltage heater ⇒ Heating, ventilation, De-energisa‐
(linear) -Z189- air conditioning system; tion and re-
Rep. gr. 87; Coolant cir‐ energisation
cuit; Removing and in‐ by HVT, work
stalling high-voltage heat‐ when system
er (linear) Z189 is de-ener‐
gised by EIP

4 Rep. gr.00 - Technical data

 e-tron GT 2022 ➤
Electric drive motor 0EG - Edition 01.2023

Component Operation Qualification

High-voltage wiring ⇒ Motor; Rep. gr. 93; De-energisa‐
harness for motor High-voltage wires; Re‐ tion and re-
(front) moving and installing energisation
high-voltage wiring har‐ by HVT, work
ness for drive motor when system
is de-ener‐
gised by EIP
High-voltage wiring ⇒ Motor; Rep. gr. 93; De-energisa‐
harness for motor High-voltage wires; Re‐ tion and re-
(rear) moving and installing energisation
high-voltage wiring har‐ by HVT, work
ness for drive motor when system
is de-ener‐
gised by EIP
High-voltage wiring ⇒ a9.3 nd installing high- De-energisa‐
harness for switch‐ voltage wiring harness tion and re-
ing unit for high- for switching unit for high- energisation
voltage battery voltage battery”, page by HVT, work
250 when system
is de-ener‐
gised by EIP
High-voltage wiring ⇒ a9.4 nd installing high- De-energisa‐
harness for voltage voltage wire for voltage tion and re-
converter converter”, page 252 energisation
by HVT, work
when system
is de-ener‐
gised by EIP
High-voltage wiring ⇒ a9.5 nd installing high- De-energisa‐
harness for electri‐ voltage wire for electrical tion and re-
cal air conditioner air conditioner compres‐ energisation
compressor sor”, page 253 by HVT, work
when system
is de-ener‐
gised by EIP
Rear subframe Removing and installing De-energisa‐
subframe with motor tion and re-
(rear) ⇒ Running gear, energisation
axles, steering; Rep. by HVT, work
gr. 42; Subframe; Explo‐ when system
ded view - subframe is de-ener‐
gised by EIP
Plenum chamber ⇒ General body repairs, De-energisa‐
partition panel exterior; Rep. gr. 50; tion and re-
Bulkhead; Removing and energisation
installing plenum cham‐ by HVT, work
ber partition panel when system
is de-ener‐
gised by EIP
Body brace (front) Removing and installing De-energisa‐
body brace (front) ⇒ Run‐ tion and re-
ning gear, axles, steer‐ energisation
ing; Rep. gr. 40; Suspen‐ by HVT, work
sion strut, upper links; when system
Removing and installing is de-ener‐
body brace. gised by EIP
Positive cable of Removing and installing De-energisa‐
battery -A- positive cable of battery tion and re-
-A- ⇒ Electrical system; energisation
Rep. gr. 27; Battery; Ex‐ by HVT, work
ploded view - battery when system
is de-ener‐
gised by EIP

3. Assessing high-voltage system risk level 5

 e-tron GT 2022 ➤
Electric drive motor 0EG - Edition 01.2023

4 Electrical components

4.1 Starting diagnosis

♦ 1. Adapting end stops for radiator blind
♦ 2. Opening electrically actuated valves in cooling system for
discharging and charging
♦ 3. Opening electrically actuated valves in cooling system
after discharging and charging
♦ 4. Bleeding cooling system
♦ 5. Renewing voltage converter for 800 V, 400 V, 48 V, 12 V
-A48-
♦ 6. Renewing charging unit 1 for high-voltage battery -AX4-
♦ 7. Renewing motor control unit -J623-
♦ 8. Renewing power contactor with boost function -J1178-
♦ 9. Renewing electric drive control unit for front axle -J1234-
♦ 10. Renewing electric drive control unit for rear axle -J1235-
♦ 11. Renewing battery regulation control unit -J840-
♦ 12. Classifying battery module
1. Adapting end stops for radiator blind
♦ Diagnostic capable system
♦ 00C5 - Thermal Management Control Module -J1024-
♦ 00C5 - Thermal Management Control Module -J1024-, func‐
tions
♦ 00C5 - Basic setting complete
♦ Referencing end stops radiator blind V544 or V550
2. Opening electrically actuated valves in cooling system for
discharging and charging
♦ Diagnostic capable system
♦ 00C5 - Thermal Management Control Module -J1024-
♦ 00C5 - Thermal Management Control Module -J1024-, func‐
tions
♦ 00C5 - Basic setting
♦ 00C5 - Fill coolant circuit
3. Opening electrically actuated valves in cooling system after
discharging and charging
♦ Diagnostic capable system
♦ 00C5 - Thermal Management Control Module -J1024-
♦ 00C5 - Thermal Management Control Module -J1024-, func‐
tions
♦ 00C5 - Basic setting
♦ 00C5 - Stop - fill cooling circuit
4. Bleeding cooling system
♦ Diagnostic capable system

6 Rep. gr.00 - Technical data

 e-tron GT 2022 ➤
Electric drive motor 0EG - Edition 01.2023

♦ 00C5 - Thermal Management Control Module -J1024-

♦ 00C5 - Thermal Management Control Module -J1024-, func‐
tions
♦ 00C5 - Basic setting
♦ 00C5 - Bleed coolant circuit
5. Renewing voltage converter for 800 V, 400 V, 48 V, 12 V
-A48-
♦ Diagnostic capable system
♦ 8104 - Voltage Converter for 800 V, 400 V, 48 V, 12 V -A48-
♦ 8104 - Voltage converter, functions
♦ 8104 - Replace control module
6. Renewing charging unit 1 for high-voltage battery -AX4-
♦ Diagnostic capable system
♦ 00C6 - High Voltage Battery Charger Control Module -
J1050-
♦ 00C6 - High voltage battery charger control module, func‐
tions
♦ 00C6 - Replace control module
7. Renewing motor control unit -J623-
♦ Diagnostic capable system
♦ 0001 - Engine electronics -J623
♦ 0001 - Engine electronics, functions
♦ 0001 - Replace control unit
8. Renewing power contactor with boost function -J1178-
♦ Diagnostic capable system
♦ 8114 - Voltage Converter 2 -J1178-
♦ 8114 - Voltage converter 2, functions
♦ 8114 - Replace control module
9. Renewing electric drive control unit for front axle -J1234-
♦ Diagnostic capable system
♦ 00CE - Electric drive 2 -J1234
♦ 00CE - Electric drive 2, functions
♦ 00CE - Replace control module
10. Renewing electric drive control unit for rear axle -J1235-
♦ Diagnostic capable system
♦ 00CE - Electric drive -J1235
♦ 0051 - Electric drive, functions
♦ 0051 - Replace control module
11. Renewing battery regulation control unit -J840-
♦ Diagnostic capable system
♦ 008C - Hybrid Battery Energy Management -J840
♦ 008C - Hybrid Battery Energy Management, functions
♦ 008C - Replace control module

4. Electrical components 7
 e-tron GT 2022 ➤
Electric drive motor 0EG - Edition 01.2023

12. Classifying battery module

♦ Diagnostic capable system
♦ 008C - Hybrid Battery Energy Management -J840
♦ 008C - Hybrid Battery Energy Management - functions
♦ 008C - Classification of battery module

8 Rep. gr.00 - Technical data

 e-tron GT 2022 ➤
Electric drive motor 0EG - Edition 01.2023

5 Identification

5. Identification 9
 e-tron GT 2022 ➤
Electric drive motor 0EG - Edition 01.2023

10 – Removing and installing engine

1 Safety and repair instructions

1.1 Safety information

Observe safety information ⇒ Safety information and repair
notes; Rep. gr. 00; Safety information.

1.2 Repair instructions

Observe repair instructions ⇒ Safety and repair instructions;
Rep. gr. 00; Repair instructions.

10 Rep. gr.10 - Removing and installing engine

 e-tron GT 2022 ➤
Electric drive motor 0EG - Edition 01.2023

2 Removing and installing motor

(front)

2.1 Exploded view - motor

1 - Cover
2 - Seal
❑ Not available as sepa‐
rate part
3 - Bolt
❑ 3x
❑ Renew after removing
❑ 8 Nm
4 - Drive motor rotor position
sender 1 -G713-
❑ ⇒ Rep. gr. 93; Re‐
moving and installing
drive motor rotor posi‐
tion sender 1 G713
5 - Sender wheel
6 - Transmission unit 0MG
7 - O-ring
❑ Renew after removing
8 - Coolant connection
9 - Bolt
❑ 8 Nm
10 - Bolt
❑ 8 Nm
11 - Coolant connection
12 - O-ring
❑ Renew after removing
13 - Motor 0EG
14 - Shaft
15 - Pressure equalisation element
❑ Do not remove
16 - Bolt
❑ 6x
❑ Renew after removing
❑ 3 Nm +45°
17 - Circlip
18 - Seal
19 - Circlip
20 - Grooved ball bearing

2. Removing and installing motor (front) 11

 e-tron GT 2022 ➤
Electric drive motor 0EG - Edition 01.2023

2.2 Assembly overview - motor and transmission unit

1 - Bolt
❑ 15x
❑ ⇒ page 12
2 - Transmission unit 0MG
❑ ⇒ Rep. gr. 10; Separat‐
ing motor and transmis‐
sion unit
❑ ⇒ m2.7 otor and trans‐
mission unit”, page 22
3 - Gasket
❑ Renew after removing
4 - Magnet
5 - Dowel sleeve
❑ 2x
6 - Front electric drive motor
7 - Bolt
❑ 6x
❑ Renew after removing
❑ 3 Nm +90°
8 - Stub shaft
❑ Install with protective
sleeve from assembly
tool -T90022- to protect
oil seal
9 - O-ring
❑ Renew after removing
10 - Shim for transmission
unit gear cluster
❑ After renewing motor
or transmission unit ⇒
t2.8 hickness of shim for transmission unit gear cluster”, page 26
11 - Thrust bearing
12 - O-ring
❑ Renew after removing
13 - Sun gear
❑ Paired with transmission unit
❑ Must not be interchanged
14 - Retaining ring
❑ Do not overstretch
❑ Renew after removing
15 - Stub shaft oil seal
❑ Renew after removing
16 - Oil duct

Securing transmission unit to motor - tightening torque and se‐

quence

12 Rep. gr.10 - Removing and installing engine

 e-tron GT 2022 ➤
Electric drive motor 0EG - Edition 01.2023

Stage Bolts in sequence Tightening torque

1. -1- to -14- Screw in by hand
until contact is
made
2. -1- to -14- 15 Nm
3. -1- to -14- 20 Nm
4. -1- to -14- Turn 90° further
5. -15- 30 Nm

2.3 Removing motor

Special tools and workshop equipment required
♦ Hooks -10-222A/20-
♦ Lift arm extension/workshop hoist -VAS 6101-
♦ Lifting aid -3033-
♦ Workshop hoist -VAS 6100-
♦ strap -T10059-
Removing
– Remove subframe with motor ⇒ Running gear, axles, steer‐
ing; Rep. gr. 40; Subframe; Removing and installing sub‐
frame with steering rack.
– Remove air conditioner compressor ⇒ Heating, air condition‐
ing; Rep. gr. 87; Air conditioner compressor; Removing and
installing air conditioner compressor.
– Unplug electrical connector -1- for coolant temperature
sender 1 for thermal management -G902-.

– Loosen hose clip -2- and detach coolant hose.

– Remove bolts -arrows-.

2. Removing and installing motor (front) 13

 e-tron GT 2022 ➤
Electric drive motor 0EG - Edition 01.2023

– Press bracket -1- to side with coolant pump for high-voltage

battery -V590-.
– Unplug electrical connector -3-.

– Move electrical wiring harness -2- clear at motor and tie up

to rear.
– Release catch on both sides -arrow- and move coolant hose
-1- clear.
– Remove bolt -2- and detach retaining bracket.

– Move thermal management coolant pump 2 -V618- -4- to

side.
– Unplug electrical connector -3-.
– Press drive shaft (both sides) off motor and move to side
⇒ Running gear, axles, steering; Rep. gr. 40; Drive shaft;
Removing and installing drive shaft.
– Remove bolts -arrows- and detach bracket -1-.

14 Rep. gr.10 - Removing and installing engine

 e-tron GT 2022 ➤
Electric drive motor 0EG - Edition 01.2023

– Attach lift arm extension -VAS 6101- -3- to workshop hoist

-VAS 6100- -4-.

– Secure bracket -T10059- -1- with commercially available

M8x30 bolt -arrow-.
– Engage hook -10-222A/20- -5- on motor carrier (front left).
– Engage lifting tackle -3033- -2- on motor and workshop
hoist.

CAUTION
Risk of injury if engine drops when it is lifted
Danger of trapping or crushing parts of the body
– The support hooks and retaining pins on the lifting tackle
must be secured with a locking spring.

– Raise motor using workshop hoist, guiding it as necessary.

– Take up weight of motor with workshop hoist, but do not lift.
– Unscrew nut -1- (both sides) and remove bolt -2-.

2. Removing and installing motor (front) 15

 e-tron GT 2022 ➤
Electric drive motor 0EG - Edition 01.2023

– Remove bolt -3- (both sides).

– Raise motor using workshop hoist.

2.4 Installing motor

Special tools and workshop equipment required
♦ Workshop hoist -VAS 6100-
Installing
– Align motor with subframe so that it is free of stress and
screw in bolts -arrows- on both sides.

– Detach workshop hoist -VAS 6100- and lifting tackle.

– Attach bracket -1- and tighten bolts -arrows-.

– Install drive shaft on both sides ⇒ Running gear, axles,

steering; Rep. gr. 40; Drive shaft; Removing and installing
drive shaft.
– Install thermal management coolant pump 2 -V618- -4-.

16 Rep. gr.10 - Removing and installing engine

 e-tron GT 2022 ➤
Electric drive motor 0EG - Edition 01.2023

– Fit retaining bracket and tighten bolt -2-.

– Plug in electrical connector -3-.
– Attach and secure coolant hose -1-.

– Secure electrical wiring harness -2- on motor.

– Plug in electrical connector -3-.
– Install coolant pump for high-voltage battery -V590- together
with bracket -1-.

– Tighten bolts -arrows-.

– Connect coolant hose and secure with hose clip -2-.

2. Removing and installing motor (front) 17

 e-tron GT 2022 ➤
Electric drive motor 0EG - Edition 01.2023

– Plug in electrical connector -1-.

– Install air conditioner compressor ⇒ Heating, air condition‐
ing; Rep. gr. 87; Air conditioner compressor; Removing and
installing air conditioner compressor.
– Install motor with subframe (front) ⇒ Running gear, axles,
steering; Rep. gr. 40; Subframe; Removing and installing
subframe with motor (front) and steering rack
– A potential equalisation measurement must be performed
on the high-voltage components affected after installation
of high-voltage components or potential equalisation lines ⇒
e12.2 qualisation measurement”, page 265 .

WARNING
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) re-energise the high-voltage system.

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

energising high-voltage system; Re-energising high-voltage
system.
If the motor has been renewed:
– Perform function “Replace Electric Drive Control Module on
Front Axle J1234” ⇒ Motor; Rep. gr. 00; Electrical compo‐
nents; Starting diagnosis.
Continued
Tightening torques
♦ ⇒ Motor; Rep. gr. 10; Assembly mountings (front); Assembly
overview - assembly mountings
♦ ⇒ Motor; Rep. gr. 93; High-voltage wires; Overview of fitting
locations - high-voltage wires
♦ ⇒ Running gear, axles, steering; Rep. gr. 40; Wheel bear‐
ings; Assembly overview - wheel bearing

2.5 Securing motor to engine and gearbox

support
Special tools and workshop equipment required
♦ Engine and gearbox bracket -VAS 6095A-
♦ Engine bracket -VAS 6095A/1-23-
♦ Retaining plate -VW309-

18 Rep. gr.10 - Removing and installing engine

 e-tron GT 2022 ➤
Electric drive motor 0EG - Edition 01.2023

♦ Workshop hoist -VAS 6100-

Preparing tool
– Attach retaining plate -VW309- -2- to engine bracket -VAS
6095A/1-23- -1- and tighten to 40 Nm.

– Fit retaining plate -VW309- in engine and gearbox support

-VAS 6095A- and secure.
– Release catch -4- and turn tensioning bolt -3- anti-clockwise
until guide is open by dimension -x-.
Important
• Dimension -x- = approx. 115 mm
– Pull out locking pin -5- and lock it in pulled-out position by
turning it.
Securing to engine and gearbox support
– ⇒ Rep. gr. 10; Remove motor.
– Carefully lower power unit (front) -2- onto engine bracket
-VAS 6095A/1-23- -6- using workshop hoist -VAS 6100-.

Important
• Hole -3- must be flush with locking pin -5-.
– Release locking pin and engage it in hole.
– Turn tensioning bolt -1- clockwise and tighten to 17 Nm.

2. Removing and installing motor (front) 19

 e-tron GT 2022 ➤
Electric drive motor 0EG - Edition 01.2023

– Lower workshop hoist and check that power unit is seated

securely in mounting elements -4-.

2.6 Separating motor and transmission unit

Special tools and workshop equipment required
♦ Engine and gearbox bracket -VAS 6095A-
♦ Engine bracket -VAS 6095A/1-23-
♦ Extractor hook -T20143-
♦ Used oil collection and extraction unit -VAS 6622A-
Procedure
– ⇒ Rep. gr. 10; Securing motor to engine and gearbox sup‐
port
– Remove motor carrier (front right) ⇒ a4.2.1 nd installing mo‐
tor carriers (front)”, page 41 .
– Drain gear oil ⇒ Transmission unit; Rep. gr. 34; Gear oil;
Draining and filling gear oil.
– Align engine bracket -VAS 6095A/1-23- with power unit on
engine and gearbox support -VAS 6095A-.

– Tilt power unit by angle -α- -arrow- with transmission unit

facing upwards.
Important
• Angle -α- = 10°
– Place used oil collection and extraction unit -VAS 6622A-
underneath.

– Remove bolts in the sequence -14- to -1-.

– Carefully detach transmission unit from motor.
Important

20 Rep. gr.10 - Removing and installing engine

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Electric drive motor 0EG - Edition 01.2023

• Ensure that no components fall out.

– Remove gasket -1- and magnet -2-.

– Align engine bracket -VAS 6095A/1-23- -1- with motor -2- on

engine and gearbox support -VAS 6095A- as shown.

Important
• Angle -α- = 90°
– Remove bolts -arrows-.

– Pull stub shaft -2- upwards out of motor with cover.

– Align engine bracket -VAS 6095A/1-23- with motor on en‐
gine and gearbox support -VAS 6095A- so it is once again
horizontal, as shown.

2. Removing and installing motor (front) 21

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Electric drive motor 0EG - Edition 01.2023

– Pull off oil seal -2- with extractor hook -T20143- -1-.

– Remove retaining ring -1-.

– Detach sun gear -2- and allocate it to transmission unit.

Important
• Sun gear is paired with transmission unit and must not be
used on another transmission unit.
– Remove shim -1-, thrust bearing -2- and O-ring -3-.

2.7 Assembling motor and transmission

unit
Special tools and workshop equipment required
♦ Assembly tool -T90022-
♦ Engine and gearbox bracket -VAS 6095A-
♦ Engine bracket -VAS 6095A/1-23-

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Procedure
If motor or transmission unit was renewed:
– ⇒ t2.8 hickness of shim for transmission unit gear cluster”,
page 26
Continued
– Bring shim -1-, thrust bearing -2- and new O-ring -3- into
installation position.

– Grease splines -arrows-.

– Bring sun gear -2- into installation position and secure with
new retaining ring -1-.

– Fit new oil seal -2- on thrust piece -1- of assembly tool
-T90022- and drive in as far as stop.

Important
• Open side -arrow- faces outwards.
– Align engine bracket -VAS 6095A/1-23- -1- with motor -2- on
engine and gearbox support -VAS 6095A- as shown.

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Important
• Angle -α- = 90°
– Fit new O-ring -1- on cover for stub shaft.

– To avoid damaging the oil seal when removing, fit protective

sleeve -3- from assembly tool -T90022- on stub shaft -2-.
– Carefully insert stub shaft and cover in motor from above
-arrow-.
– Detach protective sleeve.
– Fit and tighten bolts -arrows-.

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– Align engine bracket -VAS 6095A/1-23- with motor on en‐

gine and gearbox support -VAS 6095A-.

– Tilt motor by angle -α- -arrow- with flange to transmission

unit facing upwards.
Important
• Angle -α- = 10°
– Ensure that both dowel sleeves -arrows- are fitted.

– Clean sealing surfaces and fit gasket -1- on dowel sleeves.

– Insert magnet -2-.
– Ensure that oil duct -1- is fitted correctly -arrows-.

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Electric drive motor 0EG - Edition 01.2023

– Ensure that no components fall out when fitting transmission

unit.

– To make it easier to fit the transmission unit, a second me‐

chanic can turn the stub shaft to and fro.
Important
• It should be possible to fit the transmission unit without sig‐
nificant use of force.
– Tighten bolts -1- to -15-.
Tightening torques
♦ ⇒ o2.2 verview - motor and transmission unit”, page 12

2.8 Determining thickness of shim for

transmission unit gear cluster
Procedure
♦ If transmission unit (front) or motor (front) are renewed, the
setting of the gear cluster may vary due to different toleran‐
ces. As a result, thickness of shim must be re-determined in
these cases.
♦ If labels are unreadable, use a QR code scanner to deter‐
mine the adjustment dimensions via the data matrix code.
♦ Explanation of adjustment dimension for motor (front) -3-:
The last three characters of the data matrix code are the
adjustment dimension in 1/100 mm (there are a maximum of
three digits). Example: -d- 4.681 => 468.
♦ Explanation of adjustment dimension for transmission unit (front)
-2-: The three characters after the penultimate # symbol
are the adjustment dimension in 1/100mm. Example: -a-
TPF#OMG300045_________#F-61967650#VMG001000601#180801002#436048#
=> 4.36 mm.

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– Determine thickness -b- of gasket between transmission unit

and motor using an external micrometer at four opposite
points and calculate the mean. Example: 1.51 mm.

– Read off adjustment dimensions on transmission unit (front)

-1- and motor (front) -2- and determine gap “S” using the
following formula:
♦ Gap “S” = dimension -d- + dimension -b- - dimension -a-.
♦ Example calculation: gap “S” = 4.681 mm + 1.51 mm - 4.36
mm = 1.831 mm.
– Determine dimension -c- for shim using the following table.
Example: Use a shim with dimension -c- = 1.7 mm for the
calculated gap “S”.
Gap “S” Shim dimen‐ Gap “S” Shim dimen‐
mm sion -c- mm sion -c-
mm mm
Tolerance ± Tolerance ±
0.025 mm 0.025 mm
1.15 - 1.164 1.0 1) 1.665 - 1.714 1.55
1.165 - 1.214 1.05 1) 1.715 - 1.764 1.6
1.215 - 1.264 1.1 1) 1.765 - 1.814 1.65
1.265 - 1.314 1.15 1) 1.815 - 1.864 1.7
1.315 - 1.364 1.2 1) 1.865 - 1.914 1.75
1.365 - 1.414 1.25 1) 1.915 - 1.964 1.8
1.415 - 1.464 1.3 1.965 - 2.014 1.85 1)
1.465 - 1.514 1.35 2.015 - 2.064 1.9 1)
1.515 - 1.564 1.4 2.065 - 2.114 1.95 1)
1.565 - 1.614 1.45 2.115 - 2.164 2.0 1)
1.615 - 1.664 1.5 2.165 - 2.214 2.05 1)
1) Check availability of shim before assembly.

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3 Removing and installing motor (rear)

3.1 Exploded view - motor (rear)

1 - Bolt
❑ 8 Nm
2 - Pressure equalisation ele‐
ment
❑ Do not remove
3 - O-ring
❑ Renew after removing
4 - Coolant connection
5 - Bolt
❑ 8 Nm
6 - O-ring
❑ Renew after removing
7 - Coolant connection
8 - Bolt
❑ 3x
❑ Renew after removing
❑ 8 Nm
9 - Rear drive motor rotor po‐
sition sender -G1095-
❑ ⇒ a7.2 nd installing rear
drive motor rotor po‐
sition sender G1095”,
page 241
10 - Sender wheel

3.2 Assembly overview - motor and transmission unit (rear)

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1 - Rear transmission unit

0ME
❑ ⇒ Rep. gr. 10; Separat‐
ing motor and transmis‐
sion unit - rear motor
2 - O-ring
❑ Renew after removing
3 - O-ring
❑ Renew after removing
4 - Bolt
❑ 8x
❑ Renew after removing
❑ Tightening torque and
sequence ⇒ page 29
5 - Motor (rear)

Securing transmission unit to motor - tightening torque and se‐

quence

Stage Bolts in sequence Tightening torque

1. -1- to -8- Screw in by hand
until contact is
made
2. -1- to -8- 50 Nm

3. Removing and installing motor (rear) 29

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Stage Bolts in sequence Tightening torque

3. -1- to -8- Turn 60° further

3.3 Removing rear motor

Special tools and workshop equipment required
♦ Bracket -T10358-
♦ Engine lifting tackle -2024A-
♦ Holding strap -T40155A-
♦ Lift arm extension/workshop hoist -VAS 6101-
♦ Lifting aid -3033-
♦ Workshop hoist -VAS 6100-
♦ strap -T10059-
Removing
– Remove rear subframe together with motor ⇒ Running gear,
axles, steering; Rep. gr. 42; Subframe; Assembly overview -
subframe.
– Press drive shaft off motor slightly ⇒ Running gear, axles,
steering; Rep. gr. 42; Drive shaft; Removing and installing
drive shaft.
– Remove bolt -6-.

– Unscrew nut -4- and remove bolt -3-.

– Remove wheel bearing housing with drive shaft -5- and
place to one side.
Important
• Make sure you do not damage surface coating on drive
shaft.
– Repeat procedure on opposite side of vehicle.
– Remove bolts -arrows- and detach motor carrier (rear right)
-1-.

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– Remove bolts -arrows- and detach motor carrier (rear left)

-1-.

– Unplug electrical connectors -1- to -5- and move clear.

– Remove bolt -arrow- and move earth wire clear.

– Unplug electrical connectors -1- to -4-.

– Move electrical wiring harness clear and press towards rear.

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– Secure bracket -T10059- -1- and bracket -T10358- -2- with

commercially available M8x30 bolt -arrow- (tighten to 20
Nm).

– Attach lift arm extension -VAS 6101- -4- to workshop hoist

-VAS 6100- -3-.

– Attach lifting tackle -3033- -5- to motor and to workshop

hoist.
1 - Bracket -T10358-
2 - Engine lifting tackle -2024A-
6 - Bracket -T10059-
7 - Retaining strap -T40155A-

CAUTION
Risk of injury if engine drops when it is lifted
Danger of trapping or crushing parts of the body
– The support hooks and retaining pins on the lifting tackle
must be secured with a locking spring.

– Raise motor using workshop hoist, guiding it as necessary.

3.4 Installing rear motor

Installing
– Place motor on subframe.

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– Detach lifting tackle.

– Route electrical wiring harness on motor and secure.

– Plug in electrical connectors -1- to -4-.

– Secure earth wire with bolt -arrow-.
– Route electrical wiring harness on motor and secure.

– Plug in electrical connectors -1- to -5-.

– Fit motor carrier (rear left) -1-.

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– Tighten bolts -arrows-.

– Fit motor carrier (rear right) -1-.

– Tighten bolts -arrows-.

– Install wheel bearing housing ⇒ Running gear, axles, steer‐
ing; Rep. gr. 42; Wheel bearing, trailing arm; Removing and
installing wheel bearing housing.
– Install drive shaft ⇒ Running gear, axles, steering; Rep.
gr. 42; Drive shaft; Removing and installing drive shaft.
– Install rear subframe with motor ⇒ Running gear, axles,
steering; Rep. gr. 42; Subframe; Assembly overview - sub‐
frame.
– A potential equalisation measurement must be performed
on the high-voltage components affected after installation
of high-voltage components or potential equalisation lines ⇒
e12.2 qualisation measurement”, page 265 .

WARNING
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric 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.

– ⇒ Rep. gr. 19; Fill cooling system.
If motor or transmission components have been renewed:
– Perform function “Replace Electric Drive Control Module on
Rear Axle J1235” ⇒ Rep. gr. 00; Starting diagnosis.

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– Work steps after exchanging components ⇒ Transmission

unit (rear) 0ME; Rep. gr. 00; Electrical components; Starting
diagnosis

3.5 Securing motor to engine and gearbox

support
Special tools and workshop equipment required
♦ Engine and gearbox bracket -VAS 6095A-
♦ Engine bracket -VAS 6095A/1-23-
♦ Retaining plate -VW309-
♦ Workshop hoist -VAS 6100-

Preparing tool
– Attach retaining plate -VW309- -2- to engine bracket -VAS
6095A/1-23- -1- and tighten to 40 Nm.

– Fit retaining plate -VW309- in engine and gearbox support

-VAS 6095A- and secure.
– Release catch -4- and turn tensioning bolt -3- anti-clockwise
until guide is open by dimension -x-.
Important
• Dimension -x- = approx. 115 mm
– Pull out locking pin -5- and lock it in pulled-out position by
turning it.
Securing to engine and gearbox support
– ⇒ Rep. gr. 10; Remove motor (rear).
– With the help of a second mechanic, carefully position power
unit (rear) -7- on engine bracket -VAS 6095A/1-23- -3- with
workshop hoist -VAS 6100-.

3. Removing and installing motor (rear) 35

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Important
• Hole -6- must be flush with locking pin -4-.
– Release locking pin and engage it in hole.
– Turn tensioning bolt -1- clockwise and tighten to 17 Nm.
– Lower workshop hoist and check that power unit is seated
securely in mounting elements -5-.

3.6 Separating motor and transmission unit

- motor (rear)
Special tools and workshop equipment required
♦ Engine and gearbox bracket -VAS 6095A-
♦ Engine bracket -VAS 6095A/1-23-
♦ Lifting aid -3033-
♦ Round sling -VAS 501 015-
♦ Workshop hoist -VAS 6100-
Procedure
– ⇒ m3.5 otor to engine and gearbox support”, page 35
– Drain gear oil ⇒ Transmission unit; Rep. gr. 34; Gear oil;
Draining and filling gear oil.
– Remove motor carrier (front left) ⇒ a5.2.1 nd installing motor
carrier (front left)”, page 51 .
– Align engine bracket -VAS 6095A/1-23- -3- with motor on
engine and gearbox support -VAS 6095A- with transmission
unit -1-.

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– Remove bolts -2-.

– Remove bolts in the sequence -8- to -1-.

– Attach transmission unit -1- to workshop hoist -VAS 6100-

-3-:

2 - Sling -VAS 501 015-

4 - Lifting tackle -3033-
– Carefully lift transmission unit off motor -5-.
Important
• Have a second mechanic guide transmission unit so that it
stays straight.

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3.7 Assembling motor and transmission

unit - motor (rear)
Special tools and workshop equipment required
♦ Workshop hoist -VAS 6100-

– Fit new O-rings -1- in motor.

– Grease splines of shaft -arrow-.

– Position transmission unit -1- above motor -5- using work‐
shop hoist -VAS 6100- -3-.

– Carefully lower transmission unit.

Important
• Have a second mechanic guide transmission unit so that it
stays straight.
Tightening torques
♦ ⇒ o3.2 verview - motor and transmission unit (rear)”, page
28

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4 Assembly mountings (front)

4.1 Exploded view - assembly mountings

4. Assembly mountings (front) 39

 e-tron GT 2022 ➤
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1 - Bolt
❑ Renew after removing
2 - Nut
❑ Renew after removing
❑ 70 Nm +90°
3 - Motor carrier (front right)
❑ With integrated motor
mounting
❑ ⇒ a4.2.1 nd installing
motor carriers (front)”,
page 41
4 - Bolt
❑ 3x
❑ 55 Nm
5 - Dowel sleeve
❑ 2x
6 - Bolt
❑ Renew after removing
❑ 8 Nm +40°
7 - Vibration damper
8 - Bolt
❑ 160 Nm
9 - Motor mounting (rear right)
❑ Removing and instal‐
ling ⇒ a4.2.3 nd instal‐
ling motor carrier (rear
right)”, page 45
10 - Motor carrier (rear right)
❑ ⇒ a4.2.3 nd instal‐
ling motor carrier (rear
right)”, page 45
11 - Bolt
❑ 4x
❑ 55 Nm
12 - Dowel sleeve
❑ 2x
13 - Bolt
❑ 4x
❑ 55 Nm
14 - Coolant lines
15 - Bolt
❑ 8 Nm
16 - Motor carrier (rear left)
❑ ⇒ a4.2.2 nd installing motor carrier (rear left)”, page 42
17 - Motor mounting (rear left)
❑ Removing and installing ⇒ a4.2.2 nd installing motor carrier (rear left)”, page 42
18 - Bolt

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Electric drive motor 0EG - Edition 01.2023

❑ 160 Nm
19 - Vibration damper
20 - Bolt
❑ Renew after removing
❑ 8 Nm +40°
21 - Bolt
❑ 3x
❑ 55 Nm
22 - Motor carrier (front left)
❑ With integrated motor mounting
❑ ⇒ a4.2.1 nd installing motor carriers (front)”, page 41
23 - Bolt
❑ 2x
❑ Renew after removing
❑ 20 Nm +45°
24 - Nut
❑ Renew after removing
❑ 70 Nm +90°
25 - Bolt
❑ 2x
❑ Renew after removing
❑ 20 Nm +45°
26 - Bolt
❑ Renew after removing

4.2 Removing and installing motor carriers

4.2.1 Removing and installing motor carriers

(front)
Special tools and workshop equipment required
♦ Hooks -10-222A/20-
Removing
– Remove motor ⇒ Motor; Rep. gr. 10; Removing and instal‐
ling motor (front); Removing motor.
Motor carrier (front left)
– Place motor on a soft surface and disengage hook
-10-222A/20-.
All vehicles (continued)
– Remove bolts -arrows-.

4. Assembly mountings (front) 41

 e-tron GT 2022 ➤
Electric drive motor 0EG - Edition 01.2023

– Remove motor carrier (front) -1- (shown here as an exam‐

ple).
Installing
Installation is carried out in reverse sequence.
Tightening torques
♦ ⇒ Motor; Rep. gr. 10; Assembly mountings (front); Exploded
view - assembly mountings

4.2.2 Removing and installing motor carrier

(rear left)
Removing
Important
• Motor carrier (rear right) installed.
– Remove reinforcement (rear) ⇒ Running gear, axles, steer‐
ing; Rep. gr. 40; Subframe; Exploded view - subframe.
– Unscrew bolts -arrows- on both sides and remove retaining
plate -3-.

– Lower anti-roll bar, detaching lower anti-roll bar bushes while

doing so.
– Release catch on both sides -arrow- and move coolant hose
-1- clear.

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– Remove bolts -arrows- and press bracket -1- to side with

coolant pump for high-voltage battery -V590-.

Left-hand drive vehicles

– Unscrew bolts -arrows- for motor carrier (rear left) -1-.

Right-hand drive vehicles

– Remove support bracket (left-side) for subframe ⇒ Running
gear, axles, steering; Rep. gr. 40; Subframe; Exploded view
- subframe.
– Remove wheel housing liner (front left) ⇒ General body re‐
pairs, exterior; Rep. gr. 66; Wheel housing liners; Exploded
view - wheel housing liner (front).
All vehicles (continued)
– Unscrew bolt -2-, move coolant lines clear and press them to
one side.

4. Assembly mountings (front) 43

 e-tron GT 2022 ➤
Electric drive motor 0EG - Edition 01.2023

– Remove bolts -arrows- and detach motor carrier (rear left)

-1- with motor mounting.
Renewing motor mounting
– Mark installation position of motor mounting -1- in relation to
motor carrier -2-:

Important
• Cast projection -3- is flush with marking -arrow-.
– Clamp motor carrier -1- in vice with protective jaw covers -4-.

– Remove bolt -3- and detach motor mounting -2-.

All vehicles (continued)
Installing
Installation is carried out in the reverse order; note the following:
– Place motor mounting in installation position according to
mark made previously.

44 Rep. gr.10 - Removing and installing engine

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Tightening torques
♦ ⇒ Motor; Rep. gr. 10; Assembly mountings (front); Exploded
view - assembly mountings

4.2.3 Removing and installing motor carrier

(rear right)
Removing
Important
• Motor carrier (rear left) installed.
Left-hand drive vehicles
– Remove support bracket (right-side) for subframe ⇒ Running
gear, axles, steering; Rep. gr. 40; Subframe; Exploded view
- subframe.
– Remove wheel housing liner (front right) ⇒ General body re‐
pairs, exterior; Rep. gr. 66; Wheel housing liners; Exploded
view - wheel housing liner (front).
Right-hand drive vehicles
– Remove reinforcement (rear) ⇒ Running gear, axles, steer‐
ing; Rep. gr. 40; Subframe; Exploded view - subframe.
– Unscrew bolts -arrows- on both sides and remove retaining
plate -3-.

– Lower anti-roll bar, detaching lower anti-roll bar bushes while

doing so.
– Remove bolts -arrows- for motor mounting (rear right) -1-
(shown here on left side as an example).

All vehicles (continued)

– Remove nut -3- for air conditioner compressor -2- and press
air conditioner compressor upwards slightly.

4. Assembly mountings (front) 45

 e-tron GT 2022 ➤
Electric drive motor 0EG - Edition 01.2023

– Remove bolts -arrows- and detach motor carrier (rear right)

-1- with motor mounting.
Renewing motor mounting
– Mark installation position of motor mounting -2- in relation to
motor carrier -1-:

Important
• Cast projection -3- is flush with marking -arrow-.
– Clamp motor carrier -1- in vice with protective jaw covers -4-.

– Remove bolt -3- and detach motor mounting -2-.

All vehicles (continued)
Installing
Installation is carried out in reverse order; note the following:
Right-hand drive vehicles
– Install anti-roll bar ⇒ Running gear, axles, steering; Rep.
gr. 40; Anti-roll bar; Removing and installing anti-roll bar.

46 Rep. gr.10 - Removing and installing engine

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All vehicles (continued)

Tightening torques
♦ ⇒ Motor; Rep. gr. 10; Assembly mountings (front); Exploded
view - assembly mountings

4.3 Supporting motor in installation posi‐

tion
Special tools and workshop equipment required
♦ Adapter -10-222A/100-
♦ Adapter -10-222A/11-
♦ Hooks -10-222A/2-
♦ Support -10-222A/1A-
♦ strap -T10059-
Procedure
– Remove air conditioner compressor ⇒ Heating, air condition‐
ing; Rep. gr. 87; Air conditioner compressor; Removing and
installing air conditioner compressor.
– Remove bolts -arrows- and detach bracket -1-.

– Set up support bracket as shown.

♦ -1- Shackle -T10059-: Secure to drive motor with bolt -arrow-

(hand-tight).
♦ -2- Support -10-222A/1A-
♦ -3- Spindle -10-222A/11-
♦ -4- Adapter -10-222A/100-
♦ -5- Support -10-222A/1A-
♦ -6- Hook -10-222A/2-

4. Assembly mountings (front) 47

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– Take up weight of motor evenly with spindle; do not lift.

– Tighten bolt -arrow- to 20 Nm.

48 Rep. gr.10 - Removing and installing engine

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5 Assembly mountings (rear)

5.1 Exploded view - assembly mountings (rear)

5. Assembly mountings (rear) 49

 e-tron GT 2022 ➤
Electric drive motor 0EG - Edition 01.2023

1 - Bolt
❑ 2x
❑ 30 Nm
2 - Support
3 - Damper element
❑ 2x
❑ 20 Nm
4 - Intermediate piece for
damper
❑ 2x
❑ 8 Nm
5 - Nut
❑ 2x
❑ 20 Nm
6 - Bolt
❑ 2x
❑ Renew after removing
❑ 50 Nm +60°
7 - Motor carrier (front right)
❑ With integrated motor
mounting
❑ ⇒ a5.2.2 nd installing
motor carrier (front
right)”, page 55
8 - Bolt
❑ 3x
❑ Renew after removing
❑ 70 Nm +90°
9 - Bolt
❑ 2x
❑ Renew after removing
❑ 50 Nm +60°
10 - Motor carrier (rear right)
❑ ⇒ a5.2.4 nd installing motor carrier (rear right)”, page 58
11 - Bolt
❑ 3x
❑ Renew after removing
❑ 50 Nm +60°
12 - Bolt
❑ Renew after removing
❑ 8 Nm +90°
13 - Vibration damper
14 - Bolt
❑ 2x
❑ Renew after removing
❑ 50 Nm +60°
15 - Motor mounting (rear right)

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❑ Removing and installing ⇒ a5.2.4 nd installing motor carrier (rear right)”, page 58
16 - Motor mounting (rear left)
❑ Removing and installing ⇒ a5.2.3 nd installing motor carrier (rear left)”, page 58
17 - Bolt
❑ 2x
❑ Renew after removing
❑ 50 Nm +60°
18 - Bolt
❑ 3x
❑ Renew after removing
❑ 50 Nm +60°
19 - Motor carrier (rear left)
❑ ⇒ a5.2.3 nd installing motor carrier (rear left)”, page 58
20 - Bolt
❑ 2x
❑ Renew after removing
❑ 50 Nm +60°
21 - Dowel sleeve
❑ 2x
22 - Motor carrier (front left)
❑ With integrated motor mounting
❑ ⇒ a5.2.1 nd installing motor carrier (front left)”, page 51
23 - Bolt
❑ 3x
❑ Renew after removing
❑ M12
❑ 70 Nm +90°
24 - Bolt
❑ Renew after removing
❑ M10
❑ 60 Nm +90°
25 - Bolt
❑ 2x
❑ Renew after removing
❑ 50 Nm +60°
26 - Support

5.2 Removing and installing motor carriers

5.2.1 Removing and installing motor carrier

(front left)
Special tools and workshop equipment required
♦ Engine and gearbox jack -VAS 6931-
♦ mounting bracket for transm. -T40173-

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Important
• Use gearbox support -T40173- with yellow-chromated base
plate and swivel head -B- or valid CE marking -A-.
Important
• Motor carrier (front right) installed.
Removing
– Remove stub shaft (left-side) ⇒ Transmission unit (rear)
0ME; Rep. gr. 39; Differential; Removing and installing stub
shaft (left-side).
Vehicles without rear wheel steering
– Bleed air spring system; to do so, start “Replacement work
on the air suspension system” program ⇒ Running gear,
axles, steering; Rep. gr. 00; Electrical components; Starting
diagnosis.
– Switch off ignition.
– Remove shock absorber ⇒ Running gear, axles, steering;
Rep. gr. 42; Suspension strut/shock absorber, spring; Re‐
moving and installing shock absorber.
– Release fasteners on both sides -arrows-.

– Press bracket -3- with electrical connectors -4- to one side.

– Remove retaining pieces for underbody cladding (rear)
⇒ General body repairs, exterior; Rep. gr. 66; Underbody
cladding; Assembly overview - underbody cladding.

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– Release hose clip -6- and move air hose clear at retaining
clip -5-.

– Unscrew air line -arrow- and protect from dirt.

– Remove bolts -1-, -2-, -7-.
– Remove nuts -4- on both sides.
– Detach bracket -3- with accumulator.
– Remove bolts -2- and -3- on both sides.

– Detach bracket -1-.

– Move coolant hoses -2- clear at retainer -1-.

– Remove spreader rivets -arrows-.

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– Disengage retainer for coolant hoses and detach it.

– Remove bolts -arrows- for motor carrier (left-side) -1-.

Vehicles with rear wheel steering

– Remove subframe with motor ⇒ Running gear, axles, steer‐
ing; Rep. gr. 42; Subframe; Assembly overview - subframe.
All vehicles (continued)
– Remove bolts -arrows-.

– Pull motor carrier -1- off motor.

Vehicles without rear wheel steering
– Support subframe -3- with engine and gearbox jack -VAS
6931- -1- and gearbox support -T40173- -2-.

– Secure subframe to engine and gearbox jack using tension‐

ing strap -4-.
– Remove subframe bolts -1-, -2- on both sides.

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Important
• To avoid damaging threads in vehicle body, never loosen
bolts with an impact wrench.
– Use adjuster screw of gearbox support to lower subframe
slightly at rear.
– Guide motor carrier out.
Vehicles with rear wheel steering
– Guide motor carrier out.
All vehicles (continued)
Installing
Installation is carried out in reverse order; note the following:
Important
• To avoid damaging threads in vehicle body, insert bolts by
hand and make the first few turns by hand.
Tightening torques
♦ ⇒ Motor; Rep. gr. 10; Assembly mountings (rear); Assembly
overview - assembly mountings

5.2.2 Removing and installing motor carrier

(front right)
Important
• Motor carrier (front left) installed.
Removing
– Remove drive shaft (right-side) ⇒ Running gear, axles,
steering; Rep. gr. 42; Drive shaft; Removing and installing
drive shaft.
Vehicles with rear wheel steering
– Remove subframe with motor ⇒ Running gear, axles, steer‐
ing; Rep. gr. 42; Subframe; Exploded view - subframe.
All vehicles (continued)
– Remove bolts -arrows-.

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– Remove motor carrier -1- with lower bolt.

Vehicles without rear wheel steering: procedure if lower bolt
cannot be removed:
– Bleed air spring system; to do so, start “Replacement work
on the air suspension system” program ⇒ Running gear,
axles, steering; Rep. gr. 00; Electrical components; Starting
diagnosis.
– Switch off ignition.
– Release fasteners on both sides -arrows-.

– Press bracket -3- with electrical connectors -4- to one side.

– Remove retaining pieces for underbody trim (rear) on both
sides ⇒ General body repairs, exterior; Rep. gr. 66; Under‐
body trim; Exploded view - underbody trim.
– Remove bolts -2- and -3- on both sides.

– Detach bracket -1-.

– Remove bolts -arrows- (left and right) on bracket -1- for ac‐
cumulator.

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– Unscrew subframe bolts -1-, -2- on both sides by one turn.

Important
• To avoid damaging threads in vehicle body, never loosen
bolts with an impact wrench.
– Push subframe to right side.
– Remove motor carrier with lower bolt.
All vehicles (continued)
Installing
Installation is carried out in reverse order; note the following:
Important
• Renew subframe bolts one at a time.
• To avoid damaging threads in vehicle body, insert bolts by
hand and make the first few turns by hand.
Tightening torques
♦ ⇒ Motor; Rep. gr. 10; Assembly mountings (rear); Exploded
view - assembly mountings

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5.2.3 Removing and installing motor carrier

(rear left)
Removing
– Remove subframe with motor ⇒ Running gear, axles, steer‐
ing; Rep. gr. 42; Subframe; Exploded view - subframe.
– Remove bolts -arrows-.

– Detach motor carrier (rear left) -1-.

Removing motor mounting
– Remove bolts -arrows-.

– Detach motor mounting (rear left) -1-.

All vehicles (continued)
Installing
Installation is carried out in reverse sequence.
Tightening torques
♦ ⇒ Motor; Rep. gr. 10; Assembly mountings (rear); Exploded
view - assembly mountings

5.2.4 Removing and installing motor carrier

(rear right)
Removing
– Bleed air spring system; to do so, start “Replacement work
on the air suspension system” program ⇒ Running gear,
axles, steering; Rep. gr. 00; Electrical components; Starting
diagnosis.
– Switch off ignition.

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– Remove underbody trim (rear) ⇒ General body repairs, ex‐

terior; Rep. gr. 66; Underbody trim; Exploded view - under‐
body trim.
– Release fasteners on both sides -arrows-.

– Press bracket -3- with electrical connectors -4- to one side.

– Remove retaining pieces for underbody trim (rear) ⇒ Gener‐
al body repairs, exterior; Rep. gr. 66; Underbody trim; Explo‐
ded view - underbody trim.
– Release hose clip -5- and move air hose clear at retaining
clip -4-.

– Unscrew air line -arrow- and protect from dirt.

– Remove bolts -6-.
– Remove bolts -1- and nuts -3- on both sides.
– Detach bracket -2- with accumulator.
– Remove bolts -arrows- on both sides and carefully lower
anti-roll bar -2-.

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– Remove bolts -2- on motor carrier (rear right).

– Remove bolts -arrows-.

– Detach motor carrier (rear right) -1-, as shown here as an

example with motor removed.
Removing motor mounting
– Remove bolts -arrows-.

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– Detach motor mounting (rear left) -1-.

All vehicles (continued)
Installing
Installation is carried out in reverse sequence.
Tightening torques
♦ ⇒ Motor; Rep. gr. 10; Assembly mountings (rear); Exploded
view - assembly mountings

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19 – Cooling
1 Safety and repair instructions

1.1 Safety information

Observe safety information ⇒ Safety information and repair
notes; Rep. gr. 00; Safety information.

1.2 Repair instructions

Observe repair instructions ⇒ Safety and repair instructions;
Rep. gr. 00; Repair instructions.

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2 Cooling system/coolant

2.1 Exploded view - coolant expansion tank

1 - Coolant expansion tank

❑ With coolant shortage
indicator sender 2 -
G837-
❑ ⇒ Rep. gr. 19; Remov‐
ing and installing cool‐
ant expansion tank
2 - Nut
❑ 8 Nm
3 - Filler cap
❑ Check opening pres‐
sure ⇒ Rep. gr. 19;
Checking cooling sys‐
tem for leaks
4 - Plenum chamber partition
panel
5 - Coolant bleeder hose
6 - O-ring
❑ Renew if damaged
7 - O-ring
❑ Renew if damaged
8 - Coolant hose

2.2 Removing and installing coolant ex‐

pansion tank
– Remove luggage compartment pan ⇒ General body repairs,
interior; Rep. gr. 70; Luggage compartment trim panels; Re‐
moving and installing luggage compartment pan (front).
– ⇒ Rep. gr. 19; Drain coolant.
– Unplug electrical connector -1- and move electrical wiring
harness clear at coolant expansion tank.

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– Lift retaining clip -3- and disconnect coolant hose.

– Press retaining clip -2- and detach coolant bleeder line.
– Remove nuts -arrows-.
– Disengage and detach coolant expansion tank upwards.
Installing
Installation is carried out in reverse order; note the following:
– Slide coolant expansion tank -1- onto bracket -2- -arrow-.

– ⇒ Rep. gr. 19; Fill cooling system.

Tightening torques
♦ ⇒ Rep. gr. 19; Exploded view - coolant expansion tank

2.3 Connection diagram - coolant hoses

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1 - Coolant temperature send‐

er 4 for thermal management
-G905-
2 - Changeover and mixing
valve 7 for thermal manage‐
ment -V656-
3 - Coolant changeover valve
1 -N632-
4 - Thermal management
coolant pump 4 -V620-
5 - Coolant temperature send‐
er 5 for thermal management
-G906-
6 - Power contactor with
boost function -J1178-
7 - Non-return valve
8 - Charging unit 1 for high-
voltage battery -AX4-
9 - Thermal management
coolant pump 2 -V618-
10 - Heat condenser
11 - Coolant temperature
sender 7 for thermal manage‐
ment -G908-
12 - Voltage converter for 800
V, 400 V, 48 V, 12 V -A48-
13 - High-voltage heater (line‐
ar) -Z189-
14 - Heat exchanger for heat‐
er
15 - Coolant temperature
sender 2 for high-voltage bat‐
tery -G899-
16 - High-voltage battery 1 -AX2-
17 - Rear final drive
18 - Electric drive motor for rear axle -V663-
19 - Electric drive control unit for rear axle -J1235-
20 - Coolant temperature sender 1 for high-voltage battery -G898-
21 - Coolant pump for high-voltage battery -V590-
22 - Changeover and mixing valve 4 for thermal management -V653-
23 - Coolant temperature sender 2 for thermal management -G903-
24 - Changeover and mixing valve for thermal management -V650-
25 - Electric drive control unit for front axle -J1234-
26 - Coolant temperature sender 1 for thermal management -G902-
27 - Electric drive motor for front axle -V662-
28 - Filler cap
29 - Coolant expansion tank
30 - Heat exchanger for high-voltage battery with refrigerant expansion valve 2 -N637-

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31 - Non-return valve
32 - Restrictor
33 - Radiator
34 - Coolant temperature sender 9 for thermal management -G1017-
35 - Coolant temperature sender 8 for thermal management -G968-
36 - Coolant changeover valve 2 -N633-
37 - Coolant temperature sender 3 for thermal management -G904-
38 - Changeover and mixing valve 2 for thermal management -V651-

2.4 Draining coolant

Special tools and workshop equipment required
♦ Cooling system device -VAS 531 011-
♦ Hose clamps up to 40 mm -3093-
♦ Spring-type clip pliers -VAS 6891-

NOTICE
Risk of damage to high-voltage components due to overheat‐
ing.
– Do not perform high-voltage charging if coolant has been
drained.
– Indicate this on the vehicle accordingly.

Procedure
Important
• Cooling system must be discharged in full.
• Follow operating instructions for cooling system service de‐
vice -VAS 531 011-.
Preparations
– Ensure that DRAIN container of cooling system service de‐
vice -VAS 531 011- has space for 20 litres of coolant.
Note
If the cooling system is to be filled back up immediately after
being discharged, fill cooling system service device -VAS 531
011- with new coolant before starting ⇒ Rep. gr. 19; Filling
cooling system.
– End high-voltage charging process.
– Perform function “Opening electrically actuated valves in
cooling system for discharging and charging” with ⇒ Vehicle
diagnostic tester ⇒ Rep. gr. 00; Starting diagnosis.
– Remove plenum chamber cover (front) ⇒ General body re‐
pairs, exterior; Rep. gr. 50; Bulkhead; Removing and instal‐
ling plenum chamber cover.
– Turn front wheels to right.
– Remove wheel spoiler (left-side) ⇒ General body repairs,
exterior; Rep. gr. 66; Wheel housing liners; Exploded view -
wheel housing liner (front).
– Unfasten rear section of wheel housing liner (front left) and
press towards front ⇒ General body repairs, exterior; Rep.

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gr. 66; Wheel housing liners; Exploded view - wheel housing

liner (front).
– Remove underbody trim (front and rear) ⇒ General body
repairs, exterior; Rep. gr. 66; Underbody trim; Exploded view
- underbody trim.

CAUTION
The cooling system may be under pressure. Risk of scalding
due to hot steam and hot coolant
Danger of scalding skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Cover filler cap on expansion tank with a suitable cloth and
open carefully to release pressure.

– Open filler cap -arrow- on coolant expansion tank.

– Screw adapter from cooling system service device -VAS 531

011- onto coolant expansion tank and connect service hose
to adapter.
Important
• Service hose must not be disconnected from cooling system
service device.
• The total amount of coolant discharged should be between
16 and 17 litres.
Draining coolant from plug-in connector for rear final drive
– Move plug-in connector clear at retainer -4-.

– Place cooling system service device -VAS 531 011- under

coupling point to catch coolant.

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– Select “Vehicle maintenance” in main menu, then select

“Drain system”.
– Start “discharging procedure”.
– Lift retaining clip -2-, disconnect coolant hose and drain off
coolant.
– Seal off coolant hose -3- with hose clamp, up to 40 mm
-3093-.
Note
Hold coolant hose -1- in funnel of -VAS 531 011- while dis‐
charging.
– Select “Drain system”.
– Follow instructions on display and blow out coolant until it
only comes out in drops or until air comes out.
– If necessary, start “Drain system” process again.
– Remove hose clamp from coolant hose -3- and seal coolant
hose -1-.
Note
Hold coolant hose -3- in funnel of -VAS 531 011- while dis‐
charging.
– Start “Drain system” process again.
– Follow instructions on display and blow out coolant until it
only comes out in drops or until air comes out.
– If necessary, start “Drain system” process again.
– Connect plug-in connector ⇒ Motor; Rep. gr. 19; Radiator/ra‐
diator fan; Exploded view - radiator/radiator fan.
– Remove hose clamp.
Draining coolant at coolant supply for high-voltage battery
– Cover surrounding components with foil.

– Place cooling system service device -VAS 531 011- under

coupling point to catch coolant.
– Lift retaining clip -2-, disconnect coolant hose from connec‐
tion to high-voltage battery and drain off coolant.
– Seal off coolant hose -1- with hose clamp, up to 40 mm
-3093-.
Note
To make draining off easier, hold an angled coolant hose
against connection opening (e.g. 06B 121 101 E; already used
when searching for leaks in the high-voltage battery). A hose

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with an outer diameter of 16 mm can also be inserted in the

connection opening.
– Start “Drain system” process again.
– Follow instructions on display and blow out coolant until it
only comes out in drops or until air comes out.
– If necessary, start “Drain system” process again.
– Connect plug-in connector ⇒ Motor; Rep. gr. 19; Radiator/ra‐
diator fan; Exploded view - radiator/radiator fan.
– Remove hose clamp.
Draining coolant from radiator (front left)
– Place cooling system service device -VAS 531 011- under
coupling point to catch coolant.

– Release hose clip -2- with spring-type clip pliers -VAS 6891-,
disconnect coolant hose -1- and allow coolant to drain off.
– Seal off coolant hose -1- with hose clamp, up to 40 mm
-3093-.
Note
To make draining off easier, hold an angled coolant hose
against connection opening (e.g. 06B 121 101 E; already used
when searching for leaks in the high-voltage battery). A hose
with an outer diameter of 16 mm can also be inserted in the
connection opening.
– Start “Drain system” process again.
– Follow instructions on display and blow out coolant until it
only comes out in drops or until air comes out.
– If necessary, start “Drain system” process again.
– Connect coolant hose and remove hose clamp.

2.5 Filling cooling system

Special tools and workshop equipment required
♦ Cooling system device -VAS 531 011-
Important
• Coolant fully drained off ⇒ Rep. gr. 19; Draining coolant.
• Coolant circuit valves must be open. If necessary, perform
function “Opening electrically actuated valves in cooling sys‐
tem for discharging and charging” with ⇒ Vehicle diagnostic
tester again ⇒ Rep. gr. 00; Starting diagnosis.
• Follow operating instructions for cooling system service de‐
vice -VAS 531 011-.

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Procedure
– Fill “NEW” container of cooling system service device -VAS
531 011- with at least 17 litres of premixed coolant (accord‐
ing to recommended ratio) ⇒ Safety and repair instructions;
Rep. gr. 00; Repair instructions; Replacement parts, servic‐
ing materials and consumables
– Ensure that all coolant hoses are connected.
– Connect cooling system service device -VAS 531 011- (refer
to operating instructions).
– Select “Vehicle maintenance” in main menu.
– Select “Pressure test” in menu and perform hydraulic leak
test.
♦ Test duration: 120 seconds
♦ Max. Delta P => 40 mbar
♦ Pressure test: 2000 mbar
♦ Refer to notes on display.
♦ The result of the test will be shown when the test is com‐
plete.
– Select “Vacuum test” in menu and perform hydraulic leak
test.
♦ Time for vacuum: 240 seconds
♦ Specified pressure: 40 mbar
♦ Test duration: 120 seconds
♦ Max. Delta P => 30 mbar
♦ Refer to notes on display.
♦ The result of the test will be shown when the test is com‐
plete.
♦ Repeat procedure if necessary.
– Select “Charge system” from the menu and perform process.
♦ Filling quantity: enter mass of 17000 g; this corresponds to
17 litres.
♦ When the filling procedure is complete, the display shows
the amount of coolant added.
♦ When the filling procedure is complete, the service device
cleans the hoses automatically.
♦ Follow instructions on display and under no circumstances
interrupt the process.
♦ The result of the test will be shown when the test is com‐
plete.
♦ Repeat procedure if necessary.
Note
The cooling system is filled with 16 to 17 litres of coolant in this
process.
– Perform function “Opening electrically actuated valves in
cooling system after discharging and charging” with ⇒ Vehi‐
cle diagnostic tester ⇒ Rep. gr. 00; Starting diagnosis.
– Bleed cooling system ⇒ Rep. gr. 19; Bleeding cooling sys‐
tem.

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2.6 Bleeding cooling system

Special tools and workshop equipment required
♦ Cooling system device -VAS 531 011-
Procedure
Important
• Cooling system fully filled up ⇒ Rep. gr. 19; Filling cooling
system.
• Follow operating instructions for cooling system service de‐
vice -VAS 531 011-.
– Connect cooling system service device -VAS 531 011- (refer
to operating instructions).
– Select “Vehicle maintenance” in main menu.
– Select “Bleed system” from the menu and perform process.
♦ Test pressure => 1800 mbar
– Perform function “Bleeding cooling system” using ⇒ Vehicle
diagnostic tester ⇒ Rep. gr. 00; Starting diagnosis.
– Detach adapter and service hose for cooling system service
device -VAS 531 011- from coolant expansion tank.
– Check coolant level in coolant expansion tank and correct if
necessary.

Important
• Only check coolant level when fluid is at a temperature of
15° C or above.
• The coolant level is correct when the coolant is at the lower
edge -arrow- of the filler neck.
Assembling
Assembly is performed in the reverse sequence:

2.7 Checking cooling system for leaks

Special tools and workshop equipment required
♦ Adapter -VAS 691 005/5-
♦ Adapter for cooling system tester -V.A.G 1274/9-
♦ Cooling system tester -V.A.G 1274B-
♦ cooling system tester - V.A.G 1274B-

– Check cooling system tester -V.A.G 1274B- for leaks ⇒ page

72 .

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– Check cooling system for leaks ⇒ page 72 .

– Check pressure relief valve in filler cap ⇒ page 73 .

Checking cooling system tester - V.A.G 1274B- for leaks

– Operate hand pump several times and build up a pressure of
3.0 bar.
– Observe pressure on pressure gauge of cooling system test‐
er for 30 seconds.
If no pressure is built up or if pressure dissipates, cooling sys‐
tem tester must not be used.
Checking cooling system for leaks
Important
• Cooling system tester -V.A.G 1274B- checked for leaks
– Remove plenum chamber cover (front) ⇒ General body re‐
pairs, exterior; Rep. gr. 50; Bulkhead; Removing and instal‐
ling plenum chamber cover.

CAUTION
The cooling system may be under pressure. Risk of scalding
due to hot steam and hot coolant
Danger of scalding skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Cover filler cap on expansion tank with a suitable cloth and
open carefully to release pressure.

– Open filler cap -arrow-.

– Screw adapter -VAS 691 005/5- onto coolant expansion tank

and connect it to cooling system tester -V.A.G 1274B-.
– Operate hand pump several times and build up a pressure of
approx. 1.1 bar.
– If applicable, locate leak and eliminate fault.
– Release pressure at cooling system tester and detach tester
from coolant expansion tank.
– Screw on cap -arrow-.
– Perform function “Opening electrically actuated valves in
cooling system after discharging and charging” with ⇒ Vehi‐
cle diagnostic tester ⇒ Rep. gr. 00; Starting diagnosis.

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Checking pressure relief valve in filler cap

Important
• Cooling system tester -V.A.G 1274B- checked for leaks
– Remove plenum chamber cover (front) ⇒ General body re‐
pairs, exterior; Rep. gr. 50; Bulkhead; Removing and instal‐
ling plenum chamber cover.

CAUTION
The cooling system may be under pressure. Risk of scalding
due to hot steam and hot coolant
Danger of scalding skin and other parts of the body
– Put on protective gloves.
– Put on safety goggles.
– Cover filler cap on expansion tank with a suitable cloth and
open carefully to release pressure.

– Open filler cap -arrow-.

– Connect cooling system tester -V.A.G 1274B- -1- and adapt‐

er for cooling system tester -V.A.G 1274/9- -2- with filler cap
-3-.

– Operate hand pump -1- several times and build up pressure.

Important
• The pressure relief valve must open at a pressure of 0.9 bar.

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– Renew filler cap if pressure relief valve does not react as

described.

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3 Coolant pump/thermostat assembly

3.1 Overview of fitting locations - coolant pump/thermostat assembly

Overview of fitting locations - coolant pumps, coolant valves

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1 - Coolant changeover valve

1 -N632-
❑ ⇒ Motor; Rep. gr. 19;
Coolant pump/thermo‐
stat assembly; Remov‐
ing and installing cool‐
ant changeover valve 1
N632
2 - Thermal management
coolant pump 2 -V618-
❑ ⇒ Motor; Rep. gr. 19;
Coolant pump/thermo‐
stat assembly; Remov‐
ing and installing ther‐
mal management cool‐
ant pump 2 V618
3 - Coolant pump for high-
voltage battery -V590-
❑ ⇒ Motor; Rep. gr. 19;
Coolant pump/thermo‐
stat assembly; Remov‐
ing and installing cool‐
ant pump for high-volt‐
age battery V590
4 - Changeover and mixing
valve 4 for thermal manage‐
ment -V653-
❑ ⇒ Motor; Rep. gr. 19;
Coolant pump/thermo‐
stat assembly; Remov‐
ing and installing
changeover and mixing
valve 4 for thermal
management V653
5 - Changeover and mixing
valve for thermal manage‐
ment -V650-
❑ ⇒ Motor; Rep. gr. 19; Coolant pump/thermostat assembly; Removing and installing changeover and
mixing valve for thermal management V650
6 - Thermal management coolant pump 4 -V620-
❑ ⇒ Motor; Rep. gr. 19; Coolant pump/thermostat assembly; Removing and installing thermal manage‐
ment coolant pump 4 V620
7 - Coolant changeover valve 2 -N633-
❑ ⇒ Motor; Rep. gr. 19; Coolant pump/thermostat assembly; Removing and installing coolant change‐
over valve 2 N633
8 - Changeover and mixing valve 7 for thermal management -V656-
❑ ⇒ Motor; Rep. gr. 19; Coolant pump/thermostat assembly; Removing and installing changeover and
mixing valve 7 for thermal management V656
9 - Changeover and mixing valve 2 for thermal management -V651-
❑ ⇒ Motor; Rep. gr. 19; Coolant pump/thermostat assembly; Removing and installing changeover and
mixing valve 2 for thermal management V651

Overview of fitting locations - coolant temperature senders

76 Rep. gr.19 - Cooling

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Electric drive motor 0EG - Edition 01.2023

1 - Coolant temperature send‐

er 2 for thermal management
-G903-
❑ ⇒ Motor; Rep. gr. 19;
Coolant pump/thermo‐
stat assembly; Remov‐
ing and installing cool‐
ant temperature sender
2 for thermal manage‐
ment G903
2 - Coolant temperature send‐
er 7 for thermal management
-G908-
❑ ⇒ Motor; Rep. gr. 19;
Coolant pump/thermo‐
stat assembly; Remov‐
ing and installing cool‐
ant temperature sender
7 for thermal manage‐
ment G908
3 - Coolant temperature send‐
er 2 for high-voltage battery
-G899-
❑ ⇒ Motor; Rep. gr. 19;
Coolant pump/thermo‐
stat assembly; Remov‐
ing and installing cool‐
ant temperature sender
2 for high-voltage bat‐
tery G899
4 - Coolant temperature send‐
er 5 for thermal management
-G906-
❑ ⇒ Motor; Rep. gr. 19;
Coolant pump/thermo‐
stat assembly; Remov‐
ing and installing cool‐
ant temperature sender
5 for thermal management G906
5 - Coolant temperature sender 1 for high-voltage battery -G898-
❑ ⇒ Motor; Rep. gr. 19; Coolant pump/thermostat assembly; Removing and installing coolant tempera‐
ture sender 1 for high-voltage battery G898
6 - Coolant temperature sender 1 for thermal management -G902-
❑ ⇒ Motor; Rep. gr. 19; Coolant pump/thermostat assembly; Removing and installing coolant tempera‐
ture sender 1 for thermal management G902
7 - Coolant temperature sender 8 for thermal management -G968-
❑ ⇒ Motor; Rep. gr. 19; Coolant pump/thermostat assembly; Removing and installing coolant tempera‐
ture sender 8 for thermal management G968
8 - Coolant temperature sender 9 for thermal management -G1017-
❑ ⇒ Motor; Rep. gr. 19; Coolant pump/thermostat assembly; Removing and installing coolant tempera‐
ture sender 9 for thermal management G1017
9 - Coolant temperature sender 3 for thermal management -G904-
❑ ⇒ Motor; Rep. gr. 19; Coolant pump/thermostat assembly; Removing and installing coolant tempera‐
ture sender 3 for thermal management G904
10 - Coolant temperature sender 4 for thermal management -G905-
❑ ⇒ Motor; Rep. gr. 19; Coolant pump/thermostat assembly; Removing and installing coolant tempera‐
ture sender 4 for thermal management G905

3. Coolant pump/thermostat assembly 77

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3.2 Exploded view - electric coolant pump

78 Rep. gr.19 - Cooling

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1 - Subframe
2 - Bolt
❑ 2x
❑ 8 Nm
3 - Rubber bush
4 - Bracket
5 - Bolt
❑ 8 Nm
6 - Bracket
7 - Rubber bush
8 - Spacer sleeve
9 - Bolt
❑ 2x
❑ 8 Nm
10 - Thermal management
coolant pump 2 -V618-
❑ ⇒ Motor; Rep. gr. 19;
Coolant pump/thermo‐
stat assembly; Remov‐
ing and installing ther‐
mal management cool‐
ant pump 2 V618
11 - Retaining bracket
12 - Rubber bush
13 - Spacer sleeve
14 - Bolt
❑ 3x
❑ 8 Nm
15 - Coolant pump for high-voltage battery -V590-
❑ ⇒ Motor; Rep. gr. 19; Coolant pump/thermostat assembly; Removing and installing coolant pump for
high-voltage battery V590
16 - Retaining bracket
17 - Bolt
❑ 8 Nm
18 - Bracket
19 - Motor carrier (rear left)
20 - Bolt
❑ 3x
❑ 8 Nm
21 - Spacer sleeve
22 - Rubber bush
23 - Bolt
❑ 8 Nm
24 - Retaining bracket
25 - Thermal management coolant pump 4 -V620-

3. Coolant pump/thermostat assembly 79

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❑ ⇒ Motor; Rep. gr. 19; Coolant pump/thermostat assembly; Removing and installing thermal manage‐
ment coolant pump 4 V620
26 - Bracket

3.3 Exploded view - coolant valves

80 Rep. gr.19 - Cooling

 e-tron GT 2022 ➤
Electric drive motor 0EG - Edition 01.2023

1 - Subframe
2 - Coolant changeover valve
2 -N633-
❑ ⇒ Motor; Rep. gr. 19;
Coolant pump/thermo‐
stat assembly; Remov‐
ing and installing cool‐
ant changeover valve 2
N633
3 - Bolt
❑ 2 Nm
4 - Changeover and mixing
valve 2 for thermal manage‐
ment -V651-
❑ ⇒ Motor; Rep. gr. 19;
Coolant pump/thermo‐
stat assembly; Remov‐
ing and installing
changeover and mixing
valve 2 for thermal
management V651
5 - Bolt
❑ 2 Nm
6 - Coolant changeover valve
1 -N632-
❑ ⇒ Motor; Rep. gr. 19;
Coolant pump/thermo‐
stat assembly; Remov‐
ing and installing cool‐
ant changeover valve 1
N632
7 - Changeover and mixing
valve 7 for thermal manage‐
ment -V656-
❑ ⇒ Motor; Rep. gr. 19;
Coolant pump/thermostat assembly; Removing and installing changeover and mixing valve 7 for
thermal management V656
8 - Coolant distributor
9 - Changeover and mixing valve 4 for thermal management -V653-
❑ ⇒ Motor; Rep. gr. 19; Coolant pump/thermostat assembly; Removing and installing changeover and
mixing valve 4 for thermal management V653
10 - Bolt
❑ 3x
❑ 8 Nm
11 - Lower brace
12 - Bracket
13 - Spacer sleeve
❑ 3x
14 - Bracket
15 - Rubber bush
❑ 3x
16 - Nut
❑ 8 Nm

3. Coolant pump/thermostat assembly 81

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17 - Bolt
❑ 2x
❑ 8 Nm
18 - Bolt
❑ 3x
❑ 8 Nm
19 - Changeover and mixing valve for thermal management -V650-
❑ ⇒ Motor; Rep. gr. 19; Coolant pump/thermostat assembly; Removing and installing changeover and
mixing valve for thermal management V650
20 - Bolt
❑ 2x
❑ 8 Nm
21 - Bracket

3.4 Exploded view - coolant temperature sender

1 - Mounting for coolant tem‐

perature sender
❑ Example
2 - Bolt
❑ G903, G904, G905:
2 Nm
❑ G902, G906, G908,
G898, G899, G1017: 5
Nm
❑ G968: 4 Nm
3 - Coolant temperature send‐
er
❑ Example
❑ Removing and instal‐
ling ⇒ Motor; Rep.
gr. 19; Coolant pump/
thermostat assembly;
Overview of fitting lo‐
cations - coolant pump/
thermostat assembly
4 - Centring ring
❑ Check for damage. If
damaged, renew cool‐
ant temperature sender
5 - O-ring
❑ Renew after removing

82 Rep. gr.19 - Cooling

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3.5 Removing and installing coolant pump

for high-voltage battery V590
Removing
– ⇒ Motor; Rep. gr. 19; Cooling system/coolant; Draining cool‐
ing system
– Remove motor carrier (rear left) ⇒ Motor; Rep. gr. 10; As‐
sembly mountings (front); Removing and installing motor
carriers.
– Unplug electrical connector -3-.

– Remove bolt -1- and detach retaining bracket and bracket.

– Unfasten hose clips -2- and detach coolant hoses.
– Detach coolant pump for high-voltage battery -V590- -4-.
Installing
Installation is carried out in reverse order; note the following:
– ⇒ Motor; Rep. gr. 19; Cooling system/coolant; Filling cooling
system
Tightening torques
♦ ⇒ Motor; Rep. gr. 19; Coolant pump/thermostat assembly;
Exploded view - electric coolant pump

3.6 Removing and installing thermal man‐

agement coolant pump 2 V618
Removing
– Remove luggage compartment pan (front) ⇒ General body
repairs, interior; Rep. gr. 70; Luggage compartment trim
panels; Removing and installing luggage compartment pan
(front).
– ⇒ Motor; Rep. gr. 19; Cooling system/coolant; Draining cool‐
ing system
– Unfasten hose clips -1- and detach coolant hoses.

3. Coolant pump/thermostat assembly 83

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– Remove bolt -2- and detach retaining bracket.

– Detach thermal management coolant pump 2 -V618- -4-.
– Unplug electrical connector -3-.
Installing
Installation is carried out in reverse order; note the following:
– ⇒ Motor; Rep. gr. 19; Cooling system/coolant; Filling cooling
system
Tightening torques
♦ ⇒ Motor; Rep. gr. 19; Coolant pump/thermostat assembly;
Exploded view - electric coolant pump

3.7 Removing and installing thermal man‐

agement coolant pump 4 V620
Removing
– Remove luggage compartment pan (front) ⇒ General body
repairs, interior; Rep. gr. 70; Luggage compartment trim
panels; Removing and installing luggage compartment pan
(front).
– ⇒ Motor; Rep. gr. 19; Cooling system/coolant; Draining cool‐
ing system
– Remove bolts -arrows-.

– Lift retaining clip -1- and disconnect coolant hose.

– Press thermal management coolant pump 4 -V620- -2-
slightly to left side with bracket.
– Unplug electrical connector -3-.

84 Rep. gr.19 - Cooling

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Electric drive motor 0EG - Edition 01.2023

– Remove bolt -2- and detach retaining bracket.

– Detach coolant pump -4-.
– Release hose clips -1- and detach coolant hoses.
Installing
Installation is carried out in reverse order; note the following:
– ⇒ Motor; Rep. gr. 19; Cooling system/coolant; Filling cooling
system
Tightening torques
♦ ⇒ Motor; Rep. gr. 19; Coolant pump/thermostat assembly;
Exploded view - electric coolant pump

3.8 Removing and installing coolant

changeover valve 1 N632
Removing
– ⇒ Motor; Rep. gr. 19; Cooling system/coolant; Draining cool‐
ing system
– Unplug electrical connector -1-.

– Remove bolts -arrows-.

– Unfasten hose clips -2-, -3- and detach coolant hoses.
– Remove coolant changeover valve 1 -N632- -4-.
Installing
Installation is carried out in reverse order; note the following:
– ⇒ Motor; Rep. gr. 19; Cooling system/coolant; Filling cooling
system

3. Coolant pump/thermostat assembly 85

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Tightening torques
♦ ⇒ Motor; Rep. gr. 19; Coolant pump/thermostat assembly;
Exploded view - coolant valves

3.9 Removing and installing coolant

changeover valve 2 N633
Removing
– ⇒ Motor; Rep. gr. 19; Cooling system/coolant; Draining cool‐
ing system
– Remove bolts -arrows-.

– Loosen hose clips -2-, -3-.

– Unplug electrical connector -1-.
– Detach coolant hoses.
– Detach coolant changeover valve 2 -N633- -4-.
Installing
Installation is carried out in reverse order; note the following:
– ⇒ Motor; Rep. gr. 19; Cooling system/coolant; Filling cooling
system
Tightening torques
♦ ⇒ Motor; Rep. gr. 19; Coolant pump/thermostat assembly;
Exploded view - coolant valves

3.10 Removing and installing changeover

and mixing valve for thermal manage‐
ment V650
Removing
– ⇒ Motor; Rep. gr. 19; Cooling system/coolant; Draining cool‐
ing system
– Remove reinforcement (front left) ⇒ Running gear, axles,
steering; Rep. gr. 40; Subframe; Exploded view - subframe.
– Unplug electrical connector -1-.

86 Rep. gr.19 - Cooling

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Electric drive motor 0EG - Edition 01.2023

– Remove bolts -arrows-.

– Unfasten hose clips -2-, -3- and detach coolant hoses.
– Detach changeover and mixing valve for thermal manage‐
ment -V650- -4-.
Installing
Installation is carried out in reverse order; note the following:
– ⇒ Motor; Rep. gr. 19; Cooling system/coolant; Filling cooling
system
Tightening torques
♦ ⇒ Motor; Rep. gr. 19; Coolant pump/thermostat assembly;
Exploded view - coolant valves

3.11 Removing and installing changeover

and mixing valve 2 for thermal man‐
agement V651
Removing
– ⇒ Motor; Rep. gr. 19; Cooling system/coolant; Draining cool‐
ing system
– Remove bolts -arrows-.

– Unfasten hose clips -2-, -3- and detach coolant hoses.

– Unplug electrical connector -1-.
– Detach changeover and mixing valve 2 for thermal manage‐
ment -V651- -4-.
Installing
Installation is carried out in reverse order; note the following:
– ⇒ Motor; Rep. gr. 19; Cooling system/coolant; Filling cooling
system

3. Coolant pump/thermostat assembly 87

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Tightening torques
♦ ⇒ Motor; Rep. gr. 19; Coolant pump/thermostat assembly;
Exploded view - coolant valves

3.12 Removing and installing changeover

and mixing valve 4 for thermal man‐
agement V653
Removing
– ⇒ Rep. gr. 19; Drain coolant.
– Remove motor carrier (rear left) ⇒ Rep. gr. 10; Removing
and installing motor carrier.
– Remove nuts -arrows-.

– Unfasten hose clips -2-, -3- and detach coolant hoses.

– Unplug electrical connector -1-.

– Detach changeover and mixing valve 4 for thermal manage‐
ment -V653- -4-.
Installing
Installation is carried out in reverse order; note the following:
– ⇒ Rep. gr. 19; Fill cooling system.
Tightening torques
♦ ⇒ Motor; Rep. gr. 19; Coolant pump/thermostat assembly;
Exploded view - coolant valves

88 Rep. gr.19 - Cooling

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Electric drive motor 0EG - Edition 01.2023

3.13 Removing and installing changeover

and mixing valve 7 for thermal man‐
agement V656
Removing
– ⇒ Motor; Rep. gr. 19; Cooling system/coolant; Draining cool‐
ing system
– Unplug electrical connector -1-.

– Remove bolts -arrows-.

– Unfasten hose clips -2-, -3- and detach coolant hoses.
– Detach changeover and mixing valve 7 for thermal manage‐
ment -V656- -4-.
Installing
Installation is carried out in reverse order; note the following:
– ⇒ Motor; Rep. gr. 19; Cooling system/coolant; Filling cooling
system
Tightening torques
♦ ⇒ Motor; Rep. gr. 19; Coolant pump/thermostat assembly;
Exploded view - coolant valves

3.14 Removing and installing coolant short‐

age indicator sender 2 G837
Coolant shortage indicator sender 2 -G837- is integrated in
coolant expansion tank and cannot be renewed separately
⇒ Motor; Rep. gr. 19; Cooling system/coolant; Removing and
installing coolant expansion tank.

3.15 Removing and installing coolant tem‐

perature sender 1 for thermal manage‐
ment G902
Removing
– ⇒ Motor; Rep. gr. 19; Cooling system/coolant; Draining cool‐
ing system
– Unplug electrical connector -1-.

3. Coolant pump/thermostat assembly 89

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Electric drive motor 0EG - Edition 01.2023

– Remove bolt -2-.

– Detach coolant temperature sender 1 for thermal manage‐
ment -G902- -3-.
Installing
Installation is carried out in reverse order; note the following:
– ⇒ Motor; Rep. gr. 19; Cooling system/coolant; Filling cooling
system
Tightening torques
♦ ⇒ Motor; Rep. gr. 19; Coolant pump/thermostat assembly;
Exploded view - coolant temperature sender

3.16 Removing and installing coolant tem‐

perature sender 2 for thermal manage‐
ment G903
Removing
– ⇒ Motor; Rep. gr. 19; Cooling system/coolant; Draining cool‐
ing system
– Unplug electrical connector -2-.

– Remove bolt -1-.

– Detach coolant temperature sender 2 for thermal manage‐
ment -G903- -3-.
Installing
Installation is carried out in reverse order; note the following:
– ⇒ Motor; Rep. gr. 19; Cooling system/coolant; Filling cooling
system

90 Rep. gr.19 - Cooling

 e-tron GT 2022 ➤
Electric drive motor 0EG - Edition 01.2023

Tightening torques
♦ ⇒ Motor; Rep. gr. 19; Coolant pump/thermostat assembly;
Exploded view - coolant temperature sender

3.17 Removing and installing coolant tem‐

perature sender 3 for thermal manage‐
ment G904
Removing
– ⇒ Motor; Rep. gr. 19; Cooling system/coolant; Draining cool‐
ing system
– Unplug electrical connector -1-.

– Remove bolt -2-.

– Detach coolant temperature sender 3 for thermal manage‐
ment -G904- -3-.
Installing
Installation is carried out in reverse order; note the following:
– ⇒ Motor; Rep. gr. 19; Cooling system/coolant; Filling cooling
system
Tightening torques
♦ ⇒ Motor; Rep. gr. 19; Coolant pump/thermostat assembly;
Exploded view - coolant temperature sender

3.18 Removing and installing coolant tem‐

perature sender 4 for thermal manage‐
ment G905
Removing
– ⇒ Motor; Rep. gr. 19; Cooling system/coolant; Draining cool‐
ing system
– Unplug electrical connector -1-.

3. Coolant pump/thermostat assembly 91

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Electric drive motor 0EG - Edition 01.2023

– Remove bolt -2-.

– Detach coolant temperature sender 4 for thermal manage‐
ment -G905- -3-.
Installing
Installation is carried out in reverse order; note the following:
– ⇒ Motor; Rep. gr. 19; Cooling system/coolant; Filling cooling
system
Tightening torques
♦ ⇒ Motor; Rep. gr. 19; Coolant pump/thermostat assembly;
Exploded view - coolant temperature sender

3.19 Removing and installing coolant tem‐

perature sender 5 for thermal manage‐
ment G906
Removing
– ⇒ Motor; Rep. gr. 19; Cooling system/coolant; Draining cool‐
ing system
– Unplug electrical connector -1-.

– Remove bolt -2-.

– Detach coolant temperature sender 5 for thermal manage‐
ment -G906- -3-.
Installing
Installation is carried out in reverse order; note the following:
– ⇒ Motor; Rep. gr. 19; Cooling system/coolant; Filling cooling
system

92 Rep. gr.19 - Cooling

 e-tron GT 2022 ➤
Electric drive motor 0EG - Edition 01.2023

Tightening torques
♦ ⇒ Motor; Rep. gr. 19; Coolant pump/thermostat assembly;
Exploded view - coolant temperature sender

3.20 Removing and installing coolant tem‐

perature sender 7 for thermal manage‐
ment G908
Removing
– ⇒ Motor; Rep. gr. 19; Cooling system/coolant; Draining cool‐
ing system
– Remove luggage compartment pan (front) ⇒ General body
repairs, interior; Rep. gr. 70; Luggage compartment trim
panels; Removing and installing luggage compartment pan
(front).
– Unplug electrical connector -1-.

– Remove bolt -2-.

– Detach coolant temperature sender 7 for thermal manage‐
ment -G908- -3-.
Installing
Installation is carried out in reverse order; note the following:
– ⇒ Motor; Rep. gr. 19; Cooling system/coolant; Filling cooling
system
Tightening torques
♦ ⇒ Motor; Rep. gr. 19; Coolant pump/thermostat assembly;
Exploded view - coolant temperature sender

3.21 Removing and installing coolant tem‐

perature sender 8 for thermal manage‐
ment G968
Removing
– ⇒ Motor; Rep. gr. 19; Cooling system/coolant; Draining cool‐
ing system
– Remove luggage compartment pan (front) ⇒ General body
repairs, interior; Rep. gr. 70; Luggage compartment trim
panels; Removing and installing luggage compartment pan
(front).
– Unplug electrical connector -1-.

3. Coolant pump/thermostat assembly 93

 e-tron GT 2022 ➤
Electric drive motor 0EG - Edition 01.2023

– Remove bolt -2-.

– Detach coolant temperature sender 8 for thermal manage‐
ment -G968- -3-.
Installing
Installation is carried out in reverse order; note the following:
– ⇒ Motor; Rep. gr. 19; Cooling system/coolant; Filling cooling
system
Tightening torques
♦ ⇒ Motor; Rep. gr. 19; Coolant pump/thermostat assembly;
Exploded view - coolant temperature sender

3.22 Removing and installing coolant tem‐

perature sender 9 for thermal manage‐
ment G1017
Removing
– ⇒ Motor; Rep. gr. 19; Cooling system/coolant; Draining cool‐
ing system
– Unplug electrical connector -1-.

– Remove bolt -2-.

– Detach coolant temperature sender 9 for thermal manage‐
ment -G1017- -3-.
Installing
Installation is carried out in reverse order; note the following:
– ⇒ Motor; Rep. gr. 19; Cooling system/coolant; Filling cooling
system

94 Rep. gr.19 - Cooling

 e-tron GT 2022 ➤
Electric drive motor 0EG - Edition 01.2023

Tightening torques
♦ ⇒ Motor; Rep. gr. 19; Coolant pump/thermostat assembly;
Exploded view - coolant temperature sender

3.23 Removing and installing coolant tem‐

perature sender 1 for high-voltage bat‐
tery G898
Removing
– ⇒ Motor; Rep. gr. 19; Cooling system/coolant; Draining cool‐
ing system
– Unplug electrical connector -1-.

– Remove bolt -2-.

– Detach coolant temperature sender 1 for high-voltage bat‐
tery -G898- -3-.
Installing
Installation is carried out in reverse order; note the following:
– ⇒ Motor; Rep. gr. 19; Cooling system/coolant; Filling cooling
system
Tightening torques
♦ ⇒ Motor; Rep. gr. 19; Coolant pump/thermostat assembly;
Exploded view - coolant temperature sender

3.24 Removing and installing coolant tem‐

perature sender 2 for high-voltage bat‐
tery G899
Removing
– ⇒ Motor; Rep. gr. 19; Cooling system/coolant; Draining cool‐
ing system
– Unfasten rear section of wheel housing liner (front right) and
press towards front ⇒ General body repairs, exterior; Rep.
gr. 66; Wheel housing liners; Exploded view - wheel housing
liner (front).
– Unplug electrical connector -1-.

3. Coolant pump/thermostat assembly 95

 e-tron GT 2022 ➤
Electric drive motor 0EG - Edition 01.2023

– Remove bolt -2-.

– Detach coolant temperature sender 2 for high-voltage bat‐
tery -G899- -3-.
Installing
Installation is carried out in reverse order; note the following:
– ⇒ Motor; Rep. gr. 19; Cooling system/coolant; Filling cooling
system
Tightening torques
♦ ⇒ Motor; Rep. gr. 19; Coolant pump/thermostat assembly;
Exploded view - coolant temperature sender

96 Rep. gr.19 - Cooling

 e-tron GT 2022 ➤
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4 Coolant pipes

4.1 Exploded view - coolant pipes

Exploded view - coolant pipes

1 - Coolant pipes
2 - Bolt
❑ 8 Nm
3 - Coolant pipes
4 - Rubber bush
5 - Spacer sleeve
6 - Bolt
❑ 8 Nm
7 - Spacer sleeve
8 - Rubber bush
9 - Grommet
10 - Coolant pipes
11 - Grommet
12 - Spacer sleeve
13 - Bolt
❑ 8 Nm
14 - Rubber bush
15 - Coolant pipe
16 - Clip
17 - Clip
18 - Coolant pipe
19 - Rubber bush
20 - Bolt
❑ 8 Nm
21 - Spacer sleeve
22 - Bolt
❑ 8 Nm
23 - Spacer sleeve
24 - Rubber bush

Exploded view - coolant distributor

4. Coolant pipes 97
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1 - Subframe
2 - Coolant hose
3 - Spacer sleeve
4 - Rubber bush
5 - Coolant distributor
❑ ⇒ Motor; Rep. gr. 19;
Coolant pump/thermo‐
stat assembly; Remov‐
ing and installing cool‐
ant distributor
6 - Bolt
❑ 2x
❑ 8 Nm
7 - Bracket
8 - Spacer sleeve
9 - Bracket
10 - Bolt
❑ 2 Nm
11 - Rubber bush
12 - Bolt
❑ 8 Nm
13 - Coolant hose
14 - Coolant hose
15 - Coolant manifold
❑ ⇒ Motor; Rep. gr. 19;
Coolant pipes; Remov‐
ing and installing cool‐
ant manifold
16 - Longitudinal member
17 - Coolant hose
❑ Coolant hose and coolant distributor are marked with letters
18 - O-ring
❑ Renew after removing
19 - Rubber bush
20 - Spacer sleeve

4.2 Removing and installing coolant distrib‐

utor
Removing
– ⇒ Motor; Rep. gr. 19; Cooling system/coolant; Draining cool‐
ing system
– Lift retaining clips -3- and disconnect coolant hoses.

98 Rep. gr.19 - Cooling

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– Unfasten hose clips -1-, -2- and detach coolant hoses.

– Unplug electrical connector -1- for changeover and mixing
valve for thermal management -V650- and move electrical
wire clear.

– Unplug electrical connector -1- for coolant temperature

sender 1 for thermal management -G902- and move electri‐
cal wire clear.

– Unplug electrical connector -1- for coolant temperature

sender 9 for thermal management -G1017- and move elec‐
trical wire clear.

4. Coolant pipes 99
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– Remove luggage compartment pan (front) ⇒ General body

repairs, interior; Rep. gr. 70; Luggage compartment trim
panels; Removing and installing luggage compartment pan
(front).
– Unplug electrical connector -1- for thermal management
coolant pump 4 -V620-.

– Unplug electrical connector -2- and move electrical wiring

clear.
– Lift retaining clips -2- and disconnect coolant hoses.

– Remove bolts -arrows- and disengage bracket at front.

– Move coolant line -3- clear and press it to side, and detach
coolant distributor.
Installing
Installation is carried out in reverse order; note the following:
– Slide coolant distributor -1- onto bracket -2- -arrow-.

100 Rep. gr.19 - Cooling

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Electric drive motor 0EG - Edition 01.2023

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

system
Tightening torques
♦ ⇒ Motor; Rep. gr. 19; Coolant pipes; Exploded view - coolant
pipes

4.3 Removing and installing coolant mani‐

fold
Removing
– Remove coolant expansion tank ⇒ Motor; Rep. gr. 19; Cool‐
ing system/coolant; Removing and installing coolant expan‐
sion tank.
– Unplug electrical connector -4- for coolant temperature
sender 8 for thermal management -G968-.

– Move electrical wiring harness clear at coolant manifold.

– Unfasten hose clips -1-, -2- and -3- and detach coolant ho‐
ses.
– Pull coolant manifold off towards right and remove.
Installing
Installation is carried out in reverse sequence.

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5 Radiator/radiator fan

5.1 Exploded view - radiator/radiator fan

1 - Air duct
2 - Fastener
3 - Radiator
❑ ⇒ Rep. gr. 19; Remov‐
ing and installing radia‐
tor
4 - Radiator fan
❑ Right-side radiator fan
-V7-, left-side radiator
fan 2 -V177-
❑ ⇒ Rep. gr. 19; Remov‐
ing and installing radia‐
tor fan V7
❑ ⇒ Rep. gr. 19; Remov‐
ing and installing radia‐
tor fan V177
5 - Radiator cowl
❑ ⇒ Rep. gr. 19; Remov‐
ing and installing radia‐
tor cowl
6 - Bolt
❑ 3x
❑ 8 Nm
7 - Spacer sleeve
8 - Rubber bush
9 - Spacer sleeve
10 - Bolt
❑ 4.5 Nm
11 - Fastener
❑ 4x
12 - Air duct
13 - Bolt
❑ 3x
❑ 5 Nm
14 - Bracket for electrical connector
15 - Retaining frame

5.2 Exploded view - radiator blind

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1 - Radiator blind (left-side)

❑ ⇒ Rep. gr. 19; Remov‐
ing and installing radia‐
tor blind
2 - Bolt
❑ 8 Nm
3 - Radiator blind control mo‐
tor 2 -V550-
❑ ⇒ Rep. gr. 19; Remov‐
ing and installing radia‐
tor blind control motor 2
V550
4 - Bolt
❑ 2.5 Nm
5 - Bumper cover
6 - Bolt
❑ 2.5 Nm
7 - Radiator blind control mo‐
tor -V544-
❑ ⇒ Rep. gr. 19; Remov‐
ing and installing radia‐
tor blind control motor
V544
8 - Bolt
❑ 8 Nm
9 - Radiator blind (right-side)
❑ ⇒ Rep. gr. 19; Remov‐
ing and installing radia‐
tor blind

5.3 Removing and installing radiator

Special tools and workshop equipment required
♦ Socket -T10405-
Removing
– ⇒ Rep. gr. 19; Drain coolant.
– Unfasten wheel housing liner (front left) and press towards
rear ⇒ General body repairs, exterior; Rep. gr. 66; Wheel
housing liners; Assembly overview - wheel housing liner
(front).
– Remove bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63; Bumper (front); Removing and installing bumper
cover.
– Unfasten hose clips -1-, -2- and detach coolant hoses.

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– Release fasteners -arrow- all around and detach air duct -2-.

– Move breather hose -2- for headlight clear.

– Remove bolt -3- on wheel housing side using socket -

T10405-.
– Detach radiator with air duct -1-.
Detaching air ducts
– Remove spreader rivet -2-.

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– Release fasteners -arrows A- and detach air duct -1-.

– Release fasteners -arrows B- and detach air duct -3-.
All vehicles (continued)
Installing
Installation is carried out in reverse order; note the following:
– ⇒ Rep. gr. 19; Fill cooling system.
Tightening torques
♦ ⇒ Rep. gr. 19; Assembly overview - radiators/radiator fans

5.4 Removing and installing radiator fan

V7
Removing
– Unclip condensers from radiator cowl and tie up with refrig‐
erant hoses connected ⇒ Heating, air conditioning; Rep.
gr. 87; Refrigerant circuit; Removing and installing condens‐
er.
– Detach electrical connector -1- from bracket and unplug.

– Unscrew bolts -arrows- and remove radiator fan.

Installing
Installation is carried out in reverse sequence.
Tightening torques
♦ ⇒ Rep. gr. 19; Exploded view - radiator/radiator fan

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5.5 Removing and installing radiator fan

V177
Removing
– Detach radiator from radiator cowl and tie it up with coolant
hoses connected ⇒ Rep. gr. 19; Removing and installing
radiator.
– Detach electrical connector -1- from bracket and unplug.

– Unscrew bolts -arrows- and remove radiator fan.

Installing
Installation is carried out in reverse sequence.
Tightening torques
♦ ⇒ Rep. gr. 19; Exploded view - radiator/radiator fan

5.6 Removing and installing radiator blind

The removal and installation procedures are described for the
left side of the vehicle as an example.
Removing
– Remove bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63; Bumper (front); Removing and installing bumper
cover.
– Carefully release fastener -arrow- and pull left cooling flap
position sender -G794- -2- off radiator blind -1-.

– Unplug electrical connector -1- and move wiring harness

clear.

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– Unscrew bolts -2-, -3- and detach radiator blind.

Installing
Installation is carried out in reverse sequence.
Tightening torques
♦ ⇒ Rep. gr. 19; Exploded view - radiator blind

5.7 Removing and installing radiator blind

control motor V544
Removing
– Remove radiator blind (right-side) ⇒ Rep. gr. 19; Removing
and installing radiator blind.
– Remove bolts -arrows-.

– Detach radiator blind control motor -V544- -1-.

Installing
Installation is carried out in reverse order; note the following:
– Perform function “Adapting end stops for radiator blind”
⇒ Rep. gr. 00; Starting diagnosis.
Tightening torques
♦ ⇒ Rep. gr. 19; Exploded view - radiator blind

5.8 Removing and installing radiator blind

control motor 2 V550
Removing
– Remove bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63; Bumper (front); Removing and installing bumper
cover.

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– Unplug electrical connector -2- (shown here as an example).

– Remove bolts -arrows-.

– Detach radiator blind control motor 2 -V550- -1-.
Installing
Installation is carried out in reverse order; note the following:
– Perform function “Adapting end stops for radiator blind”
⇒ Rep. gr. 00; Starting diagnosis.
Tightening torques
♦ ⇒ Rep. gr. 19; Exploded view - radiator blind

5.9 Removing and installing radiator cowl

Removing
Left side of vehicle:
– Detach radiator from radiator cowl and tie it up with coolant
hoses connected ⇒ Rep. gr. 19; Removing and installing
radiator.
Right side of vehicle:
– Unclip condensers from radiator cowl and tie up with refrig‐
erant hoses connected ⇒ Heating, air conditioning; Rep.
gr. 87; Refrigerant circuit; Removing and installing condens‐
er.
All vehicles (continued)
– Unplug electrical connector -2-.

– Move electrical wiring harness clear.

– Unscrew bolts -arrows- and detach radiator cowl.

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Installing
Installation is carried out in reverse order; note the following:
– Press radiator cowl -1- downwards at side -arrow- and set
distance -a-.

Important
• Distance -a- = approx. 10 mm.
Tightening torques
♦ ⇒ Rep. gr. 19; Exploded view - radiator/radiator fan

5. Radiator/radiator fan 109

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93 – Electric drive systems

1 Safety and repair instructions

1.1 Safety information

Observe safety information ⇒ Safety information and repair
notes; Rep. gr. 00; Safety information.

1.2 Repair instructions

Observe repair instructions ⇒ Safety and repair instructions;
Rep. gr. 00; Repair instructions.

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2 High-voltage components

2.1 Overview of fitting locations - high-volt‐

age components

2.1.1 Overview of fitting locations - high-voltage components (front)

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1 - Transmission unit for elec‐

tric drive motor
❑ ⇒ Front transmission
unit 0MG; Rep. gr. 34;
Removing and instal‐
ling transmission unit;
Removing transmission
unit
2 - Electrical air conditioner
compressor -V470-
❑ ⇒ Heating, air condi‐
tioning; Rep. gr. 87;
Air conditioner com‐
pressor; Exploded view
- air conditioner com‐
pressor
❑ ⇒ Heating, air condi‐
tioning; Rep. gr. 87;
Air conditioner com‐
pressor; Removing and
installing air conditioner
compressor
3 - High-voltage battery
charging socket 1 -UX4-
❑ ⇒ Rep. gr. 93; Explo‐
ded view - charging
socket
❑ ⇒ Rep. gr. 93; Remov‐
ing and installing high-
voltage battery charg‐
ing socket 1 UX4
4 - Power contactor with
boost function -J1178-
❑ ⇒ Rep. gr. 93; Explo‐
ded view - voltage con‐
verter
❑ ⇒ a15.3 nd installing
power contactor with boost function”, page 306
5 - Charging unit 1 for high-voltage battery -AX4-
❑ ⇒ Rep. gr. 93; Exploded view - charging unit 1 for high-voltage battery
❑ ⇒ Rep. gr. 93; Removing and installing charging unit 1 for high-voltage battery AX4
6 - High-voltage heater (linear) -Z189-
❑ ⇒ Heating, air conditioning; Rep. gr. 87; Coolant circuit; Exploded view - high-voltage heater (PTC)
7 - Voltage converter for 800 V, 400 V, 48 V, 12 V -A48-
❑ ⇒ Rep. gr. 93; Exploded view - voltage converter
❑ ⇒ Rep. gr. 93; Removing and installing voltage converter
8 - Switching unit for high-voltage battery -SX6-
❑ ⇒ Motor; Rep. gr. 93; High-voltage battery components; Exploded view - switching unit for high-voltage
battery
❑ ⇒ Motor; Rep. gr. 93; High-voltage battery unit; Removing and installing switching unit for high-voltage
battery SX6
9 - High-voltage battery charging socket 2 -UX5-
❑ ⇒ Rep. gr. 93; Exploded view - charging socket 2
❑ ⇒ Rep. gr. 93; Removing and installing high-voltage battery charging socket 2 UX5
10 - Electric drive control unit for front axle -J1234-

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❑ ⇒ v6.1.1 iew - electric drive control unit for front axle J1234”, page 232
❑ ⇒ a6.2.1 nd installing electric drive control unit for front axle J1234”, page 234
11 - Electric drive motor for front axle -V662-
❑ ⇒ Rep. gr. 10; Exploded view - motor
❑ ⇒ Rep. gr. 10; Removing motor

2.1.2 Overview of fitting locations - high-voltage components (rear)

1 - High-voltage battery 1 -
AX2- (level 2)
❑ ⇒ Motor; Rep. gr. 93;
High-voltage battery
components; Exploded
view - high-voltage bat‐
tery
2 - Transmission unit for elec‐
tric drive motor
3 - Electric drive motor for
rear axle -V663-
❑ ⇒ Motor; Rep. gr. 10;
Removing and instal‐
ling motor (rear); Explo‐
ded view - motor (rear)
❑ ⇒ Rep. gr. 10; Remov‐
ing motor (rear)
4 - Electric drive control unit
for rear axle -J1235-
❑ ⇒ v6.1.2 iew - electric
drive control unit for
rear axle J1235”, page
232
❑ ⇒ a6.2.2 nd instal‐
ling electric drive con‐
trol unit for rear axle
J1235”, page 238
5 - High-voltage battery 1 -
AX2- (level 1)
❑ ⇒ Motor; Rep. gr. 93;
High-voltage battery
components; Exploded
view - high-voltage bat‐
tery

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3 Warning labels

3.1 Checking warning labels

Procedure
♦ Warning labels are affixed to all high-voltage components.
♦ When performing maintenance work, it is important to en‐
sure that these warning labels do not get damaged or dirty,
and that they are present on all high-voltage components.
Important
• Renew warning label if necessary.
There are warning labels on the following components:
♦ Emergency notice on left side next to electronics box in front
of plenum chamber.

♦ Emergency notice inside vehicle behind luggage compart‐

ment side trim (right-side).

♦ Electric drive motor for front axle -V662-

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♦ Electric drive motor for rear axle -V663-

♦ Electrical air conditioner compressor -V470-

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♦ High-voltage heater (linear) -Z189-

♦ Charging unit 1 for high-voltage battery -AX4-

♦ Power contactor with boost function -J1178-

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♦ Voltage converter for 800 V, 400 V, 48 V, 12 V -A48-

3. Warning labels 117

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4 High-voltage battery unit

4.1 Assembly overview - high-voltage battery 1 AX2

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1 - High-voltage battery 1 -
AX2-
❑ ⇒ Rep. gr. 93; Remov‐
ing and installing high-
voltage battery 1 AX2
2 - Potential equalisation line
3 - High-voltage wiring har‐
ness
❑ To electric drive motor
for rear axle -V663-
4 - Retainer
❑ For high-voltage wiring
harness
❑ Renew after removing
5 - Grommet
6 - High-voltage battery, level
2
❑ ⇒ a5.9 nd installing bat‐
tery housing (level 2)”,
page 191
7 - Retainers
❑ For high-voltage wiring
harness
❑ Removing and instal‐
ling ⇒ Electric drive mo‐
tor 0EG; Rep. gr. 93;
High-voltage wiring;
Overview of fitting loca‐
tions - high-voltage wir‐
ing
8 - Nut for potential equalisa‐
tion line
❑ 8 Nm
9 - Bracket for assembly mountings
❑ Removing and installing ⇒ Electric drive motor 0EG; Rep. gr. 10; Assembly mountings (rear); Assem‐
bly overview - assembly mountings
10 - Bolts
❑ M8x60
❑ 4x
❑ 20 Nm
11 - Retainer
❑ 2x
12 - Bolts
❑ 8x
❑ 20 Nm
13 - Bolts
❑ 4x
❑ 20 Nm
14 - Grommet
15 - Bolt
❑ M10x50

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❑ 2x
❑ Tightening sequence ⇒ page 120
❑ 55 Nm
16 - Bolt
❑ M10x65
❑ 18x
❑ Tightening sequence ⇒ page 120
❑ 55 Nm
17 - Bolt
❑ M10x155
❑ 10x
❑ Tightening sequence ⇒ page 120
❑ 55 Nm

Bolts securing high-voltage battery to body - tightening se‐

quence

120 Rep. gr.93 - Electric drive systems

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4.2 Determining mean cell voltage

Special tools and workshop equipment required
♦ Adapter cable -VAS 5581/1A-2-
♦ Diagnosis lead -VAS 5581A/12-
♦ High-voltage diagnostics box -VAS 5581-
♦ vehicle diagnostic tester
The mean cell voltage must be determined before a battery
module is renewed.

Preparatory work with high-voltage battery removed:

– Connect high-voltage diagnostics box -VAS 5581- to vehicle
diagnostic tester with diagnostic cable -VAS 5581A/12- and
adapter cable -VAS 5581/1A-2-.
Important
• CAN bus terminal resistor of high-voltage diagnostics box
-VAS 5581- is pre-set to 120 Ω and must not be changed.
– Connect diagnostic cable -VAS 5581A/12- to 12V connec‐
tion on switching unit with adapter cable -VAS 5581/1A-2-.
– Connect black earth clamps of diagnostic cable -VAS
5581A/12- and adapter cable -VAS 5581/1A-2- to earth on
battery housing.
Determining mean cell voltage:
– Select and start Diagnosis mode on vehicle diagnostic test‐
er.
– Select Test plan tab.
– Choose Select own test and select following options one
after the other:
♦ Diagnostic capable system
♦ 008C - Hybrid Battery Energy Management -J840
♦ 008C - Hybrid Battery Energy Management - functions
♦ 008C - Determine mean cell voltage
– Start selected program and follow instructions on display of
vehicle diagnostic tester.

4.3 Charging and discharging battery mod‐

ules
Special tools and workshop equipment required
♦ Connection line -VAS 6910/12B-1-
♦ Connection line -VAS 6910/12B-2-
♦ Connection line -VAS 6910/19-
♦ Shock-proof protection -T40421-
♦ Vehicle diagnostic tester
♦ Voltage balancing device for high-voltage battery module
(module balancer) -VAS 6910-
A new battery module must be charged or discharged prior
to installation according to the result of the mean cell voltage
calculation ⇒ m4.2 ean cell voltage”, page 121 .

4. High-voltage battery unit 121

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Important
• Battery module removed ⇒ Rep. gr. 93; Removing battery
module.

– Connect module balancing device -VAS 6910- ⇒ manual for

module balancing device -VAS 6910- .
– Start program and follow instructions given by module bal‐
ancing device -VAS 6910-.
– After charging or discharging new battery module, fit contact
protection -T40421-.
– When new battery module has been charged or discharged
to the calculated voltage, install new battery module ⇒ Rep.
gr. 93; Installing battery module.

4.4 Leak test for high-voltage battery 1

AX2

4.4.1 Test equipment layout - leak test for high-voltage battery

1 - Junction
❑ Junction -VAS 691
005/1-
❑ ⇒ a4.4.2 nd checking
test tools”, page 124
2 - Pressure sensor
❑ Pressure sensor -VAS
611 013-
❑ ⇒ a4.4.2 nd checking
test tools”, page 124
3 - Connection cable
❑ Connection cable -VAS
5051/66-
4 - Test instrument box
❑ Individual test instru‐
ment box -VAS 6356/1-
5 - Switching unit for high-
voltage battery -SX6-
6 - Test connector set
❑ Test connector set -
VAS 6911/3A-
7 - Cooling system tester
❑ Cooling system tester -
V.A.G 1274B-

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1 - Adapter cable
- Adapter cable -VAS 5581/6-
- For sealing off 12V electrical connection on switching unit
2 - Test connector
- From test connector set -VAS 6911/3-
- For sealing off high-voltage connection and test pressure con‐
nection

1 - Leak-tight connector
- Leak-tight connector -T40349-
- 2 bolts M6 x 20
- 8 Nm

1 - Cover
- Cover -T90012-
- For leak test for levels 1 and 2 together

4. High-voltage battery unit 123

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- Fit on housing (level 2) -2-

- 4 Nm

2 - Seal
- Seal -T40449-
- For leak test for level 1
- Fit in cover for battery housing (level 1) -1-
- Tighten in diagonal sequence to 3 Nm

4.4.2 Cleaning and checking test tools

Special tools and workshop equipment required
♦ Cooling system tester -V.A.G 1274B-
♦ Cooling system tester for high voltage batteries -VAS 691
005-
♦ Directional valve -VAS 691 005/1-
♦ Pressure sensor -V.A.G 1397B-
♦ Test adapter -VAS 691 005/4-
♦ Test plug set -VAS 6911/3-
♦ Turbocharger tester -V.A.G 1397A-
Proceed as follows to ensure that no coolant residue remains in
cooling system testing set for high-voltage batteries -VAS 691
005-:

– Fit test adapter -VAS 691 005/4- on outlet -B-.

– Fit cleaning nozzle -D- from testing set on outlet -A-.

– Close open outlet -C- with lever.

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– Hold outlet -B- upwards and blow through with compressed

air; any coolant present will come out of cleaning nozzle -D-
when you do this.
Self-test for junction -VAS 691 005/1- with turbocharger tester
-V.A.G 1397A-:
– Assemble the following parts:

♦ Junction -VAS 691 005/1-

♦ Test connector set -VAS 6911/3- assembled -2-
♦ Turbocharger tester -V.A.G 1397A- -1-
♦ Cooling system tester -V.A.G 1274B- -3-
– Open cut-off valves “A” and “C” on junction -VAS 691 005/1-.

– Switch on turbocharger tester -V.A.G 1397A- and select set‐

ting “II”.
– Generate pressure using cooling system tester -V.A.G
1274B- until turbocharger tester -V.A.G 1397A- shows a val‐
ue of 300 … 350 mbar.
– Close cut-off valve “C” on junction -VAS 691 005/1-.

4. High-voltage battery unit 125

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– Wait approx. one minute (settling time), then check drop in

pressure on turbocharger tester -V.A.G 1397A-.
Important
• Maximum pressure loss after 30 seconds: less than 5 mbar
Self-test for junction -VAS 691 005/1- with pressure sensor
-V.A.G 1397B-:
– Assemble the following parts:

♦ Junction -VAS 691 005/1-

♦ Test connector set -VAS 6911/3- assembled -1-
♦ Pressure sensor -V.A.G 1397B- -2-
♦ Cooling system tester -V.A.G 1274B- -3-
– Open cut-off valve “C” on junction -VAS 691 005/1-.

– Switch on pressure sensor -V.A.G 1397B- and press menu

button until “P relative” appears.
– Press “OK” and then press reset button. The display should
show 0 mbar.
– Generate pressure using cooling system tester -V.A.G
1274B- until pressure sensor -V.A.G 1397B- shows a value
of 300 … 350 mbar.
– Close cut-off valve “C” on junction -VAS 691 005/1-.

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– Wait approx. one minute (settling time), then check drop in

pressure on pressure sensor -V.A.G 1397B-.
Important
• Maximum pressure loss after 30 seconds: less than 5 mbar

4.4.3 Leak test for battery housing

Special tools and workshop equipment required
♦ Adapter cable -VAS 5581/1A-2-
♦ Diagnosis lead -VAS 5581A/12-
♦ High-voltage diagnostics box -VAS 5581-
♦ Test instrument box, single -VAS 6356/1-
♦ vehicle diagnostic tester

Setting up test equipment

– ⇒ a4.4.2 nd checking test tools”, page 124
– ⇒ e4.4.1 quipment layout - leak test for high-voltage battery”,
page 122
– Connect test equipment box -VAS 6356/1- to vehicle diag‐
nostic tester.
– Connect high-voltage diagnostics box -VAS 5581- to vehicle
diagnostic tester with diagnostic cable -VAS 5581A/12- and
adapter cable -VAS 5581/1A-2-.
Important
• CAN bus terminal resistor of high-voltage diagnostics box
-VAS 5581- is pre-set to 120 Ω and must not be changed.
– Connect black earth clamps of diagnostic cable -VAS
5581A/12- and adapter cable -VAS 5581/1A-2- to earth on
battery housing.
– Select and start Diagnosis mode on vehicle diagnostic test‐
er.
– Select Test plan tab.
– Choose Select own test and select following options one
after the other:
♦ Diagnostic capable system
♦ 008C - Hybrid Battery Energy Management -J840
♦ 008C - Hybrid Battery Energy Management - functions
♦ 008C - start up operations

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– Start selected program and follow instructions on display of

vehicle diagnostic tester.
Note
While performing test, VAS 5581A/12 at switching unit must be
exchanged for VAS 5581/6 directly before building up pressure.
VAS 5581A/12 is not sealed.
If leak has been identified:
– Check for leaks ⇒ Rep. gr. 93; Checking high-voltage battery
1 AX2 for leaks.
Important
• Before performing another leak test on the housing, release
all pressure from the system. Open all valves, disconnect
adapter from high-voltage connection on electronics box
(front) and wait 15 minutes.

4.4.4 Leak test for coolant circuit

Special tools and workshop equipment required
♦ Adapter cable -VAS 5581/1A-2-
♦ Connection lead -VAS 5051/66-
♦ Cooling system tester -V.A.G 1274B-
♦ Cooling system tester for high voltage batteries -VAS 691
005-
♦ Diagnosis lead -VAS 5581A/12-
♦ Directional valve -VAS 691 005/1-
♦ High-voltage diagnostics box -VAS 5581-
♦ Pressure sensor -V.A.G 1397B-
♦ Test instrument box, single -VAS 6356/1-
♦ vehicle diagnostic tester

– Connect leak-tight connector and adapter connector from

cooling system testing set for high-voltage batteries -VAS
691 005- to coolant connections on high-voltage battery.

– Connect pressure sensor -V.A.G 1397B- to individual test

instrument box -VAS 6356/1- using connection cable -VAS
5051/66-.
– Connect pressure sensor -V.A.G 1397B-, cooling system
tester -V.A.G 1274B- and high-voltage battery to junction
-VAS 691 005/1-.
– Connect test equipment box -VAS 6356/1- to vehicle diag‐
nostic tester.

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– Connect high-voltage diagnostics box -VAS 5581- to vehicle

diagnostic tester with diagnostic cable -VAS 5581A/12- and
adapter cable -VAS 5581/1A-2-.
Important
• CAN bus terminal resistor of high-voltage diagnostics box
-VAS 5581- is pre-set to 120 Ω and must not be changed.
– Connect black earth clamps of diagnostic cable -VAS
5581A/12- and adapter cable -VAS 5581/1A-2- to earth on
battery housing.
– Select and start Diagnosis mode on vehicle diagnostic test‐
er.
– Select Test plan tab.
– Choose Select own test and select following options one
after the other:
♦ Diagnostic capable system
♦ 008C - Hybrid Battery Energy Management -J840
♦ 008C - Hybrid Battery Energy Management - functions
♦ 008C - start up operations
– Start selected program and follow instructions on display of
vehicle diagnostic tester.
– If a drop in pressure is identified, localise and repair leak.

4.5 Checking high-voltage battery 1 AX2

for leaks
Note
Only carry out the procedure for localising leaks on high-voltage
battery 1 -AX2- if the leak test was failed.

– Generate pressure ⇒ Rep. gr. 93; Leak test for high-voltage

battery 1 AX2.
– Use leak detection spray to localise leak. Leaks create bub‐
bles.
– Repair leak.

4.6 Removing and installing high-voltage

battery 1 AX2
Special tools and workshop equipment required
♦ Cap -VAS 691 005/3-
♦ Cooling system tester for high voltage batteries -VAS 691
005-
♦ Pllug -VAS 691 005/2-
♦ Scissor-type assembly platform VAS 6131B 208 - 230V -
VAS 6131B-
♦ mountings -VAS 6131/19-
♦ vehicle diagnostic tester
Removing
For information on use of impact wrenches, refer to ⇒ ; Rep.
gr. ; Repair instructions.

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Lifting the removed battery ⇒ Rep. gr. 93; Lifting high-voltage

battery 1 AX2
Important
• If the high-voltage battery is opened after removal, a leak
test must be performed after assembly ⇒ t4.4.3 est for bat‐
tery housing”, page 127 .
• The mean cell voltage of the high-voltage battery must be
determined if one or several battery modules need to be
renewed after removing the high-voltage battery ⇒ m4.2 ean
cell voltage”, page 121 .
• New battery modules must be charged or discharged prior to
installation according to the result of the mean cell voltage
calculation ⇒ Rep. gr. 93; Charging and discharging battery
modules.
• The arms of the lifting platform must not hinder the lowering
of the high-voltage battery later.
– Drain coolant ⇒ Motor; Rep. gr. 19; Cooling system/coolant;
Draining cooling system.
– Disconnect coolant circuit connections from high-voltage
battery and seal off using cap -VAS 691 005/3- and plug
-VAS 691 005/2- from cooling system testing set for high-
voltage batteries -VAS 691 005-.

DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have an Audi high-voltage technician (HVT) or an Audi
high-voltage expert (HVE) de-energise the high-voltage
system.

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

energising high-voltage system.
– Perform classification of high-voltage battery 1 -AX2- ⇒ Rep.
gr. 93; Inspecting and classifying high-voltage battery 1 AX2.
– Remove luggage compartment floor ⇒ General body repairs,
interior; Rep. gr. 70; Luggage compartment trim panels; As‐
sembly overview - luggage compartment floor.
– Open door window (driver side). Open bonnet and rear lid
and secure to prevent them from closing unintentionally.
– Lift cover -1- for access to high-voltage wire for electric drive
motor for rear axle -V663- using a plastic wedge -2- and
detach.

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– Remove bolts -1-.

– Disconnect high-voltage connector for electric drive motor

for rear axle -V663- ⇒ Motor; Rep. gr. 93; High-voltage wir‐
ing; Unplugging high-voltage connectors.
– Unfasten rear section of wheel housing liners (front left and
right) ⇒ General body repairs, exterior; Rep. gr. 66; Wheel
housing liners; Assembly overview - front wheel housing lin‐
er.
– Remove reinforcement (rear) ⇒ Running gear, axles, steer‐
ing; Rep. gr. 40; Subframe; Assembly overview - subframe.
– Remove remaining underbody cladding ⇒ General body re‐
pairs, exterior; Rep. gr. 66; Underbody cladding; Assembly
overview - underbody cladding.
– Remove wheel spoiler (rear) ⇒ General body repairs, exteri‐
or; Rep. gr. 66; Wheel housing liners; Assembly overview -
rear wheel housing liner.
– Remove cross pieces ⇒ General body repairs, exterior; Rep.
gr. 66; Underbody cladding; Assembly overview - underbody
struts.
– Unscrew nut -1- at potential equalisation line (rear right) be‐
tween body and high-voltage battery, and remove line.

– Disconnect high-voltage wire -1- at switching unit for high-

voltage battery (front) ⇒ Motor; Rep. gr. 93; High-voltage
wiring; Unplugging high-voltage connectors.

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– Unplug 12V connector -2-.

– Unscrew bolts -2- on brackets -1- (rear left and right) for
high-voltage battery.

– Unclip electrical wiring harness from bracket on high-voltage

battery and move it clear.
– Press plugs -1, 2- out of foot garages.

– Unscrew bolts -1, 2, 13, 14, 23, 24, 25, 26, 27, 28, 29, 30-
on body for mounting high-voltage battery.
– Fit supports -VAS 6131/19- -2- on fully extended scissor-
type assembly platform -1-. Do not tighten bolts yet.

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– Set supports -2- to dimensions -x1, x2 and y-.

Important
• Dimension -x1- = 1430 mm, high-voltage battery (rear)
• Dimension -x2- = 1525 mm, high-voltage battery (front)
• Dimension -y- = 1735 mm
– Position scissor-type assembly platform -VAS 6131B- -1-
with supports -VAS 6131/19- -2- under vehicle. (Shown with‐
out lifting platform for illustration purposes)

Important
• Drawbar of scissor-type assembly platform points to rear of
vehicle.
– Carefully position scissor-type assembly platform -VAS
6131B- with four supports -VAS 6131/19- against high-volt‐
age battery from underneath.
– Carefully guide supports into openings on battery housing.
– Tighten bolts of supports on scissor-type assembly platform
to 25 Nm.
– Position mountings at locations where bolts -13-, -14-, -25-,
-26- were removed.

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– Screw knurled screws -2- of supports -1- in until they make

contact.

– Unscrew four bolts securing high-voltage battery to rear

axle.
– Unscrew remaining bolts securing high-voltage battery to
body.

NOTICE
Danger of damage to wires and hoses if the high-voltage
battery is lowered.
– Check that all connections between high-voltage battery
and body have been detached.
– Carefully guide high-voltage battery out of body when low‐
ering.

– Carefully lower high-voltage battery, initially by only approx.

50 mm.

– Guide disconnected high-voltage wire -2- for electric drive

motor for rear axle -V663- out when lowering battery -1-
further.

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– Lower scissor-type assembly platform -VAS 6131B- com‐

pletely.
Installing
Installation is carried out in reverse order; note the following:
– Position high-voltage battery on scissor-type assembly plat‐
form -VAS 6131B- with four mountings -VAS 6131/19- un‐
derneath vehicle.
– Raise high-voltage battery and scissor-type assembly plat‐
form with supports until high-voltage wire for electric drive
motor for rear axle -V663- can be guided in at subframe
(rear).
– Fit bolts securing high-voltage battery to body.
– Tighten bolts as far as stop.
– Lower scissor-type assembly platform. Fit remaining bolts.
– Tighten all bolts for high-voltage battery according to speci‐
fied sequence.
– Tighten nut -1- for potential equalisation line at body.

A potential equalisation measurement must be performed on

the high-voltage components affected after installation of high-
voltage components or potential equalisation lines.
– Connect vehicle diagnostic tester.
– Select and start ODIS-Service mode.
– Select Special functions tab.
– Select the following:
♦ High Voltage
♦ Potential equalization measurement on high-voltage compo‐
nents

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♦ 008C - Potential equalization measurement - AX2 - high-

voltage battery 1
– Start selected program and follow instructions on display of
vehicle diagnostic tester.
– Plug in high-voltage connector -1- and 12V connector -2-.

– Plug in high-voltage connector in luggage compartment floor

and tighten bolts -1-.

– Fit other attachments.

WARNING
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have an Audi high-voltage technician (HVT) or an Audi
high-voltage expert (HVE) re-energise the high-voltage
system.

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

energising high-voltage system.
– Fill up cooling system ⇒ Electric drive motor 0EG; Rep.
gr. 19; Cooling system/coolant; Filling cooling system.
– Bleed cooling system ⇒ Electric drive motor 0EG; Rep.
gr. 19; Cooling system/coolant; Bleeding cooling system.
– Lifting the removed battery ⇒ Rep. gr. 93; Lifting high-volt‐
age battery 1 AX2
Tightening torques
♦ ⇒ Rep. gr. 93; Assembly overview - high-voltage battery 1
AX2

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♦ ⇒ Running gear, axles, steering; Rep. gr. 42; Subframe; As‐

sembly overview - subframe
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Underbody
cladding; Assembly overview - underbody cladding
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Underbody
cladding; Assembly overview - underbody struts
♦ ⇒ Running gear, axles, steering; Rep. gr. 40; Subframe; As‐
sembly overview - subframe
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Wheel housing
liners; Assembly overview - rear wheel housing liner

4.7 Lifting high-voltage battery 1 AX2

Special tools and workshop equipment required
♦ Adapter -T40416/4-
♦ Forklift cross beam -VAS 501 009-
♦ Sling chain, separate -VAS 501 011-
♦ Tow hitch -T40416-

Note
Proceed in the same manner to lift high-voltage battery out of its
packaging; to do so, remove side panels of packaging.
– Position a support tool -T40416- and an adapter -T40416/4-
at each of the locations on battery frame -1- marked by
-arrows- in illustration. The fasteners for the side under‐
body cladding must be removed in these areas marked by
-arrows-.

– Tighten bolts -arrows- to 40 Nm.

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– Slide forklift crossbeam -VAS 501 009- onto fork arms of

forklift.

– Attach four sling chains, single -VAS 501 011- to forklift

crossbeam -VAS 501 009-.

– Position forklift crossbeam -VAS 501 009- on fork arms of

forklift.

Important
• Dimension -a- = 1000 mm
– Fix crossbeam to fork arms to prevent slipping; to do so,
tighten retaining bolts to 10 Nm and also secure with nut.

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– Shorten the two chains that are to be attached to high-volt‐

age battery at rear (as seen in direction of travel) with
mounting -arrow-.

Important
• Eight free chain links must be visible.
– Attach sling chain, single -VAS 501 011- to support tool
-T40416- with adapter -T40416/4-.
Important
• The open sides of the hooks must face outwards.

WARNING
Risk of injury if unsuitable forklift is used
Danger of trapping or crushing parts of the body
– Observe operating instructions for forklift crossbeam -VAS
501 009-.
– Observe permissible load centre distance of forklift.

– Raise high-voltage battery with forklift.

4.8 Removing and installing skid plate for

high-voltage battery
Special tools and workshop equipment required
♦ Blade set -V.A.G 1561A/31-
♦ Double cartridge gun -VAS 5237-
♦ Electric cutter V.A.G 1561B -V.A.G 1561B-
♦ Scraper set -VAS 861 005-
♦ U-shaped blade, 32 mm -V.A.G 1561/5-
♦ Wire for removal tool -VAS 6452/2-
♦ guide bolt -T40199-
Removing
– De-energise high-voltage system ⇒ Rep. gr. 93; De-energis‐
ing high-voltage system.
– Check high-voltage battery 1 -AX2- and skid plate for high-
voltage battery for damage.
– Unfasten rear section of wheel housing liners (front) ⇒ Gen‐
eral body repairs, exterior; Rep. gr. 66; Wheel housing lin‐
ers; Assembly overview - front wheel housing liner.

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– Remove reinforcement (rear) from front axle subframe

⇒ Running gear, axles, steering; Rep. gr. 40; Subframe; As‐
sembly overview - subframe.
– Remove underbody cladding (side) ⇒ General body repairs,
exterior; Rep. gr. 66; Underbody cladding; Assembly over‐
view - underbody cladding.
– Remove wheel spoiler (rear) ⇒ General body repairs, exteri‐
or; Rep. gr. 66; Wheel housing liners; Assembly overview -
rear wheel housing liner.
– Remove cross pieces ⇒ General body repairs, exterior; Rep.
gr. 66; Underbody cladding; Assembly overview - underbody
struts.
– Remove outer bolts -1- on skid plate.

– Remove plugs -2- from skid plate.

– Remove remaining bolts on skid plate.
Important
• Support skid plate in centre with gearbox jack.
• Second mechanic required
– Cut through adhesive bead -1- on skid plate with electric
cutter -V.A.G 1561B- and a 12 mm blade from blade set
-V.A.G 1561A/31-.

– Move sharp blade along evenly to avoid smoke being gener‐

ated. Ensure good ventilation.
– If smoke is generated, interrupt work briefly, make sure not
to breathe in any smoke, and use an extraction system.
– Lift side -item 2- slightly using a wedge and use a long wire
to guide wire for separator -VAS 6452/2- from left to right
between high-voltage battery and skid plate.

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– Cut through adhesive bead -1- at lugs of skid plate using

wire for separator -VAS 6452/2- -5-, lifting skid plate slightly
with a wedge -4- when doing so.
– Press skid plate down slightly and check that wire for sepa‐
rator -VAS 6452/2- is not touching coolant lines, connections
etc. and will not damage them when cutting through adhe‐
sive bead.
– Carefully cut through adhesive bead through openings -3-
using electric cutter -V.A.G 1561B- and blade (U-shaped,
32mm) -V.A.G 1561/5-.
– Take care not to damage coolant lines -1- on inside.

– Detach skid plate.

– Inspect and classify high-voltage battery ⇒ Rep. gr. 93; In‐
specting and classifying high-voltage battery 1 AX2.
Important
• The remaining adhesive is required all around as a base
for better adhesion of the new adhesive. Keep cut surfaces
clean and free of grease but do not clean them with cleaning
solution.
– Cut back adhesive bead on frame of high-voltage battery
and on skid plate using scraper from scraper set -VAS 861
005-. Some adhesive must remain all around.

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– Remove remnants of adhesive bead and other dirt in area of

skid plate using a vacuum cleaner.
Installing
– Insert four guide pins -T40199- at corners -1- of frame for
high-voltage battery.

– Apply a thin layer of activator to adhesive beads on frame of

high-voltage battery and skid plate. Observe flash-off time.
– Observe information on using 2-component adhesive ⇒
o5.8.4 n using 2-component adhesive for high-voltage bat‐
teries”, page 189 .
– Apply adhesive to new skid plate using double cartridge gun
-VAS 5237-.

– Fit skid plate quickly via guide pins and fit new bolts.
– Remove guide pins and insert new bolts in their place.
– Tighten all bolts -1- in diagonal sequence.

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– Renew plugs -2-.

– The remaining installation steps are carried out in the re‐
verse sequence.
Tightening torques
♦ ⇒ Rep. gr. 93; Assembly overview - high-voltage battery 1
AX2
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Wheel housing
liners; Assembly overview - front wheel housing liner
♦ ⇒ Running gear, axles, steering; Rep. gr. 40; Subframe; As‐
sembly overview - subframe
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Underbody
cladding; Assembly overview - underbody cladding
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Wheel housing
liners; Assembly overview - rear wheel housing liner
♦ ⇒ General body repairs, exterior; Rep. gr. 66; Underbody
cladding; Assembly overview - underbody struts
♦ ⇒ Running gear, axles, steering; Rep. gr. 42; Subframe; As‐
sembly overview - subframe

4.9 Removing and installing battery regula‐

tion control unit J840
Special tools and workshop equipment required
♦ Cover -T90014-
Removing
If control unit is renewed, test plan for renewal of control unit
must be performed:
– Perform “Replace control module” function with ⇒ Vehicle
diagnostic tester ⇒ Rep. gr. 00; Starting diagnosis.
Continued
– Remove switching unit for high-voltage battery -SX6- ⇒ Rep.
gr. 93; Removing and installing switching unit for high-volt‐
age battery SX6.
– Unscrew bolts -1 ... 12- and detach cover.

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– Unplug electrical connectors -2- from battery regulation con‐

trol unit -J840-.

– Fit cover -T90014- at all leadthroughs.

– Remove bolts -1, 3, 4, 5, 6- from battery regulation control
unit -J840- and lift control unit out.
Installing
– Insert control unit in its position.
– Screw in new bolts (pay attention to tightening sequence).
– Remove covers at electrical connectors.
– Plug in electrical connectors.
– Fit cover and screw in bolts. Observe correct tightening se‐
quence.
– Install switching unit for high-voltage battery -SX6- ⇒ Rep.
gr. 93; Removing and installing switching unit for high-volt‐
age battery SX6.
– Remaining installation steps are performed in reverse order
of removal.

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Tightening torques
♦ ⇒ Rep. gr. 93; Assembly overview - switching unit for high-
voltage battery SX6
♦ ⇒ Rep. gr. 93; Overview of fitting locations - battery connec‐
tors

4.10 Removing and installing switching unit

for high-voltage battery SX6
Special tools and workshop equipment required
♦ -T90024B/1-
♦ -T90024B/2-
♦ -T90024B/3-
♦ -T90024B/5-
♦ Assembly tool -T90024B-
♦ Depth gauge -VAS 6082-
♦ Leak-tight connector -T40349-
♦ guide bolt -T40199-

DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injury from electric shock or electric
arcs.
– The following work must only be performed by a qualified
high-voltage technician (HVT).

Important
• Required qualification for the following work: HVT, second
mechanic EIP
Removing
Removing switching unit for high-voltage battery SX6:
– Remove high-voltage battery 1 -AX2- ⇒ Rep. gr. 93; Remov‐
ing and installing high-voltage battery 1 AX2.
– Put on protective equipment: fabric gloves, safety goggles,
safety shoes with ESD protection.
– Carefully clean area around switching unit for high-voltage
battery -SX6-.
Important
• It is important that no dirt gets into opening of switching unit
for high-voltage battery -SX6-.
– Remove bolts -1-, unplug high-voltage wiring harness -2-
and place to side.

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– Fit leak-tight connector -T40349- -1- at high-voltage connec‐

tion on switching unit -2- and secure with two M6x20 bolts
tightened to 8 Nm.

– Cover 12V electrical connection -1- and high-voltage con‐

nection -3- to protect against dirt.

– Remove bolts -arrows- and screw guide pins -T40199- into

the four threaded holes.

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– Unscrew remaining bolts for switching unit for high-voltage

battery -SX6-.
– Remove swarf from threaded holes using vacuum cleaner
-1-.

Second mechanic required

NOTICE
Risk of damage to electronic components due to improper
handling
– Only place switching unit for high-voltage battery down
with open side facing up.

– With the help of a second mechanic, lift switching unit for

high-voltage battery -SX6- off high-voltage battery 1 -AX2-
-arrow-.

– Do not turn switching unit for high-voltage battery -SX6- over

above high-voltage battery to prevent short circuits if unit
falls.
– Open side -arrow- of switching unit faces upwards when it is
set down.

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– Without setting it down, turn switching unit for high-voltage

battery -SX6- over, and then set it down.
Continued

DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– When renewing, install the new switching unit immediately
after removing the old one.
– Never leave the high-voltage battery unattended when the
switching unit is removed.
– Never insert tools into the openings in the high-voltage
battery when the switching unit is removed.

– Cover connections on high-voltage battery immediately with

a lint-free cloth.
Removing seal:
– Screw sections of assembly tool -T90024B/1- -4- together
completely at adjustment thread -3-.

– Insert tool in opening on switching unit so that lugs on tool

are positioned underneath seal -1-.
– Using an open-end spanner (10 mm), move sections of tool
apart at spindle -3- -arrows- until tool is touching seal -1-.
– Prepare assembly tool -T90024B/5- -2- by cleaning spindle
-4- with a brass brush, wiping with a lint-free cloth and oiling.

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– Check whether spindle can be turned very easily.

– Fit -T90024B/5- -2- on -T90024B/1- -1- and screw in at pins
-5- -arrows-.
– Screw cross-shaped piece -3- onto upper third of spindle -4-
by hand.
– Secure support -T90024B/2- -1- in pins -5- so that it lies
flush.

– Adjust cross-shaped piece -3- and screw it on with spindle

so that it engages in pins -2- of support -1-.
– Turn spindle -4- evenly using wrench (13 mm). Pull out seal.
Installing new seal:
– Clean contact surfaces of seal using isopropanol and a lint-
free cloth.

– Cover inside of switching unit with an absorbent, lint-free

cloth. Position cloth so that it cannot be pressed in with seal.

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– Press new seal -1- onto underside of pressing-in tool -

T90024B/3- -2- and lay them flat onto switching unit open‐
ing.

Important
• Note installation position of seal: markings on seal must face
pressing-in tool and must not be visible.
Note
Lubricant must not be used on the outer seal.
– Position -T90024B/3- -1- so that cut-outs are aligned central‐
ly with high-voltage contacts -2-.

– Insert tension rods -3- in cut-outs.

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– Position -T90024B/3- -2- so that lower hooks of tension rods

-3- face outwards and engage flush in housing of switching
unit underneath seat for new seal -1-.
– Fit -T90024B/5- -1- and secure with pins.

– Align assembly tool -T90024B- and seal with switching unit

and set spindle so that an even gap remains between
switching unit and seal.

Important
• Dimension -a- = 2 mm
• The seal must not make contact with the switching unit yet.
– Wet seal with distilled water.

Note
Use a large amount of distilled water. Small puddles of water
may form on the outside of the switching unit. No water must be
allowed to enter the inside of the switching unit.
– Immediately position torque wrench with socket (13 mm) -2-
on spindle drive and press seal in evenly with 10 Nm.

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– Press seal in three times with a 30-second wait between

each time.
– Remove distilled water using an absorbent, lint-free cloth.
– Remove assembly tool -T90024B- and clean with a lint-free
cloth.
– Check seal is seated correctly and dry it using an absorbent,
lint-free cloth.
Important
• Writing on seal must be legible in this position.
Installation depth of seal must be the same all around.
– Use depth gauge -VAS 6082- to perform measurement at
four locations at 90° intervals without indentations or writing.

Important
• Seal must lie at least 0.4 mm lower than metal collar of
switching unit.
• Difference between measured values must be a maximum of
0.2 mm.
– Remove lint-free cloth from connections.
Renewing seals on contact surfaces of switching unit:
– Remove seals from switching unit.

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– Clean and degrease contact surfaces for seals.

– Fit new self-adhesive seals.
Installing
Installation is carried out in reverse order; note the following:
– Re-tighten spacer sleeves -arrows- at attachment points for
switching unit ⇒ o5.1.2 verview - high-voltage battery 1 AX2
(level 2)”, page 159 .

– Coat flanges of attachment points -arrows- with special lubri‐

cant ⇒ Electronic parts catalogue.

– Use brush -1- to coat flanges -2- of attachment points for

studs with special lubricant ⇒ Electronic parts catalogue.

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Important
• Keep contact surfaces of switching unit free of grease.
– Screw guide pins -T40199- into corner threads for switching
unit.
– Apply a thin layer of P80 special lubricant (⇒ Electronic parts
catalogue) outside coloured area -arrow- only.

– Coat sealing lip of seal -2- with a thin layer of P80 special
lubricant ⇒ Electronic parts catalogue.

– Check that rectangular connector -1- on switching unit is

positioned centrally so that it will make contact with opposite
part on battery.
– Flat seal -1- must be free of grease.

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– Perform voltage measurement between switching unit and

battery housing using a commercially available hand-held
multimeter until no voltage is measured.
Note
The components may become charged with a low capacity
during removal and installation (similar to a capacitor). Briefly
measuring the voltage with the voltage tester before removal
and installation will dissipate the capacity.
– Fit switching unit in exact position via guide pins -T40199-.
– Fit bolts and also remove guide pins and fit bolts in their
place.
– Tighten all bolts and coat them with special lubricant ⇒ Elec‐
tronic parts catalogue.

– Select Diagnosis mode and start this mode.

– Select Test plan tab.
– Choose Select own test and select following options one
after the other:
♦ 0001 - Diagnostic capable system
♦ 008C - Hybrid Battery Energy Management -J840
♦ 008C - Hybrid Battery Energy Management - functions
♦ 008C - start up operations
– Start selected program and follow instructions on display of
vehicle diagnostic tester.
– Perform potential equalisation measurement on switching
unit for high-voltage battery -SX6-.
– Depending on work already done, perform leak test for bat‐
tery housing (level 1) or for battery housing (levels 1 and 2
together) ⇒ t4.4.3 est for battery housing”, page 127 .

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– Coat heads of securing bolts for electronics box and tran‐

sition between electronics box and cover for high-voltage
battery with special lubricant ⇒ Electronic parts catalogue.
– Install high-voltage battery 1 -AX2- ⇒ Rep. gr. 93; Removing
and installing high-voltage battery 1 AX2.
Tightening torques
♦ ⇒ Rep. gr. 93; Assembly overview - switching unit for high-
voltage battery SX6

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5 High-voltage battery components

5.1 Assembly overview - high-voltage bat‐

tery 1 AX2

5.1.1 Assembly overview - high-voltage battery 1 AX2 (level 1)

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1 - Skid plate
❑ For high-voltage battery
❑ ⇒ a4.8 nd installing skid
plate for high-voltage
battery”, page 139
2 - O-ring
3 - Coolant connection
4 - Bolt
❑ 16x
❑ 8 Nm
5 - Battery housing
6 - Cover
❑ For battery housing
❑ Renew after removing
❑ ⇒ a5.8.2 nd installing
cover for battery hous‐
ing (level 1)”, page 179
7 - Bolt
❑ For cover (outer)
❑ Tightening torques ⇒
page 159
8 - Bolt
❑ For cover (inner)
❑ Tightening torques ⇒
page 159
9 - Bracket
❑ Seal between battery
housing (levels 1 and
2)
❑ Renew after removing
10 - Bolt
❑ 10x
❑ Renew after removing
❑ 8 Nm
11 - Spacer sleeve
❑ 10x
❑ 8 Nm
12 - Connection
❑ For switching unit for high-voltage battery -SX6-
13 - Bolt
❑ For outer skid plate
❑ 22x
❑ Renew after removing
❑ 8 Nm
14 - Bolt
❑ For inner skid plate
❑ 68x
❑ Renew after removing

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❑ 8 Nm

Cover for battery housing (level 1) - tightening torques

1 - Bolts (outer)
❑ 165x
❑ Renew after removing
❑ ⇒ r5.7 eplacement bolts
for cover for battery
housing”, page 172
❑ Torque for new bolt: 2
Nm, torque for replace‐
ment bolt: 4 Nm
2 - High-voltage battery hous‐
ing (level 1)
3 - Cover for high-voltage bat‐
tery (level 1)
❑ Renew after removing
❑ ⇒ a5.8 nd installing
cover for battery hous‐
ing”, page 172
4 - Bolt
❑ 2x
❑ Renew after removing
❑ 8 Nm
5 - Bolts (inner)
❑ 6x or 8x (depending on
version)
❑ Renew after removing
❑ 8 Nm

5.1.2 Assembly overview - high-voltage battery 1 AX2 (level 2)

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1 - O-ring
2 - Coolant adapter
❑ 2x
3 - Bolt
❑ 8x
❑ 8 Nm
4 - Bracket
❑ Seal between battery
housing (levels 1 and
2) must be renewed
after removing battery
housing (level 2)
❑ Renew after removing
5 - Pressure equalisation
membrane
❑ Tighten
❑ Renew after removing
❑ Installing pressure
equalisation membrane
⇒ page 161
6 - Bolt
❑ M4x20
❑ 10x
❑ Renew after removing
❑ 8 Nm
7 - Coolant hose
8 - Bracket
9 - Clip
10 - Battery housing
❑ Level 2
❑ ⇒ a5.9 nd installing battery housing (level 2)”, page 191
11 - Bolt
❑ Pay attention to any replacement bolts
❑ 54x
❑ Renew after removing
❑ ⇒ r5.7 eplacement bolts for cover for battery housing”, page 172
❑ Torque for new bolt: 2 Nm
❑ Torque for replacement bolt: 4 Nm
12 - Cover
❑ For battery housing (level 2)
❑ Renew after removing
❑ ⇒ a5.8.1 nd installing cover for battery housing (level 2)”, page 172
13 - Nut
❑ 10x
❑ Renew after removing
❑ Tightening torque and sequence ⇒ page 161
14 - Stud
❑ 10x

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❑ Renew after removing

❑ 20 Nm

Installing pressure equalisation membrane

Pfeil - Tighten bolts in diago‐

nal sequence
❑ 8 Nm

Securing nuts for battery housing (level 2) - tightening torque

and sequence

1 bis 10 - Nut
❑ Tighten to 9 Nm in se‐
quence shown

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5.2 Assembly overview - switching unit for high-voltage battery SX6

1 - High-voltage battery 1 -
AX2-
❑ ⇒ High-voltage battery;
Rep. gr. 93; High-
voltage battery compo‐
nents; Assembly over‐
view - high-voltage bat‐
tery 1 AX2
2 - Seal
❑ Renew after removing
3 - Switching unit for high-
voltage battery -SX6-
❑ ⇒ High-voltage battery;
Rep. gr. 93; High-volt‐
age battery unit; Re‐
moving and installing
switching unit for high-
voltage battery SX6
4 - Bolt
❑ Tightening torque and
sequence
❑ 9x
❑ Renew after removing
❑ ⇒ page 162
5 - High-voltage battery con‐
trol unit
6 - Gasket
❑ Renew after removing
7 - Bolt
❑ Tightening torque and
sequence
❑ 12x
❑ Renew after removing
❑ ⇒ page 163
8 - Cover
9 - Bolt
❑ Tightening torque and sequence
❑ ⇒ page 163
10 - Oil seal
❑ 9x
❑ Renew after removing

Switching unit for high-voltage battery -SX6- - tightening torque

and sequence

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Stage Tightening se‐ Tightening torque

quence
1. -1 … 9- 8 Nm
2. After 30 minutes -1 … 9- 8 Nm
Cover to switching unit for high-voltage battery - tightening tor‐
que and sequence

Stage Tightening se‐ Tightening torque

quence
1. -1 … 12- 2 Nm
2. -1 … 12- 5 Nm
3. -1 … 12- 16 Nm
High-voltage battery control unit - tightening torque and se‐
quence

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Item Tightening torque

-1, 3, 4, 6- 10 Nm
-5- 5.5 Nm

5.3 Assembly overview - battery modules

Battery module (level 1)

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1-17 und 21-27 - Battery mod‐

ules
❑ The battery modules
must be re-installed in
the same locations.
❑ Mark battery modules
for re-installation with
number and arrow indi‐
cating direction of trav‐
el, as shown. Use a
waterproof felt-tip pen
for marking.
❑ Some battery modules
are fitted with standard
layout of battery ter‐
minals, some with mir‐
rored layout ⇒ b5.6 at‐
tery modules and bat‐
tery connectors”, page
172
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-
13 - Battery module 13 -J1045-
14 - Battery module 14 -J1046-
15 - Battery module 15 -J1047-
16 - Battery module 16 -J1048-
17 - Battery module 17 -J1049-
21 - Battery module 21 -J1080-
22 - Battery module 22 -J1081-
23 - Battery module 23 -J1082-
24 - Battery module 24 -J1083-
25 - Battery module 25 -J1084-
26 - Battery module 26 -J1085-
27 - Battery module 27 -J1130-
28 - Battery module 28 -J1199-
29 - Battery module 29 -J1200-

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30 - Battery module 30 -J1201-

31 - Battery module 31 -J1202-
32 - Battery module 32 -J1203-
33 - Battery module 33 -J1204-

Battery module (level 2)

18 - Battery module 18 -
J1077-
19 - Battery module 19 -
J1078-
20 - Battery module 20 -
J1079-

Battery modules - tightening torque

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Pfeile - Bolts
❑ Tighten in two stages
(5 Nm and then 8 Nm)
in diagonal sequence.

5.4 Overview of fitting locations - battery connectors

Battery connectors (level 1)

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1-2 bis 32-33 - Battery con‐

nector
❑ Battery connectors
must be renewed after
removal ⇒ b5.6 attery
modules and battery
connectors”, page 172
❑ The designation of
the battery connector
stems from the num‐
bering of the battery
modules connected at
this point.
❑ Before installing battery
connector, press bolts
back until they engage.
❑ Do not touch bolts or
contact surfaces with
your bare hands.
❑ Use isopropanol to
clean battery connec‐
tors.
A - Connection for switching
unit for high-voltage battery -
SX6-
❑ Securing bolts
❑ 6x
❑ 8 Nm

Battery connectors (level 2)

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17-18 bis 20-21 - Battery con‐

nector
❑ Battery connectors
must be renewed after
removal ⇒ b5.6 attery
modules and battery
connectors”, page 172 .
❑ The designation of
the battery connector
stems from the num‐
bering of the battery
modules connected at
this point.
❑ Before installing battery
connector, press bolts
back until they engage.
❑ Do not touch bolts or
contact surfaces with
your bare hands.
❑ Use isopropanol to
clean battery connec‐
tors.

Battery connectors - tightening torque

Pfeile - Bolts for battery con‐

nectors
❑ 4x
❑ 6 Nm

Battery connector bracket - tightening torques

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4 - Bolts securing battery con‐

nector bracket to high-voltage
battery
❑ 4x
❑ 8 Nm
6 - Nuts securing battery con‐
nector to battery connector
bracket
❑ 4
❑ 4.5 Nm

Wiring harness cover - tightening torque

2 - Bolts securing wiring har‐

ness cover to high-voltage
battery
❑ 6x
❑ 8 Nm

5.5 Inspecting and classifying high-voltage

battery 1 AX2
Special tools and workshop equipment required
♦ Adapter cable -VAS 5581/1A-2-

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♦ Diagnosis lead -VAS 5581A/12-

♦ High-voltage diagnostics box -VAS 5581-
♦ vehicle diagnostic tester

CAUTION
Risk to health due to toxic vapours, dust and liquids.
– Never perform work on high-voltage batteries in which a
short circuit has occurred.

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 a high-voltage expert if problems were reported or if
there are entries in the event memory.

Visual inspection of high-voltage battery 1 AX2

Check for the following on high-voltage battery 1 -AX2-.
– Cracks in top or bottom section of battery housing
– Deformations in top or bottom section of battery housing
– Temperature-induced discolourations and heat tinting on
battery housing
– Escaping electrolyte
– Damage to high-voltage contacts
– Presence and legibility of information and warning labels
– Correct fitting of potential equalisation line
– Corrosion damage
– After performing visual inspection, perform a classification of
high-voltage battery 1 -AX2-.
Preparatory work with high-voltage battery removed:
– Connect high-voltage diagnostics box -VAS 5581- to vehicle
diagnostic tester with diagnostic cable -VAS 5581A/12- and
adapter cable -VAS 5581/1A-2-.
Important
• CAN bus terminal resistor of high-voltage diagnostics box
-VAS 5581- is pre-set to 120 Ω and must not be changed.
– Connect black earth clamps of diagnostic cable -VAS
5581A/12- and adapter cable -VAS 5581/1A-2- to earth on
battery housing.
Classification of high-voltage battery:
– Select and start ODIS-Service mode on vehicle diagnostic
tester.
– Select Special functions tab.
– Select the following:
♦ High Voltage

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♦ 008C - Classification of high-voltage battery

– Start selected program and follow instructions on display of
vehicle diagnostic tester.

5.6 Marking battery modules and battery

connectors
Important
• Mark battery modules and battery connectors before remov‐
ing. Use a waterproof felt-tip pen for marking.
Identification
Various battery modules are fitted in level 1 of battery housing:
♦ Battery modules with standard layout of battery terminals
♦ Battery modules with mirrored layout of battery terminals
♦ Allocation of battery modules ⇒ Electronic parts catalogue
Battery connectors must be renewed after removal. Marking the
battery connectors that are removed makes assembly easier if
several or all battery modules are removed. Use a waterproof
felt-tip pen for marking.
♦ ⇒ Rep. gr. 93; Overview of fitting locations - battery modules
♦ ⇒ Rep. gr. 93; Overview of fitting locations - battery connec‐
tors

5.7 Handling replacement bolts for cover

for battery housing
Renew all bolts using repair bolt 1. If a thread in the battery
housing is damaged, a replacement bolt (= repair bolt 2) can be
used; distinguishing features:
♦ Repair bolt 1 - T20 Torx head or 7 mm, 4x18 ⇒ Electronic
parts catalogue
♦ Repair bolt 2 - T20 Torx head or 7 mm, 4.3x18 ⇒ Electronic
parts catalogue
If a replacement bolt is identified when removing the cover for
battery housing, this bolt and its installation position must be
marked for re-installation.
Important
• During installation, screw in marked replacement bolt in
marked threaded hole.

5.8 Removing and installing cover for bat‐

tery housing

5.8.1 Removing and installing cover for bat‐

tery housing (level 2)
Special tools and workshop equipment required
♦ Blade set -V.A.G 1561A/31-
♦ Double cartridge gun -VAS 5237-
♦ Electric cutter V.A.G 1561B -V.A.G 1561B-
♦ Guide pin -T40448-
♦ Plastic wedge set -VAS 852 015-

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♦ Pneumatic gun, 18 bar -VAS 6648-

♦ Scraper set -VAS 861 005-
♦ Suction cup -VAS 6788-
Important
• Required qualification for the following work: HVE, second
mechanic EIP
Removing
– Remove high-voltage battery 1 AX2 ⇒ High-voltage battery;
Rep. gr. 93; High-voltage battery unit; Removing and instal‐
ling high-voltage battery 1 AX2.
– Perform leak test ⇒ High-voltage battery; Rep. gr. 93; High-
voltage battery unit; Leak test for high-voltage battery 1 AX2.

DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injury from electric shock or electric
arcs.
– The following work must only be performed by a qualified
high-voltage expert (HVE).

– Clean area around battery housing carefully.

Put on the necessary protective equipment before performing
the following work steps:
♦ Fabric gloves
♦ Safety goggles
♦ Safety shoes with ESD protection
♦ The second mechanic required to assist with installation
must put on the same protective equipment.

– Bend open tabs -2- on cover.

– Apply a commercially available socket (7 mm) firmly to sepa‐

rate adhesive from bolt head. Remove all outer cover bolts
-arrow-.
– If performing a repeat repair, remove any excessive adhe‐
sive mechanically beforehand. Take care not to damage bat‐
tery housing.
– Pay attention to any replacement bolts ⇒ r5.7 eplacement
bolts for cover for battery housing”, page 172 .
– Clean thread using a vacuum cleaner.

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Note
The remaining material from the old bonded seam serves as a
bonding surface for the new adhesive. There must not be any
blank areas.
Important
• Clean blade with isopropanol before using.
• Clean blade again after passing it through an area with anti-
corrosion material.
• Hold blade at right angle to bonded seam.
• Cut close to cover.
• Protect battery housing from damage.
– Separate cover for high-voltage battery (level 2) using elec‐
tric cutter -V.A.G 1561B- and short 9 mm blade from blade
set -V.A.G 1561A/31-.
– Move sharp blade along evenly to avoid smoke being gener‐
ated. Ensure good ventilation.
– If smoke is generated, interrupt work briefly, make sure not
to breathe in any smoke, and use an extraction system.
– Lift blade slightly towards cover.
– Remove remnants of adhesive bead and other dirt in area of
thread using a vacuum cleaner.

NOTICE
The plastic wedge can be driven too far into the battery hous‐
ing. Risk of damage to components in high-voltage battery.
– Pay attention to maximum penetration depth of plastic
wedge.

– Pay attention to penetration depth of plastic wedge ⇒

w5.8.3 edge from plastic wedge set VAS 852 015 with limi‐
ted penetration depth”, page 188 .
– Mask off battery housing with adhesive tape and place
soft material under plastic wedge to protect battery housing
against damage or scratches.
– First lift cover for battery housing at corners; to do so, apply
wedge from plastic wedge set -VAS 852 015- between cover

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and housing wall, keeping wedge close to battery cover at all

times.
Note
The cover cannot be removed without damaging it irreparably.
Renew cover after removing.
– Detach cover for high-voltage battery (top level).
– Clean scraper with isopropanol before using.
– Cut back remaining adhesive on battery housing to a thick‐
ness of approx. 1 mm using scraper set -VAS 861 005-.
Important
• The remaining adhesive is required all around as a base
for better adhesion of the new adhesive. Keep cut surfaces
clean and free of grease.
– Remove remnants of adhesive bead and other dirt in area
of high-voltage battery and threaded holes using a vacuum
cleaner.

– Check width of remaining adhesive bead.

Note
If the width of the remaining adhesive bead is < 6 mm, addition‐
al sealant must be applied from the outside.
Note
If the width of the remaining adhesive bead is < 4 mm, a repair
is no longer permitted.
Installing
Important
• Provisional energisation of the high-voltage battery should
be performed before finally bonding on the battery cover in
order to check the electrical function of control units and
battery modules. The cover for battery housing remains re‐
moved during this procedure ⇒ e5.13 nergisation of high-
voltage battery 1 AX2”, page 217 High-voltage battery 1
-AX2-.
– Check all threads on high-voltage battery housing to ensure
bolts can be inserted without difficulty. To do so, fit each bolt
and screw in and out by 5 turns.

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– If necessary, widen beginning of thread with a suitable tool.

Do not remove ridge.
– Mark sections where remaining adhesive bead is narrow
(width < 6 mm) on outside of battery housing with adhesive
tape. Extend marked area where adhesive bead is narrow
by 30 mm on left and right.

– Cut back adhesive bead on high-voltage battery cover (top

level) to a thickness of approx. 1 mm using scraper set -VAS
861 005-.
Important
• Clean scraper with isopropanol before using.
• The remaining adhesive is required all around as a base
for better adhesion of the new adhesive. Keep cut surfaces
clean and free of grease.
– Screw four guide pins -T40448- into threads for bolts
-arrows- for cover for battery housing.

– Apply a thin layer of activator to cut-back adhesive beads

on cover for high-voltage battery and high-voltage battery
housing (top level) in one continuous motion and leave to
flash off.
– Prepare adhesive for application and ensure tools and bolts
are to hand.
– Observe information on using 2-component adhesive for
high-voltage batteries ⇒ o5.8.4 n using 2-component adhe‐
sive for high-voltage batteries”, page 189 .
– Apply adhesive bead evenly on cover for battery using dou‐
ble cartridge gun -VAS 5237-. Width of adhesive bead: ap‐
prox. 6 mm

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Important
• The point on the adhesive bead where a new cartridge is
started must be at least 50 mm away from any corner.
• The assistance of a second mechanic is required to fit the
cover.
– Fit cover for battery housing onto high-voltage battery (level
2) via guide pins -T40448- using suction cup -VAS 6788-
Remaining installation steps are carried out in reverse se‐
quence; note the following:
– First fit new bolts -arrow-.

– Remove guide pins and insert new bolts in their place.

– Screw in bolts until they make contact with cover using pow‐
er screwdriver.
– Tighten bolts for cover for battery housing ⇒ o5.1.2 verview -
high-voltage battery 1 AX2 (level 2)”, page 159 .
– If necessary, use and tighten replacement bolt.
– Apply joint sealant to bolts and edges using compressed air
gun, 18 bar -VAS 6648- in order to seal them.

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– Spread joint sealant using a plastic scraper. The bolt heads

and the areas around them must be completely covered by
joint sealant so that the seal is air tight. The bolt heads
must no longer stand out. Time for skin to form: approx. 10
minutes
– Clean any damage to electrophoretic coating with isopropa‐
nol and, after a flash-off time of 15 minutes, cover with joint
sealant.
– Seal cover for high-voltage battery with joint sealant in areas
marked previously with adhesive tape (areas where width of
adhesive bead is < 6 mm). Joint sealant must be extended
30 mm to the left and right of the area with the narrow
adhesive bead. Observe drying time for adhesive bead on
cover for high-voltage battery (2 hours).
– Spread joint sealant and press into bonded joint using a
plastic scraper.

Important
• Joint sealant must have a width of 20 mm on cover and on
housing.
• Ensure that sufficient joint sealant is applied at corners and
seal carefully.
– After waiting for drying time for joint sealant, perform leak
test for battery housing (levels 1 and 2) ⇒ High-voltage
battery; Rep. gr. 93; High-voltage battery; Leak test for high-
voltage battery 1 AX2.
– Check stickers containing warnings and information on haz‐
ardous substances and renew if necessary. Observe coun‐
try-specific legal requirements.
Tightening torques
♦ ⇒ o5.1.2 verview - high-voltage battery 1 AX2 (level 2)”,
page 159

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♦ ⇒ o5.1.1 verview - high-voltage battery 1 AX2 (level 1)”,

page 157

5.8.2 Removing and installing cover for bat‐

tery housing (level 1)
Special tools and workshop equipment required
♦ Blade set -V.A.G 1561A/31-
♦ Cover -T90028-
♦ Double cartridge gun -VAS 5237-
♦ Electric cutter V.A.G 1561B -V.A.G 1561B-
♦ Frame -T40447-
♦ Guide pin -T40448-
♦ Plastic wedge set -VAS 852 015-
♦ Pneumatic gun, 18 bar -VAS 6648-
♦ Scraper set -VAS 861 005-
Important
• Required qualification for the following work: HVE, second
mechanic EIP
Removing
– Remove switching unit for high-voltage battery -SX6-
⇒ High-voltage battery; Rep. gr. 93; High-voltage battery
unit; Removing and installing switching unit for high-voltage
battery SX6.
– Cover electrical connections with lint-free cloth.
– Remove battery housing (level 2) ⇒ a5.9 nd installing battery
housing (level 2)”, page 191 .

DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injury from electric shock or electric
arcs.
– The following work must only be performed by a qualified
high-voltage expert (HVE).

– Clean area around battery housing carefully.

– Put on protective equipment before performing the following
work steps:
♦ Fabric gloves
♦ Safety goggles
♦ Safety shoes with ESD protection
Important
• Mechanics required to assist with installation must put on the
same protective equipment.
– Remove studs -1- for high-voltage battery housing (level 2).

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– Remove anti-corrosion material from attachment points of

studs using isopropanol.
– Remove high-voltage wiring harness for rear drive motor
⇒ a9.2.2 nd installing high-voltage wiring harness for drive
motor (rear)”, page 248 .
– Remove bolts -4, 5- on cover for high-voltage battery.

– Remove outer bolts on cover -1- for high-voltage battery.

– Apply a commercially available socket (7 mm) firmly to sepa‐
rate adhesive from bolt head. Remove all outer cover bolts
-1-.
– If performing a repeat repair, remove any excessive adhe‐
sive mechanically beforehand. Take care not to damage bat‐
tery housing.
– Pay attention to any replacement bolts ⇒ r5.7 eplacement
bolts for cover for battery housing”, page 172 .
– Remove swarf from threaded holes using a vacuum cleaner
-1-.

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Note
The remaining material from the old bonded seam serves as a
bonding surface for the new adhesive. There must not be any
blank areas.
Important
• Clean blade with isopropanol before using.
• Clean blade again after passing it through an area with anti-
corrosion material.
• Hold blade at right angle to bonded seam.
• Cut close to cover.
• Protect battery housing from damage.
– Carefully cut through adhesive bead on cover for high-volt‐
age battery along edge of cover using electric cutter -V.A.G
1561B- and longer 12 mm blade from blade set -V.A.G
1561A/31-.
– Move sharp blade along evenly to avoid smoke being gener‐
ated. Ensure good ventilation.
– If smoke is generated, interrupt work briefly, make sure not
to breathe in any smoke, and use an extraction system.

NOTICE
The plastic wedge can be driven too far into the battery hous‐
ing. Risk of damage to components in high-voltage battery.
– Pay attention to maximum penetration depth of plastic
wedge.

– Pay attention to penetration depth of plastic wedge ⇒

w5.8.3 edge from plastic wedge set VAS 852 015 with limi‐
ted penetration depth”, page 188 .
– First lift cover for battery housing -1- at an easily accessi‐
ble point; to do so, apply wedge from plastic wedge set
-VAS 852 015- between cover and housing wall -2-, keeping
wedge close to battery cover at all times.

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Note
The cover cannot be removed without damaging it irreparably.
Renew cover after removing.
– Lift cover for battery housing further (if necessary, use two
wedges from plastic wedge set -VAS 852 015- to do so).
– Detach cover for battery housing (level 1). Second mechanic
required
– Clean scraper with isopropanol before using.
– Cut back remaining adhesive on battery housing to a thick‐
ness of approx. 1 mm using scraper set -VAS 861 005-.
Important
• The remaining adhesive is required all around as a base
for better adhesion of the new adhesive. Keep cut surfaces
clean and free of grease.
– Remove remnants of adhesive bead and other dirt in area
of high-voltage battery and threaded holes using a vacuum
cleaner.

– Check width of remaining adhesive bead.

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Note
If the width of the remaining adhesive bead is < 6 mm, addition‐
al sealant must be applied from the outside.
Note
If the width of the remaining adhesive bead is < 4 mm, a repair
is no longer permitted.
Installing
Important
• Provisional energisation of the high-voltage battery should
be performed before finally bonding on the battery covers
in order to check the electrical function of control units and
battery modules. The covers for battery housing remain re‐
moved during this procedure ⇒ e5.13 nergisation of high-
voltage battery 1 AX2”, page 217 .
– Check that all spacer sleeves for inner bolts are seated se‐
curely and tighten ⇒ o5.1.1 verview - high-voltage battery 1
AX2 (level 1)”, page 157 .

– Check all threads on high-voltage battery housing to ensure

bolts can be inserted without difficulty. To do so, fit each bolt
and screw in and out by 5 turns.
– If necessary, widen beginning of thread with a suitable tool.
Do not remove ridge. While widening, clean area using a
vacuum cleaner.
– Mark sections where remaining adhesive bead is narrow
(width < 6 mm) -arrow- on outside of battery housing with
adhesive tape -1-. Extend marked area by 30 mm on left and
right.

– Cut back adhesive bead on high-voltage battery cover (bot‐

tom level) to a thickness of approx. 1 mm using scraper set
-VAS 861 005-.
Important

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• Clean scraper with isopropanol before using.

• The remaining adhesive is required all around as a base
for better adhesion of the new adhesive. Keep cut surfaces
clean and free of grease.
– Position frame -T40447- -1- on outside of new cover -2- and
connect to suction cups -3-.

– Turn over new cover for battery housing with frame -T40447-
and set it down.
– Secure new bracket on cover for battery housing.
Note
Seal between battery housing (levels 1 and 2).
– Screw four guide pins -T40448- into battery housing at loca‐
tions shown -arrows-.

– Apply a thin layer of activator to cut-back adhesive beads

on cover for battery housing and on high-voltage battery
housing in one continuous motion and leave to flash off.
– Prepare adhesive for application and ensure tools and bolts
are to hand.

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– Fit studs securing high-voltage battery (level 2) with caps -1-

supplied with cover -T90028- so they are hand-tight.

– Fit contact points for switching unit for high-voltage battery

-SX6- (front) with cover -T90028- -2- so it is hand-tight.
Important
• Cover -T90028- must only be removed again after the 2-
component adhesive has hardened fully.
– Observe information on using 2-component adhesive for
high-voltage batteries ⇒ o5.8.4 n using 2-component adhe‐
sive for high-voltage batteries”, page 189 .
Important
• Due to pot life of 2-component adhesive, apply adhesive and
fit bolts on cover for high-voltage battery in a team of four
people.
– Apply adhesive bead evenly on cover for battery using dou‐
ble cartridge gun -VAS 5237-. Width of adhesive bead: ap‐
prox. 6 mm
Note
Due to pot life of 2-component adhesive, it is recommended that
two mechanics (each using a double cartridge gun) apply the
adhesive bead.
– The point on the adhesive bead where a new cartridge is
started must be at least 50 mm away from any corner.

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– Mark position of adhesive around inner openings according

to impressions on used cover.
– Fit cover for battery housing onto battery housing via guide
pins using frame -T40447-.
Remaining installation steps are carried out in reverse se‐
quence; note the following:
♦ Fit new bolts on cover for high-voltage battery.
♦ If necessary, use replacement bolts.
♦ Remove guide pins -T40448- and insert new bolts in their
place.
♦ Screw in all bolts until they make contact with cover using
power screwdriver.
– Tighten inner bolts -4-.

– Tighten bolts for cover -5- for battery housing.

– Coat bolts -5- with anti-corrosion material ⇒ Electronic parts
catalogue.
– Tighten outer bolts for cover -1- for battery housing.
♦ Tightening torques ⇒ o5.1.1 verview - high-voltage battery 1
AX2 (level 1)”, page 157
– Apply joint sealant to outer bolts using compressed air gun,
18 bar -VAS 6648- in order to seal them.

– Spread joint sealant using a plastic scraper.

Important

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• The bolt heads and the areas around them must be com‐
pletely covered by joint sealant so that the seal is air tight.
• The bolt heads must no longer stand out.
• Time for skin to form: approx. 10 minutes
– Clean any damage to electrophoretic coating with isopropa‐
nol and, after a flash-off time of 15 minutes, cover with joint
sealant.
– Seal cover for high-voltage battery with joint sealant in areas
marked previously with adhesive tape (areas where width of
adhesive bead is < 6 mm).
Important
• Joint sealant must be extended 30 mm to the left and right of
the area with the narrow adhesive bead.
• Observe drying time for adhesive bead on cover for high-
voltage battery (2 hours).
– Spread joint sealant and press into bonded joint using a
plastic scraper.

Important
• Joint sealant must have a width of 20 mm on cover and on
housing.
• Ensure that sufficient joint sealant is applied at corners and
seal carefully.
– Bond damping elements -2- to new cover.

– Install switching unit for high-voltage battery -SX6- ⇒ High-

voltage battery; Rep. gr. 93; High-voltage battery unit; Re‐
moving and installing switching unit for high-voltage battery
SX6.
– After waiting for drying time for joint sealant, perform leak
test for battery housing (level 1) ⇒ High-voltage battery; Rep.

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gr. 93; High-voltage battery unit; Leak test for high-voltage

battery 1 AX2.
– Install high-voltage wiring harness for rear drive motor ⇒
a9.2.2 nd installing high-voltage wiring harness for drive mo‐
tor (rear)”, page 248 .
– Install battery housing (level 2) ⇒ a5.9 nd installing battery
housing (level 2)”, page 191 .
– Check stickers containing warnings and information on haz‐
ardous substances and renew if necessary. Observe coun‐
try-specific legal requirements.
Tightening torques
♦ ⇒ o5.1.1 verview - high-voltage battery 1 AX2 (level 1)”,
page 157
♦ ⇒ Electric drive motor 0EG; Rep. gr. 93; High-voltage wiring;
Overview of fitting locations - high-voltage wiring

5.8.3 Using wedge from plastic wedge set VAS 852 015 with limited penetration
depth

Pfeil - Make marking for

limited penetration depth on
wedge from plastic wedge set
VAS 852 015.
❑ The permitted penetra‐
tion depth -a- of the
wedge is the same on
both sides of the bat‐
tery housing.

Cover for battery housing (level 1)

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Maximum penetration depth of Dimension in mm

wedge in area
-a- 20 mm
-b- 35 mm
-c- 25 mm
-d- 15 mm
-e- 30 mm
Cover for battery housing (level 2)

Maximum penetration depth of Dimension in mm

wedge in area
-c- 25 mm
-e- 30 mm

5.8.4 Information on using 2-component ad‐

hesive for high-voltage batteries
Note
Observe safety data sheets for 2-component adhesive.

Preparing bonding surfaces

Important
• Throughout the processing and drying time, the temperature
must not drop below 10 °C or exceed 35 °C.

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• The vehicle, components and adhesive sealants must be

brought to the correct processing temperature (acclimatised)
before processing. They must be left at the processing tem‐
perature for 30 minutes before processing the bonding surfa‐
ces.
• After cleaning surfaces, make sure not to touch them again
so as to avoid any sweat and dirt being transferred to the
bonding surface.
• The remaining adhesive is required as a base for better
adhesion of the new adhesive. Keep cut surfaces clean and
free of grease but do not clean them with cleaning solution.
• Activate cut surface on battery cover once with activator.
• Apply a thin layer of activator in one continuous motion using
an applicator brush. Avoid applying to the same area twice.
• Leave activated cut surface to flash off for 10 minutes.
• Battery cover must be bonded on with battery frame within 2
hours.
Handling adhesive
Important
• The adhesive sealant must not be used after the expiry date
printed on it has passed. Observe the permitted processing
time for opened cartridges of adhesive sealant.
• The vehicle, components and adhesive sealants must be
brought to the correct processing temperature (acclimatised)
before processing. They must be left at the processing tem‐
perature for 30 minutes before processing the bonding surfa‐
ces.
• Process adhesive sealant within processing time. Within this
time, the adhesive sealant must be applied and the compo‐
nents must be joined. Observe the instructions for the com‐
ponents in the Workshop Manual with regard to the joining
process that must be carried out in the area of the bonded
joint.
• Do not put any strain on bonded parts until they have hard‐
ened.
• During the winter, at night and in cold countries, suitable
measures must be taken to ensure that the minimum hard‐
ening temperature is reached.
• Optimise the heating system, e.g. by deactivating the night-
time reduction function.
• Keep doors and windows closed and avoid draughts.
• Install additional heaters in the area where battery repairs
are being performed.
• The processing time of the adhesive is 20 minutes at room
temperature (23 °C). Within this time, the adhesive must be
applied and the component must be joined.
• Press out an adhesive bead (10 to 20 cm long) from the
fresh adhesive sealant onto a piece of cardboard before
starting work to confirm it is completely mixed
• Throughout the processing and drying time, the temperature
must not drop below 10 °C or exceed 35 °C.
• Once the assembly strength has been reached (after 1 hour
at 23 °C), assembly work can be carried out on the vehicle
and the vehicle can be moved in the workshop.

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• The minimum required waiting time after joining the compo‐

nents before the vehicle can be used is 8 hours at 23 °C.
• To ensure that the adhesive bond has been applied correctly
and for purposes of documentation, a work sample must
be made and tested. The procedure for making the work
sample is described in the processing instructions of the
adhesive.
Making a work sample
– Also apply an adhesive bead (approx. 10 cm long) for the
work sample onto a solid material.

– After assembly strength has been reached, cut open work

sample -2- at several locations with blade -1- and check
hardening on basis of cut surface -3-.
Important
• The adhesive must have hardened fully; there must be no
areas where it is liquid.
Note
If the work sample produces a negative result (hardening not
correct), a correct adhesive bond cannot be ensured. The adhe‐
sive bond must be checked and remade.

5.9 Removing and installing battery hous‐

ing (level 2)
Special tools and workshop equipment required
♦ Holding strap -T40155A-
♦ Shackle -VAS 691 009A-
♦ Shock-proof protection -T40421-
♦ Voltage tester -VAS 6762/45-
♦ Workshop hoist -VAS 6100-
♦ sealing piece -T40449-
Removing
– Remove high-voltage battery ⇒ Rep. gr. 93; Removing and
installing high-voltage battery 1 AX2.

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– Remove cover for battery housing (level 2) ⇒ a5.8.1 nd in‐

stalling cover for battery housing (level 2)”, page 172 .

DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injury from electric shock or electric
arcs.
– The following work must only be performed by a qualified
high-voltage expert (HVE).

DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Suitable personal protective equipment (PPE) must be
worn for the following work.
– The following steps require a second suitably qualified per‐
son 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.

– Clean area around battery housing carefully.

– Before continuing with work, the voltage must be measured
between the battery (+) and the battery housing using volt‐
age tester -VAS 6762/45-.
Note
The battery housing may become charged with a low capacity
during removal and installation (similar to a capacitor). Briefly
measuring the voltage with the voltage tester before removal
and installation will dissipate the capacity.
– Put on the following protective equipment:
♦ Clothing approved for working with electric arcs (jacket and
trousers or overalls), min. protection class 2 up to 318 kJ
♦ Coat approved for working with electric arcs, min. protective
effect of 630 kJ (in combination with aforementioned cloth‐
ing)
♦ Helmet with visor and protective hood approved for working
with electric arcs, combined min. protective effect of 630 kJ
♦ Gloves approved for working with electric arcs with nitrile
glove liners, min. protective effect of 630 kJ, min. insulating
effect up to 500 V
♦ Safety shoes with ESD protection
⇒ Electronic parts catalogue

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NOTICE
Grease or dirt on the contact surfaces increase contact resist‐
ance.
The battery may overheat when activated – risk of fire!
– Only touch contact surfaces of battery connectors or bat‐
tery terminals of battery modules if wearing gloves.
– Clean contaminated contact surfaces immediately with iso‐
propanol.

– Remove bolts -1- and take out battery connector -2-.

– Remove swarf from threaded holes on battery connectors

using vacuum cleaner -1-.

– Immediately after removing battery connectors, fit contact

protection -T40421- at free contact surfaces of battery mod‐
ules.

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– Remove bolts -4- and take out battery connector -3-.

– Remove swarf from threaded holes on battery connectors

using vacuum cleaner -1-.

– Immediately after removing battery connectors, fit contact

protection -T40421- at free contact surfaces of battery mod‐
ules.

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– Press back bolts for battery connectors.

– Unscrew bolts for battery connector -5- and remove battery
connector.

– Remove swarf from threaded holes on battery connectors

using vacuum cleaner -1-.

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– Immediately after removing battery connectors, fit contact

protection -T40421- at free contact surfaces of battery mod‐
ules.

– Unscrew bolts for battery connector -6- and remove battery

connector.

– Remove swarf from threaded holes on battery connectors

using vacuum cleaner -1-.

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– Immediately after removing battery connectors, fit contact

protection -T40421- at free contact surfaces of battery mod‐
ules.

– Press back bolts for battery connector.

Note
Battery connector -6- must be removed so that voltage falls
below the current level of 60 Volts.
– Put on the following protective equipment:
♦ Fabric gloves
♦ Safety goggles
♦ Safety shoes with ESD protection
⇒ Electronic parts catalogue
– Unplug electrical connector -3- of communication wiring har‐
ness.

– Unclip and lift fastener cover -2-.

– Unclip connector -3- of communication wiring harness from
retainer of fastener cover from below.
– Clip fastener cover back in.
– Remove bolt -1- on housing (level 2).
– Remove bolts -1- and lift coolant adapters -2- slightly.

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– Lift fastener between coolant hose and coolant adapter

-arrow- and place coolant adapter to side.

Important
• Leave coolant hose connected.
– Cover opening on coolant adapter where it connects to high-
voltage battery (level 1) with adhesive tape or a lint-free
cloth.
– Remove nuts -1- on housing (level 2) -2-.

Second mechanic required

– Put retaining straps -T40155A- under housing -5- on both
sides.

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– Attach battery housing (level 2) with retaining straps -

T40155A- -4- and shackles -VAS 691 009A- -3- and lift it
carefully with workshop hoist -VAS 6100- -1-.
Note
One mechanic should operate the workshop hoist and the other
should guide the battery housing.
– Set battery housing down on a large flat clean surface.
Important
• The surface must be large enough so that battery housing
(level 2) rests on it at the locations where it would make
contact with battery housing (level 1).
– Immediately after setting battery housing 2 down, seal off
opening in battery housing 1 with sealing piece -T40449-.
Continued
– Immediately after setting battery housing 2 down, seal off
opening in cover for battery housing 1 -1- with sealing piece
-T40449- -2-.

Installing
Installation is carried out in reverse order; note the following:
– Remove stud -1-.

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– Use brush -1- to coat flanges -2- of attachment points for

studs with anti-corrosion material ⇒ Electronic parts cata‐
logue.

Important
• Keep contact surfaces free of grease.
– Screw in new studs -1- for securing high-voltage battery
(level 2) and tighten them ⇒ o5.1.2 verview - high-voltage
battery 1 AX2 (level 2)”, page 159 .

– Perform voltage measurement between battery housing (lev‐

el 1) and battery housing (level 2) using voltage tester -VAS
6762/45- until no voltage is measured.
Note
The components may become charged with a low capacity
during removal and installation (similar to a capacitor). Briefly
measuring the voltage with the voltage tester before removal
and installation will dissipate the capacity.
– Carefully fit battery housing.
Important

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• High-voltage wiring harness for drive motor (rear) must be

installed.
• Communication wiring harness must be in correct position.
– Position bolts (inside) -1-.

– Position nuts -1-.

– Tighten bolts on inside of housing (level 2) in diagonal se‐

quence
– Tighten nuts -1- on outside of housing (level 2)
– Plug in communication wiring harness -3- and guide it into
retaining clip.

Important
• You must feel the electrical connector engage.
– Use brush -1- to coat flanges -2- of attachment points for
coolant adapter with anti-corrosion material ⇒ Electronic
parts catalogue.

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Important
• Keep contact surfaces free of grease.
– Fit coolant adapter -2-.

DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Suitable personal protective equipment (PPE) must be
worn for the following work.
– The following steps require a second suitably qualified per‐
son 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 following protective equipment:

♦ Clothing approved for working with electric arcs (jacket and
trousers or overalls), min. protection class 2 up to 318 kJ
♦ Coat approved for working with electric arcs, min. protective
effect of 630 kJ (in combination with aforementioned cloth‐
ing)
♦ Helmet with visor and protective hood approved for working
with electric arcs, combined min. protective effect of 630 kJ
♦ Gloves approved for working with electric arcs with nitrile
glove liners, min. protective effect of 630 kJ, min. insulating
effect up to 500 V
♦ Safety shoes with ESD protection

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⇒ Electronic parts catalogue

– Remove contact protection -T40421- for battery connector
that is to be installed.

DANGER
Wrong installation of battery modules and module connectors.
Risk of severe injury or death due to short-circuit with electric
arc.
– Check battery modules and module connectors for proper
installation.
– Proceed with the work only if there is no voltage between
the battery terminals.

– Before fitting battery connectors, measure voltage between

battery terminals to be connected using voltage tester -VAS
6762/45-.

– When performing measurement before fitting last battery

connector, a voltage can be measured when switching unit
for high-voltage battery -SX6- is installed. In this case, a
load can be applied by pressing both buttons on voltage
tester -VAS 6762/45-. If voltage tester -VAS 6762/45- no
longer shows any voltage with load applied, work may be
continued.

DANGER
Danger from possible electric arc
– To increase distance between hand and battery connector,
use pliers with protective insulation from high-voltage tool
set to apply battery connector.

– If previously removed, insert battery connector -1- and tight‐

en bolts.

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– Fit battery connector -6- and tighten bolts.

– Fit battery connector -5- and tighten bolts.
– Fit battery connectors -2-, -3- and tighten bolts.

– Perform potential equalisation measurement and provisional

energisation ⇒ e5.13 nergisation of high-voltage battery 1
AX2”, page 217 .
– Install cover for battery housing (level 2) ⇒ a5.8.1 nd instal‐
ling cover for battery housing (level 2)”, page 172 .
– After end of hardening time for adhesive, perform leak test
⇒ Rep. gr. 93; Leak test for high-voltage battery 1 AX2.
Tightening torques
♦ ⇒ o5.1.2 verview - high-voltage battery 1 AX2 (level 2)”,
page 159

5.10 Removing battery module

Special tools and workshop equipment required
♦ -T40424/2-
♦ -T40424/3-
♦ Lifting eye -VAS 691 013-
♦ Modullöser -T40424-
♦ Plates -T40424/5-

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♦ Platform scales -VAS 231 007-

♦ Release tool -T90027-
♦ Shock-proof protection -T40421-
♦ Workshop hoist -VAS 6100-
Removing
Preparations
Important
• If a battery module needs to be renewed, the mean cell
voltage of the high-voltage battery must be determined first
⇒ m4.2 ean cell voltage”, page 121 .
• A new battery module must be charged or discharged ac‐
cording to the result of the mean cell voltage calculation
before installing ⇒ Rep. gr. 93; Charging and discharging
battery modules.
– Remove high-voltage battery 1 -AX2- ⇒ Rep. gr. 93; Remov‐
ing and installing high-voltage battery 1 AX2.
– Remove cover for battery housing (level 2) ⇒ a5.8.1 nd in‐
stalling cover for battery housing (level 2)”, page 172 .
Removing battery module (level 1):

DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Suitable personal protective equipment (PPE) must be
worn for the following work.
– The following steps require a second suitably qualified per‐
son 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.

– Remove cover for battery housing (level 1) ⇒ a5.8.2 nd in‐

stalling cover for battery housing (level 1)”, page 179 .
– Put on protective equipment before performing the following
work steps:
♦ Clothing approved for working with electric arcs (jacket and
trousers or overalls), min. protection class 2 up to 318 kJ
♦ Coat approved for working with electric arcs, min. protective
effect of 630 kJ (in combination with aforementioned cloth‐
ing)
♦ Helmet with visor and protective hood approved for working
with electric arcs, combined min. protective effect of 630 kJ
♦ Gloves approved for working with electric arcs with nitrile
glove liners, min. protective effect of 630 kJ, min. insulating
effect up to 500 V
♦ Safety shoes with ESD protection
♦ ⇒ Electronic parts catalogue
– Mark battery connectors and battery modules ⇒ b5.6 attery
modules and battery connectors”, page 172 .

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Important
• To make sure components can be installed at original posi‐
tions, make sketches or take pictures of installation positions
of individual components, especially of routing of electrical
wiring.
– If necessary, mark spacer sleeves for cover bolts -arrows-
and remove.

Important
• They must be re-installed in the same positions later; they
must not be mixed up ⇒ o5.1.1 verview - high-voltage bat‐
tery 1 AX2 (level 1)”, page 157 .
– Unplug electrical connector of communication wiring harness
at battery module that is to be removed using release tool
-T90027- -1-.

– If necessary, unclip retainer for communication wiring har‐

ness.

NOTICE
Grease or dirt on the contact surfaces increase contact resist‐
ance.
The battery may overheat when activated – risk of fire!
– Only touch contact surfaces of battery connectors or bat‐
tery terminals of battery modules if wearing gloves.
– Clean contaminated contact surfaces immediately with iso‐
propanol.

– Remove battery connectors one after the other on both sides

of battery module to be removed.
– Remove bolts -arrows- on battery connector.

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– Remove swarf from threaded holes on battery connectors

using a vacuum cleaner -1-.

– Immediately after removing battery connectors, fit contact

protection -T40421- at free contact surfaces of battery mod‐
ules.

Removing bus bar:

Modules underneath bus bar:
– Mark position of bus bar cover with a felt-tip pen -arrows-.

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NOTICE
Grease or dirt on the contact surfaces increase contact resist‐
ance.
The battery may overheat when activated – risk of fire!
– Only touch contact surfaces of battery connectors or bat‐
tery terminals of battery modules if wearing gloves.
– Clean contaminated contact surfaces immediately with iso‐
propanol.

– Remove bolts -1-.

– Remove bolts -2-, detach bus bar cover and unclip commu‐
nication wiring harness -3-.

– Remove swarf from threaded holes on battery connectors

using a vacuum cleaner -1-.

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– Fit contact protection -T40421- at free contact surfaces of

battery modules.
– Release battery connector bracket -1- and unclip communi‐
cation wiring harness -2-.

Continued for all models:

– Put on protective equipment before performing the following
work steps:
♦ Fabric gloves
♦ Safety goggles
♦ Safety shoes with ESD protection
♦ ⇒ Electronic parts catalogue
– Unscrew bolts -arrows- for battery module.

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– Fit hooks -T40424/2- on clamping piece from module re‐

lease tool -T40424- ⇒ Operating instructions for module re‐
lease tool -T40424-.

– Secure clamping piece -2- from module release tool -

T40424- to battery module -1- to be removed.
Important
• Hooks of clamping piece must engage in housing ribs on
front and rear of battery module. Ensure that knurled screw
is on side of connector for communication wiring harness.
If necessary, move module slightly with a plastic wedge so
that clamping piece can be fitted.
– Clamp hooks hand-tight using knurled screw.
– Fit plates -T40424/5- above plastic feet on support bridge.
– Connect support bridge from module release tool -T40424-
to clamping piece using pin -2- (example illustration).

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– If necessary, compensate for difference in height with plastic

feet -T40424/3- (supplied with release tool) ⇒ Operating in‐
structions for module release tool -T40424-.
– Slowly and carefully release battery module from thermal
grease using spindle -1- with maximum of 7 Nm.
Note
If the battery module cannot be released, wait for a minute,
release the spindle and then repeat the procedure.
– After releasing, lower battery module and detach support
bridge.
– Take hold of battery module by grip and lift it out of battery
housing.
– Alternatively, the previously released battery module can be
lifted out using the workshop hoist -VAS 6100- by removing
the grip and fitting the swivel bolt -VAS 691 013- (tightening
torque: 10 Nm) ⇒ Operating instructions for module release
tool -T40424-.
Important
• The battery module must first be released with the spindle.
– Detach battery module and set it down on its side on a
clean, lint-free surface.
Note
The thermal grease contains silicone; contact with bonding sur‐
faces must therefore be avoided.
– Scrape remaining thermal grease off battery module using a
wide plastic scraper and place on a thin film.
– Scrape remaining thermal grease out of mounting in battery
housing using a commercially available plastic scraper and
also place on the film.
– Clean mounting in battery housing using isopropanol and a
lint-free cloth.

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– Measure total weight of thermal grease used on platform

scales -VAS 231 007-.
– Remove swarf from threaded holes for bolted connections
for modules using a vacuum cleaner -1-.

– Clean mounting for battery module in battery housing with a

dry, lint-free cloth.

5.11 Installing battery module

Special tools and workshop equipment required
♦ Hand-cartridge gun -V.A.G 1628-
♦ Platform scales -VAS 231 007-
♦ Shock-proof protection -T40421-
♦ Template -T90023-
♦ Voltage tester -VAS 6762/45-

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Installing

DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injury from electric shock or electric
arcs.
– The following work must only be performed by a qualified
high-voltage expert (HVE).

– A new battery module must be charged or discharged ac‐

cording to the result of the mean cell voltage calculation
before installing ⇒ Rep. gr. 93; Charging and discharging
battery modules.
– Put on protective equipment before performing the following
work steps:
♦ Fabric gloves
♦ Safety goggles
♦ Safety shoes with ESD protection
♦ ⇒ Electronic parts catalogue
– Allow thermal grease to reach room temperature before us‐
ing.
Note
The thermal grease contains silicone; contact with bonding sur‐
faces must therefore be avoided.
– Clean underside of module that is to be fitted with a clean,
lint-free cloth.
– Place new module -2- upside-down on platform scales -VAS
231 007- -1- on a lint-free cloth.

– Place template -T90023- -3- on new module.

– Cut down nozzle of cartridge so length of dimension -a- =
6.5 cm.
– Set scales to 0 (tare weight).
– Now apply 6 lines of thermal grease with a total weight equal
to that of the old grease (measured previously) using hand-
cartridge gun -V.A.G 1628- -4-.
– Apply evenly and press on slightly with a wide plastic scra‐
per.
– Insert battery module in battery housing according to mark
made during removal within 60 minutes.

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– Tighten bolts -arrows- for battery module in diagonal se‐

quence and in stages.

– Before performing further assembly steps, check that battery

module is in correct installation position.

Important
• The battery module is installed correctly if the battery con‐
nector can connect the positive and negative terminals of the
battery modules -arrows-.

DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Suitable personal protective equipment (PPE) must be
worn for the following work.
– The following steps require a second suitably qualified per‐
son 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 before performing the following

work steps:
♦ Clothing approved for working with electric arcs (jacket and
trousers or overalls), min. protection class 2 up to 318 kJ
♦ Coat approved for working with electric arcs, min. protective
effect of 630 kJ (in combination with aforementioned cloth‐
ing)

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♦ Helmet with visor and protective hood approved for working

with electric arcs, combined min. protective effect of 630 kJ
♦ Gloves approved for working with electric arcs with nitrile
glove liners, min. protective effect of 630 kJ, min. insulating
effect up to 500 V
♦ Safety shoes with ESD protection
♦ ⇒ Electronic parts catalogue
– Detach contact protection -T40421- from installed battery
module and from adjacent battery modules.

– Before fitting battery connectors, measure voltage between

battery terminals to be connected using voltage tester -VAS
6762/45-.

NOTICE
Grease or dirt on the contact surfaces increase contact resist‐
ance.
The battery may overheat when activated – risk of fire!
– Only touch contact surfaces of battery connectors or bat‐
tery terminals of battery modules if wearing gloves.
– Clean contaminated contact surfaces immediately with iso‐
propanol.

– Press back bolts on battery connector.

– When performing measurement before fitting last battery
connector, a voltage can be measured when switching unit

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for high-voltage battery -SX6- is installed. In this case, a

load can be applied by pressing both buttons on voltage
tester -VAS 6762/45-. If voltage tester -VAS 6762/45- no
longer shows any voltage with load applied, work may be
continued.

DANGER
Wrong installation of battery modules and module connectors.
Risk of severe injury or death due to short-circuit with electric
arc.
– Check battery modules and module connectors for proper
installation.
– Proceed with the work only if there is no voltage between
the battery terminals.

– If voltage measurement is OK, fit battery connector -arrows-

immediately ⇒ High-voltage battery; Rep. gr. 93; High-volt‐
age battery components; Overview of fitting locations - bat‐
tery connectors.

– Put on protective equipment before performing the following

work steps:
♦ Fabric gloves
♦ Safety goggles
♦ Safety shoes with ESD protection
♦ ⇒ Electronic parts catalogue
– Fit and secure electrical connector for communication wiring
harness on battery module.
– Fit communication wiring harness, spacer sleeves and bus
bar cover.
– Perform provisional energisation ⇒ e5.13 nergisation of high-
voltage battery 1 AX2”, page 217 .
Battery module (level 2) installed:
– Install cover for battery housing (level 2) ⇒ a5.8.1 nd instal‐
ling cover for battery housing (level 2)”, page 172 .
Battery module (level 1) installed:
– Install cover for battery housing (level 1) ⇒ a5.8.2 nd instal‐
ling cover for battery housing (level 1)”, page 179 .
Tightening torques
♦ ⇒ Rep. gr. 93; Assembly overview - battery modules

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5.12 Visually inspecting and classifying bat‐

tery module
Special tools and workshop equipment required
♦ Voltage balancing device for high-voltage battery module
(module balancer) -VAS 6910-

CAUTION
Risk to health due to toxic vapours, dust and liquids.
– Never perform work on high-voltage batteries in which a
short circuit has occurred.

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 a high-voltage expert if problems were reported or if
there are entries in the event memory.

Visually inspecting battery module

Check battery module for the following:
– Cracks in battery module housing
– Deformations in battery module housing
– Temperature-induced discolourations and heat tinting on
battery module housing
– Escaping electrolyte
– Damage to high-voltage contacts
– Presence and legibility of information and warning stickers
– Corrosion damage
– After performing visual inspection, classify battery module.
Classifying battery module
⇒ Vehicle diagnostic tester and module balancer -VAS 6910-
must be used to classify battery module ⇒ Rep. gr. 93; Charg‐
ing and discharging battery modules.
– Classify battery module using ⇒ Vehicle diagnostic tester
⇒ Rep. gr. 00; Starting diagnosis.

5.13 Provisional energisation of high-volt‐

age battery 1 AX2
Special tools and workshop equipment required
♦ Adapter cable -VAS 5581/1A-2-
♦ Diagnosis lead -VAS 5581A/12-
♦ Diagnosis lead -VAS 6558A/39-1-
♦ High-voltage diagnostics box -VAS 5581-
♦ Insulating mat -VAS 6762/44-

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♦ diagnostic cable -VAS 6558A-39-2-

♦ vehicle diagnostic tester
Important
• Provisional energisation of the high-voltage battery should
be performed before finally bonding on the battery covers
in order to check the electrical function of control units and
battery modules. The covers for battery housing remain re‐
moved during this procedure.
• If only components from level 2 of high-voltage battery 1
-AX2- were removed and installed as part of the repair work
performed beforehand, contrary to the description provided
here, the cover for level 1 should remain closed and the
switching unit for high-voltage battery -SX6- should remain
installed.
Procedure

– Connect high-voltage diagnostics box -VAS 5581- to vehicle

diagnostic tester with diagnostic cable -VAS 5581A/12- and
adapter cable -VAS 5581/1A-2-.
Important
• CAN bus terminal resistor of high-voltage diagnostics box
-VAS 5581- is pre-set to 120 Ω and must not be changed.

DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Suitable personal protective equipment (PPE) must be
worn for the following work.
– The following steps require a second suitably qualified per‐
son 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.

– Set up test equipment; when doing so, proceed as follows

and observe warnings:
– Put on the following protective equipment:
♦ Clothing approved for working with electric arcs (jacket and
trousers or overalls), min. protection class 2 up to 318 kJ
♦ Coat approved for working with electric arcs, min. protective
effect of 630 kJ (in combination with aforementioned cloth‐
ing)
♦ Helmet with visor and protective hood approved for working
with electric arcs, combined min. protective effect of 630 kJ
♦ Gloves approved for working with electric arcs with nitrile
glove liners, min. protective effect of 630 kJ, min. insulating
effect up to 500 V
♦ Safety shoes with ESD protection
⇒ Electronic parts catalogue

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DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injury from electric shock or electric
arcs.
– Carry out visual inspection of high-voltage battery to en‐
sure there is sufficient contact protection.

– Check high-voltage battery has sufficient contact protection.

– Protective equipment required if there is sufficient contact
protection:
♦ Fabric gloves
♦ Safety goggles
♦ Safety shoes with ESD protection

– Turn over switching unit for high-voltage battery -SX6- next

to high-voltage battery 1 -AX2- and place on insulating mat
-VAS 6762/44-.
The open side of the switching unit must face upwards.
– Connect switching unit to battery housing (level 1) with diag‐
nostic cable -VAS 6558A-39-2- -1-.

– Place battery housing (level 2) on a clean, level surface and

connect communication wiring harness (top level) to commu‐
nication wiring harness (bottom level) with diagnostic cable
-VAS 6558A/39-1- -1-.

– Connect diagnostic cable -VAS 5581A/12- to 12V connec‐

tion on switching unit with adapter cable -VAS 5581/1A-2-.
– Connect black earth clamps of diagnostic cable -VAS
5581A/12- and adapter cable -VAS 5581/1A-2- to earth on
battery housing.

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– Starting diagnosis:
♦ Select “Diagnosis” mode and then “Start diagnosis”.
♦ Select “Test plan” tab.
♦ Choose “Select own test” tab and select test program under
“Diagnostic capable system”:
♦ 008C - Hybrid Battery Energy Management -J840
♦ 008C - Hybrid Battery Energy Management - functions
♦ 008C - start up operations
– Start selected program, select program point “Generate bat‐
tery overview” and follow instructions on display of vehicle
diagnostic tester.
If electrical function is OK, assemble high-voltage battery com‐
pletely:
♦ Install cover for battery housing (level 1) ⇒ a5.8.2 nd instal‐
ling cover for battery housing (level 1)”, page 179 .
♦ Install cover for battery housing (level 2) ⇒ a5.8.1 nd instal‐
ling cover for battery housing (level 2)”, page 172 .

5.14 Removing and installing communica‐

tion wiring harness on high-voltage
battery 1 AX2

5.14.1 Removing communication wiring har‐

ness on high-voltage battery 1 AX2
(level 2)
Special tools and workshop equipment required
♦ Release tool -T90027-
♦ Shock-proof protection -T40421-
♦ Voltage tester -VAS 6762/45-

DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Suitable personal protective equipment (PPE) must be
worn for the following work.
– The following steps require a second suitably qualified per‐
son 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.

Important
• Remove cover for battery housing (level 2) ⇒ a5.8.1 nd in‐
stalling cover for battery housing (level 2)”, page 172 .
• To make sure components can be installed at original posi‐
tions, make sketches or take pictures of installation positions
of individual components, especially of routing of electrical
wiring.

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• Before continuing with work, the voltage must be measured

between the battery (+) and the battery housing using volt‐
age tester -VAS 6762/45-.
Removing
– Put on the following protective equipment:
♦ Clothing approved for working with electric arcs (jacket and
trousers or overalls), min. protection class 2 up to 318 kJ
♦ Coat approved for working with electric arcs, min. protective
effect of 630 kJ (in combination with aforementioned cloth‐
ing)
♦ Helmet with visor and protective hood approved for working
with electric arcs, combined min. protective effect of 630 kJ
♦ Gloves approved for working with electric arcs with nitrile
glove liners, min. protective effect of 630 kJ, min. insulating
effect up to 500 V
♦ Safety shoes with ESD protection
⇒ Electronic parts catalogue
– Immediately after removing each individual battery connec‐
tor, fit contact protection -T40421- at free contact surfaces of
battery modules.
– Remove bolts and take out battery connector -2-. Fit contact
protection.

– Remove bolts and take out battery connector -3-. Fit contact
protection.
– Remove bolts and take out battery connector -5-. Fit contact
protection.

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– Remove bolts and take out battery connector -6-. Fit contact
protection.
– Press back bolts for battery connectors.
– Remove swarf from threaded holes on battery connectors
using a vacuum cleaner -1-.

– Unplug electrical connector -3- of communication wiring har‐

ness.

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– Unclip and lift fastener cover -2-.

– Unclip connector -3- of communication wiring harness from
retainer of fastener cover from below.
– Clip fastener cover back in.
– Unplug electrical connector of communication wiring harness
at battery modules using release tool -T90027- -1-.

– Carefully release communication wiring harness at mounting

points on battery frame using plastic scraper and remove.
Installing
– Installation is carried out in reverse order; note the following:

DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Suitable personal protective equipment (PPE) must be
worn for the following work.
– The following steps require a second suitably qualified per‐
son 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 following protective equipment:

♦ Clothing approved for working with electric arcs (jacket and
trousers or overalls), min. protection class 2 up to 318 kJ

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♦ Coat approved for working with electric arcs, min. protective

effect of 630 kJ (in combination with aforementioned cloth‐
ing)
♦ Helmet with visor and protective hood approved for working
with electric arcs, combined min. protective effect of 630 kJ
♦ Gloves approved for working with electric arcs with nitrile
glove liners, min. protective effect of 630 kJ, min. insulating
effect up to 500 V
♦ Safety shoes with ESD protection
⇒ Electronic parts catalogue

DANGER
Wrong installation of battery modules and module connectors.
Risk of severe injury or death due to short-circuit with electric
arc.
– Check battery modules and module connectors for proper
installation.
– Proceed with the work only if there is no voltage between
the battery terminals.

– Install communication wiring harness and fit and secure

electrical connectors on battery modules.
– Detach contact protection -T40421- from installed battery
module and from adjacent battery modules.

– Before fitting battery connectors, measure voltage between

battery terminals to be connected using voltage tester -VAS
6762/45-.

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– If voltage measurement is OK, immediately fit battery con‐

nectors in reverse order of removal -arrows- ⇒ Rep. gr. 93;
Overview of fitting locations - battery connectors.

– Perform provisional energisation ⇒ e5.13 nergisation of high-

voltage battery 1 AX2”, page 217 .
Tightening torques
⇒ Rep. gr. 93; Overview of fitting locations - battery connectors

5.14.2 Removing communication wiring har‐

ness on high-voltage battery 1 AX2
(level 1)
Special tools and workshop equipment required
♦ Release tool -T90027-
♦ Shock-proof protection -T40421-
♦ Voltage tester -VAS 6762/45-

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DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Suitable personal protective equipment (PPE) must be
worn for the following work.
– The following steps require a second suitably qualified per‐
son 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.

Important
• Remove cover for battery housing (level 2) ⇒ a5.8.1 nd in‐
stalling cover for battery housing (level 2)”, page 172 .
• To make sure components can be installed at original posi‐
tions, make sketches or take pictures of installation positions
of individual components, especially of routing of electrical
wiring.
• Before continuing with work, the voltage must be measured
between the battery (+) and the battery housing using volt‐
age tester -VAS 6762/45-.
Removing
– Remove cover for battery housing (level 1) ⇒ a5.8.2 nd in‐
stalling cover for battery housing (level 1)”, page 179 .
Before transferring components:
– Put on the following protective equipment:
♦ Clothing approved for working with electric arcs (jacket and
trousers or overalls), min. protection class 2 up to 318 kJ
♦ Coat approved for working with electric arcs, min. protective
effect of 630 kJ (in combination with aforementioned cloth‐
ing)
♦ Helmet with visor and protective hood approved for working
with electric arcs, combined min. protective effect of 630 kJ
♦ Gloves approved for working with electric arcs with nitrile
glove liners, min. protective effect of 630 kJ, min. insulating
effect up to 500 V
♦ Safety shoes with ESD protection
⇒ Electronic parts catalogue
– Remove battery connectors one at a time. Remove swarf
from threaded holes on battery connectors immediately us‐
ing a vacuum cleaner -1-.

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NOTICE
Grease or dirt on the contact surfaces increase contact resist‐
ance.
The battery may overheat when activated – risk of fire!
– Only touch contact surfaces of battery connectors or bat‐
tery terminals of battery modules if wearing gloves.
– Clean contaminated contact surfaces immediately with iso‐
propanol.

– Fit contact protection -T40421- on all free contact surfaces

of battery modules immediately.

– Remove nuts -6-.

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– Remove relevant bolts -3- and take out battery connector

-1-. Fit contact protection -T40421-.
– Remove bolts and take out battery connector -2-. Fit contact
protection.
– Remove bolts and take out battery connector -5-. Fit contact
protection.
– Remove bolts -4-.
– Remove additional battery connectors -2, 3- one at a time
and fit contact protection -T40421- immediately.

– Press back bolts for battery connectors.

– Mark position of bus bar cover with a felt-tip pen -arrows-.

– Remove bolts -1-.

– Remove bolts -2-, detach bus bar cover and unclip commu‐
nication wiring harness -3-.

– Fit contact protection -T40421- at free contact surfaces of

battery modules.

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– Release battery connector bracket -1- and unclip communi‐

cation wiring harness -2-.

– Unplug electrical connector of communication wiring harness

at battery modules using release tool -T90027- -1-.

– Carefully release communication wiring harness at mounting

points on battery frame using plastic scraper and remove.
Installing
– Installation is carried out in reverse order; note the following:
– Put on the following protective equipment:
♦ Clothing approved for working with electric arcs (jacket and
trousers or overalls), min. protection class 2 up to 318 kJ
♦ Coat approved for working with electric arcs, min. protective
effect of 630 kJ (in combination with aforementioned cloth‐
ing)
♦ Helmet with visor and protective hood approved for working
with electric arcs, combined min. protective effect of 630 kJ
♦ Gloves approved for working with electric arcs with nitrile
glove liners, min. protective effect of 630 kJ, min. insulating
effect up to 500 V
♦ Safety shoes with ESD protection
⇒ Electronic parts catalogue
– Install communication wiring harness and fit and secure
electrical connectors on battery modules.
– Detach contact protection -T40421- from installed battery
module and from adjacent battery modules.

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DANGER
Wrong installation of battery modules and module connectors.
Risk of severe injury or death due to short-circuit with electric
arc.
– Check battery modules and module connectors for proper
installation.
– Proceed with the work only if there is no voltage between
the battery terminals.

– Before fitting battery connectors, measure voltage between

battery terminals to be connected using voltage tester -VAS
6762/45-.

– If voltage measurement is OK, immediately fit battery con‐

nectors in reverse order of removal -arrows- ⇒ High-voltage
battery; Rep. gr. 93; High-voltage battery components; Over‐
view of fitting locations - battery connectors.

230 Rep. gr.93 - Electric drive systems

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– Perform provisional energisation ⇒ e5.13 nergisation of high-

voltage battery 1 AX2”, page 217 .
Tightening torques
⇒ High-voltage battery; Rep. gr. 93; High-voltage battery com‐
ponents; Overview of fitting locations - battery connectors

5. High-voltage battery components 231

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6 Power and control electronics for

electric drive

6.1 Exploded view - power and control

electronics for electric drive

6.1.1 Exploded view - electric drive control unit for front axle J1234

1 - Cover for connection

housing
❑ With sealing element
❑ Renew after removing
2 - Bolt
❑ 8x
❑ Renew after removing
❑ 3 Nm +35° über Kreuz
3 - Bolt
❑ For high-voltage wires
❑ 3x
❑ 8 Nm
4 - Seal
❑ Renew after removing
5 - Bolt
❑ 3x
❑ 30 Nm
6 - Insulation
7 - Electric drive control unit
for front axle -J1234-
❑ ⇒ a6.2.1 nd installing
electric drive control
unit for front axle
J1234”, page 234
8 - Coolant pipe
❑ To motor (rear)
9 - Bolt
❑ Renew after removing
❑ 40 Nm +45°
10 - Separating element
11 - Bolt
❑ 2x
❑ 8 Nm

6.1.2 Exploded view - electric drive control unit for rear axle J1235

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1 - Cover for connection

housing
❑ Renew after removing
2 - Bolt
❑ 16x
❑ Renew after removing
❑ 5 Nm +30° über Kreuz
3 - Current bar
4 - Bolt
❑ For high-voltage wires
❑ 3x
❑ 8 Nm
5 - Bolt
❑ M8x25 mm
❑ 6x
❑ Renew after removing
❑ 16 Nm +45°
6 - Bolt
❑ M8x50 mm
❑ Renew after removing
❑ 16 Nm +45°
7 - Connection housing
❑ With sealing elements
❑ For electric drive con‐
trol unit for rear axle -
J1235-
❑ Removing and instal‐
ling ⇒ a6.2.2 nd instal‐
ling electric drive con‐
trol unit for rear axle
J1235”, page 238
❑ Renew after removing
8 - Coolant pipe
❑ To motor (rear)
9 - Bolt
❑ 4x
❑ 30 Nm
10 - Insulation
11 - Electric drive control unit for rear axle -J1235-
❑ ⇒ a6.2.2 nd installing electric drive control unit for rear axle J1235”, page 238
12 - Coolant pipe
❑ From coolant manifold (front)
13 - Separating element
14 - Bolt
❑ 3x
❑ 8 Nm
15 - Bolt
❑ M8x50 mm

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❑ Renew after removing

❑ 16 Nm +45°
16 - Bolt
❑ For high-voltage wires
❑ 3x
❑ 8 Nm

6.2 Removing and installing power and

control electronics for electric drive

6.2.1 Removing and installing electric drive

control unit for front axle J1234
Removing
If control unit is renewed, test plan for renewal of control unit
must be performed:
– Perform “Replace control module” function with ⇒ Vehicle
diagnostic tester ⇒ Rep. gr. 00; Starting diagnosis.
Continued

DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) de-energise the high-voltage system.

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

energising high-voltage system; De-energising high-voltage
system.
– Drain coolant ⇒ Motor; Rep. gr. 19; Cooling system/coolant;
Draining cooling system.
– Switch off ignition. Deposit vehicle key and other drive au‐
thorisation systems (e.g. smartphone) outside vehicle.
– Remove reinforcement (rear) ⇒ Running gear, axles, steer‐
ing; Rep. gr. 40; Subframe; Assembly overview - subframe.
– Release catch on both sides -arrow- and move coolant hose
-1- clear.

– Unplug high-voltage connector -1- ⇒ Motor; Rep. gr. 93;

High-voltage wires; Unplugging high-voltage connectors.

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– Remove bolt -arrow-.

– Remove bracket for power contactor with boost function ⇒
a15.4 nd installing bracket for power contactor with boost
function”, page 312 .
– Unplug high-voltage connector -1- ⇒ Motor; Rep. gr. 93;
High-voltage wires; Unplugging high-voltage connectors.

– Remove bolts -arrows- and press bracket -1- to side with

coolant pump for high-voltage battery -V590-.

– Remove bolt -1-.

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– Release hose clips -arrows- and disconnect coolant hoses.

– Move bracket for coolant lines -2- clear.
– Unscrew bolts -arrows- and detach cover -1-.

– Remove bolts -arrows-.

– Counterhold at connector housing and unplug electrical con‐

nectors -1-.
– Unplug electrical connector -1-.

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– Remove bolt -3-.

– Detach potential equalisation line -2-.
– Remove bolts -arrows-.
– Raise control unit -6- as far as necessary for coolant hose
-4- to be accessible.
– Release hose clip -5- and detach coolant hose.
– Remove control unit.
Installing
Installation is carried out in reverse order; note the following:
– Tighten bolts for new cover for high-voltage wires in diagonal
sequence.
– A potential equalisation measurement must be performed
on the high-voltage components affected after installation
of high-voltage components or potential equalisation lines
⇒ Rep. gr. 93; Potential equalisation measurement.
– Fill cooling system ⇒ Motor; Rep. gr. 19; Cooling sys‐
tem/coolant; Filling cooling system.

WARNING
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) re-energise the high-voltage system.

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

energising high-voltage system; Re-energising high-voltage
system.
Tightening torques
♦ ⇒ Motor; Rep. gr. 93; Power and control electronics for elec‐
tric drive; Assembly overview - power and control electronics
for electric drive
♦ ⇒ Motor; Rep. gr. 93; High-voltage wires; Overview of fitting
locations - high-voltage wires

6. Power and control electronics for electric drive 237

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♦ ⇒ Motor; Rep. gr. 19; Coolant pump/thermostat assembly;

Assembly overview - electric coolant pump

6.2.2 Removing and installing electric drive

control unit for rear axle J1235
Removing
If control unit is renewed, test plan for renewal of control unit
must be performed:
– Perform “Replace control module” function with ⇒ Vehicle
diagnostic tester ⇒ Rep. gr. 00; Starting diagnosis.
Continued
– ⇒ Rep. gr. 10; Remove motor (rear).
– Release hose clip -arrow- and detach coolant hose.

– Unscrew bolts -arrows- and detach cover -1-.

– Remove bolts -arrows-.

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– Detach current bridge -1-.

– Counterhold at connector housing and unplug electrical con‐
nectors -2-.
– Unscrew bolts -arrows- and detach control unit -1-.

– Remove bolts -arrows-.

– Detach connection housing -1-.

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Installing
Installation is carried out in reverse order; note the following:
– Tighten bolts for new cover for high-voltage wires in diagonal
sequence.
– A potential equalisation measurement must be performed
on the high-voltage components affected after installation
of high-voltage components or potential equalisation lines
⇒ Rep. gr. 93; Potential equalisation measurement.
Tightening torques
♦ ⇒ Motor; Rep. gr. 93; Power and control electronics for elec‐
tric drive; Assembly overview - power and control electronics
for electric drive

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7 Electric drive motor

7.1 Removing and installing drive motor ro‐

tor position sender 1 G713
Removing
– ⇒ Rep. gr. 10; Separate motor and transmission unit.
– Remove electric drive control unit for front axle -J1234- ⇒
a6.2.1 nd installing electric drive control unit for front axle
J1234”, page 234 .
– Remove bolts -arrows- and detach separating element -1-.
To do so, move electrical wiring -2- clear.

– Remove bolts -arrows- and detach drive motor rotor position

sender 1 -G713- -1-, guiding out electrical wire to do so.

Installing
Installation is carried out in reverse sequence.
Tightening torques
♦ ⇒ Rep. gr. 10; Exploded view - motor

7.2 Removing and installing rear drive mo‐

tor rotor position sender G1095
Removing
– Remove electric drive control unit for rear axle -J1235- ⇒
a6.2.2 nd installing electric drive control unit for rear axle
J1235”, page 238 .
– Remove bolts -arrows- and detach separating element -1-.
To do so, move electrical wiring -2- clear.

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– Remove bolts -arrows- and detach rear drive motor rotor

position sender 1 -G1095- -1-, guiding out electrical wire to
do so.

Installing
Installation is carried out in reverse sequence.
Tightening torques
♦ ⇒ Rep. gr. 10; Assembly overview - motor (rear)

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8 Motor control unit

8.1 Removing and installing motor control

unit J623
Removing
If control unit is renewed, test plan for renewal of control unit
must be performed:
– Perform “Replace control module” function with ⇒ Vehicle
diagnostic tester ⇒ Rep. gr. 00; Starting diagnosis.
Continued
– Switch off ignition. Deposit vehicle key and other drive au‐
thorisation systems (e.g. smartphone) outside vehicle.
– Remove luggage compartment side trim ⇒ General body re‐
pairs, interior; Rep. gr. 70; Luggage compartment trim pan‐
els; Removing and installing luggage compartment side trim.
– Remove nuts -arrows-.

– Detach protective housing -1-.

– Detach motor control unit -J623- -2-.
– Unplug electrical connectors -3-.
Installing
Installation is carried out in reverse sequence.
Tightening torques
Component Tightening torque
Nuts for protective housing 3 Nm

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9 High-voltage wiring

9.1 Overview of fitting locations - high-volt‐

age wires

9.1.1 Overview of fitting locations - high-voltage wires, charging unit, power

contactor with boost function, charging socket

1 - High-voltage wire to charg‐

ing unit 1 for high-voltage bat‐
tery -AX4-
❑ To charging unit 1 for
high-voltage battery -
AX4-
❑ ⇒ Motor; Rep. gr. 93;
Charging unit for high-
voltage battery; Explo‐
ded view - charging unit
for high-voltage battery
2 - High-voltage wiring har‐
ness with high-voltage battery
charging socket 1 -UX4-
❑ To charging unit 1 for
high-voltage battery -
AX4-/power contactor
with boost function -
J1178-
❑ Depending on vehicle
equipment
❑ ⇒ Motor; Rep. gr. 93;
Charging socket; Ex‐
ploded view - charging
socket 2
3 - High-voltage wire with
high-voltage battery charging
socket 2 -UX5-
❑ To charging unit 1 for
high-voltage battery -
AX4-
❑ ⇒ Motor; Rep. gr. 93;
Charging socket; Ex‐
ploded view - charging
socket
4 - Power contactor with
boost function -J1178-
❑ ⇒ Motor; Rep. gr. 93; Voltage converter; Exploded view - voltage converter
5 - Charging unit 1 for high-voltage battery -AX4-
❑ ⇒ Motor; Rep. gr. 93; Charging unit for high-voltage battery; Exploded view - charging unit for high-
voltage battery

9.1.2 Overview of fitting locations - high-voltage wires, voltage converter, high-

voltage heater, air conditioner compressor

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1 - High-voltage wire to high-

voltage heater (linear) -Z189-
❑ ⇒ a9.7 nd installing
high-voltage wire for
high-voltage heater”,
page 257
2 - Electrical air conditioner
compressor -V470-
3 - Power contactor with
boost function -J1178-
4 - High-voltage wire to volt‐
age converter for 800 V, 400
V, 48 V, 12 V -A48-
❑ ⇒ a9.4 nd instal‐
ling high-voltage wire
for voltage converter”,
page 252
5 - Voltage converter for 800
V, 400 V, 48 V, 12 V -A48-
❑
6 - High-voltage wire to elec‐
trical air conditioner compres‐
sor -V470-
❑ ⇒ Motor; Rep. gr. 93;
High-voltage wires; Re‐
moving and installing
high-voltage wire for
electrical air conditioner
compressor
7 - High-voltage heater (line‐
ar) -Z189-

9.1.3 Overview of fitting locations - high-voltage wires, electric drive control unit
(front), switching unit, high-voltage charge current distributor

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1 - High-voltage wiring har‐

ness to electric drive control
unit for front axle -J1234-
❑ ⇒ a9.2.1 nd installing
high-voltage wiring har‐
ness for drive motor
(front)”, page 247
❑ Schraube 8 Nm
2 - Retainer
❑ Schraube 8 Nm
3 - Switching unit for high-
voltage battery -SX6-
4 - High-voltage wiring har‐
ness to switching unit for
high-voltage battery -SX6-
❑ ⇒ a9.3 nd installing
high-voltage wiring har‐
ness for switching unit
for high-voltage bat‐
tery”, page 250
5 - Power contactor with
boost function -J1178-
6 - Electric drive control unit
for front axle -J1234-
❑
7 - Bracket for strain relief for
high-voltage wiring harness
❑ Schraube 8 Nm

9.1.4 Overview of fitting locations - high-voltage wires, electric drive control unit
for rear axle

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1 - Switching unit for high-

voltage battery -SX6-
2 - Cable guide
❑ Renew after removing
3 - Retainer
❑ Schraube 8 Nm
4 - High-voltage wiring har‐
ness to electric drive control
unit for rear axle -J1235-
❑ ⇒ a9.2.2 nd installing
high-voltage wiring har‐
ness for drive motor
(rear)”, page 248
❑ Schraube 8 Nm
5 - Electric drive control unit
for rear axle -J1235-
6 - Cable guide
❑ Renew after removing

9.2 Removing and installing high-voltage

wiring harness for drive motor

9.2.1 Removing and installing high-voltage

wiring harness for drive motor (front)
Removing

DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) de-energise the high-voltage system.

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

energising high-voltage system; De-energising high-voltage
system.

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– Remove bracket for power contactor with boost function ⇒

a15.4 nd installing bracket for power contactor with boost
function”, page 312 .
– Unplug high-voltage connector -1- ⇒ Motor; Rep. gr. 93;
High-voltage wires; Unplugging high-voltage connectors.

Installing
Installation is carried out in reverse order; note the following:
– Perform a potential equalisation measurement on the high-
voltage components affected after installation of high-voltage
components or potential equalisation lines ⇒ Rep. gr. 93;
Potential equalisation measurement.

WARNING
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) re-energise the high-voltage system.

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

energising high-voltage system; Re-energising high-voltage
system.
Tightening torques
♦ ⇒ Motor; Rep. gr. 93; High-voltage wires; Overview of fitting
locations - high-voltage wires

9.2.2 Removing and installing high-voltage

wiring harness for drive motor (rear)
Removing
– Remove high-voltage battery 1 -AX2- ⇒ Motor; Rep. gr. 93;
High-voltage battery unit; Removing and installing high-volt‐
age battery 1 AX2.
– Remove battery housing (level 2) ⇒ a5.9 nd installing battery
housing (level 2)”, page 191 .
– Remove bolt -arrow-.

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– Disengage retainer -1- at support bracket -3-.

– Move high-voltage wiring harness -2- clear at retainer.
Important
• Mark position of wire guides -2-, -3-, -4- and wire retainer on
new cover for battery housing (level 1).
– Pry wire guides -2-, -3-, -4- off battery -1-.

– Disconnect high-voltage wiring harness -2- and move it clear

⇒ Motor; Rep. gr. 93; High-voltage wires; Unplugging high-
voltage connectors.

– Detach high-voltage wiring harness.

Installing
Installation is carried out in reverse order; note the following:
Important
• Battery and wire guide must be at room temperature.
• The bonding surfaces must be free of dirt and grease.

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– Peel protective film off bonding surfaces -1-, -3- and press
wire guide -2- and wire retainer onto new cover at marked
locations.
Important
• Leave battery standing at room temperature for at least 30
minutes.
– Perform a potential equalisation measurement on the high-
voltage components affected after installation of high-voltage
components or potential equalisation lines ⇒ Rep. gr. 93;
Potential equalisation measurement.
Tightening torques
♦ ⇒ Motor; Rep. gr. 93; High-voltage wires; Overview of fitting
locations - high-voltage wires

9.3 Removing and installing high-voltage

wiring harness for switching unit for
high-voltage battery
Removing

DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) de-energise the high-voltage system.

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

energising high-voltage system; De-energising high-voltage
system.
– Switch off ignition. Deposit vehicle key and other drive au‐
thorisation systems (e.g. smartphone) outside vehicle.
– Remove reinforcement (rear) ⇒ Running gear, axles, steer‐
ing; Rep. gr. 40; Subframe; Exploded view - subframe.
– Disconnect high-voltage wiring harness -2- for switching unit
for high-voltage battery -1- ⇒ Motor; Rep. gr. 93; High-volt‐
age wires; Unplugging high-voltage connectors.

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– Remove bracket -2- for power contactor with boost function

⇒ a15.4 nd installing bracket for power contactor with boost
function”, page 312 .

Important
• Bracket remains installed after being released.
– Guide high-voltage wiring harness -1- out upwards.
Installing
Installation is carried out in reverse order; note the following:
– Perform a potential equalisation measurement on the high-
voltage components affected after installation of high-voltage
components or potential equalisation lines ⇒ Rep. gr. 93;
Potential equalisation measurement.

WARNING
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) re-energise the high-voltage system.

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

energising high-voltage system; Re-energising high-voltage
system.
Tightening torques
♦ ⇒ Motor; Rep. gr. 93; High-voltage wires; Overview of fitting
locations - high-voltage wires

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9.4 Removing and installing high-voltage

wire for voltage converter
Removing

DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) de-energise the high-voltage system.

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

energising high-voltage system; De-energising high-voltage
system.
– Switch off ignition. Deposit vehicle key and other drive au‐
thorisation systems (e.g. smartphone) outside vehicle.
Left-hand drive vehicles
– Remove battery ⇒ Electrical system; Rep. gr. 27; Battery;
Removing and installing battery.
All vehicles (continued)
– Remove body brace (front) ⇒ Running gear, axles, steering;
Rep. gr. 40; Suspension strut, upper links; Removing and
installing body brace (front).
– Unplug high-voltage connectors -1-, -2- ⇒ Motor; Rep.
gr. 93; High-voltage wires; Unplugging high-voltage connec‐
tors.

– Move high-voltage wire -3- clear and detach.

Installing
Installation is carried out in reverse order; note the following:
– Perform a potential equalisation measurement on the high-
voltage components affected after installation of high-voltage
components or potential equalisation lines ⇒ Rep. gr. 93;
Potential equalisation measurement.

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WARNING
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) re-energise the high-voltage system.

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

energising high-voltage system; Re-energising high-voltage
system.

9.5 Removing and installing high-voltage

wire for electrical air conditioner com‐
pressor
Removing
– Remove bracket for power contactor with boost function ⇒
a15.4 nd installing bracket for power contactor with boost
function”, page 312 .
Important
• Bracket remains installed after being released.
– Press bracket for power contactor with boost function -1-
upwards on right side until you can reach in with your hand.

– Move high-voltage wire -3- clear at bracket.

– Release fasteners -arrows- and move high-voltage wire -4-
clear.
– Unplug high-voltage connector -2- ⇒ Motor; Rep. gr. 93;
High-voltage wires; Unplugging high-voltage connectors.
Installing
Installation is carried out in reverse order; note the following:
– Perform a potential equalisation measurement on the high-
voltage components affected after installation of high-voltage
components or potential equalisation lines ⇒ Rep. gr. 93;
Potential equalisation measurement.

9.6 Unplugging high-voltage connectors

Important
• High-voltage wiring harness must be renewed if a high-volt‐
age connector is damaged.

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5-pin high-voltage connector with one-stage release mechanism

– Pull out connector locking element -1- -arrow A-.

– Press connector locking mechanism in direction of -arrow B-

and, at the same time, unplug high-voltage connector -2-.
8-pin high-voltage connector with one-stage release mechanism
– Release connector locking mechanism -1- to side -arrow A-.

– Press catch -2- in direction of -arrow B- and, at the same

time, unplug high-voltage connector.
4-pin high-voltage connector with one-stage release mechanism
– Release connector locking mechanism -1- to side -arrow A-.

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– Press catch -2- in direction of -arrow B- and, at the same

time, unplug high-voltage connector.
2-pin high-voltage connector with two-stage release mechanism
– Pull out connector locking element -3- -arrow A-.

– Press release catch -4- in direction of -arrow B- and pull

high-voltage connector -1- approx. 5 mm to next release
level.
– Press release catch -5- in direction of -arrow D- and pull
connector off connector mounting -2- -arrow C-.
4-pin high-voltage connector (small version) with two-stage re‐
lease mechanism
– Press down and pull out fastener -arrow A- and pull connec‐
tor locking mechanism -1- out as far as stop -arrow B-.

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– Press fastener in direction of -arrow C- and unplug high-volt‐

age connector.
3-pin high-voltage connector (large version) with two-stage re‐
lease mechanism
– Press down and pull out fastener -arrow A- and pull connec‐
tor locking mechanism -1- out as far as stop -arrow B-.

– Press fastener in direction of -arrow C- and unplug high-volt‐

age connector.
4-pin high-voltage connector with bracket
– Remove bolts -arrows-.

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– Unplug high-voltage connector -1-.

4-pin high-voltage connector without bracket
– Remove bolts -1-.

– Unplug high-voltage connector -2-.

All vehicles (continued)
Tightening torques
♦ ⇒ Motor; Rep. gr. 93; High-voltage wires; Overview of fitting
locations - high-voltage wires

9.7 Removing and installing high-voltage

wire for high-voltage heater
Removing
– Remove luggage compartment pan (front) ⇒ General body
repairs, interior; Rep. gr. 70; Luggage compartment trim
panels; Removing and installing luggage compartment pan
(front).

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DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) de-energise the high-voltage system.

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

energising high-voltage system; De-energising high-voltage
system.
Left-hand drive vehicles
– Remove battery ⇒ Electrical system; Rep. gr. 27; Battery;
Removing and installing battery.
All vehicles (continued)
– Remove bolt -arrow-.

– Move potential equalisation line -3- clear.

– Unplug high-voltage connectors -1-, -4- ⇒ Electric drive mo‐
tor 0EG; Rep. gr. 93; High-voltage wires; Unplugging high-
voltage connectors.
– Guide high-voltage wire -2- out forwards.
Installing
Installation is carried out in reverse order; note the following:
– Perform a potential equalisation measurement on the high-
voltage components affected after installation of high-voltage
components or potential equalisation lines ⇒ Rep. gr. 93;
Potential equalisation measurement.

WARNING
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) re-energise the high-voltage system.

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

energising high-voltage system; Re-energising high-voltage
system.

9.8 Removing and installing high-voltage

wire for charging unit 1 for high-voltage
battery
Removing

DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) de-energise the high-voltage system.

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

energising high-voltage system; De-energising high-voltage
system.
– Remove high-voltage heater (linear) -Z189- and move to
side with coolant hoses connected ⇒ Heating, ventilation, air
conditioning system ; Rep. gr. 87; Coolant circuit; Removing
and installing high-voltage heater (linear) Z189.
– Remove plenum chamber partition panel ⇒ General body
repairs, exterior; Rep. gr. 50; Bulkhead; Removing and in‐
stalling plenum chamber partition panel.
– Unplug high-voltage connectors -2-, -3- ⇒ Motor; Rep.
gr. 93; High-voltage wires; Unplugging high-voltage connec‐
tors.

– Guide high-voltage wire -1- out forwards.

Installing
Installation is carried out in reverse order; note the following:
– Perform a potential equalisation measurement on the high-
voltage components affected after installation of high-voltage
components or potential equalisation lines ⇒ Rep. gr. 93;
Potential equalisation measurement.

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WARNING
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) re-energise the high-voltage system.

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

energising high-voltage system; Re-energising high-voltage
system.

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10 De-energising high-voltage system

10.1 De-energising high-voltage system

Special tools and workshop equipment required
♦ padlock -T40262/1-

DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) de-energise the high-voltage system.

– De-energise high-voltage system using ⇒ Vehicle diagnostic

tester.
– Select and start “ODIS-Service” mode.
– Select “Special functions” tab and select following options
one after the other:
♦ High-voltage
♦ 0051 - High-voltage power disconnect
– If the contact protection on high-voltage components is re‐
moved, you will be prompted to perform a redundant voltage
measurement while running the programme.
– You will be requested to unplug maintenance connector for
high-voltage system TW while running through programme.
Important
• The maintenance connector for high-voltage system -TW-
is an electrical bridge between the contactors and the high-
voltage battery -AX2- and is always unplugged if the high-
voltage system needs to be de-energised.
• Fitting location: in motor compartment (front left) next to
electronics box in front of plenum chamber.
– Remove plenum chamber cover (front) ⇒ General body re‐
pairs, exterior; Rep. gr. 50; Bulkhead; Removing and instal‐
ling plenum chamber cover.
– Pull securing clip -2- out of connector housing.

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– Press release mechanism down and pull out maintenance

connector for high-voltage system -TW- -1- as far as stop.
– Secure maintenance connector for high-voltage system -
TW- -1- with padlock -T40262/1-.

Important
• When the maintenance connector for high-voltage system
-TW- is unplugged, the link to the contactors is disconnected
and the remaining voltage in the high-voltage system dissi‐
pates. At this point, the system is de-energised.

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11 Re-energising high-voltage system

11.1 Re-energising high-voltage system

Special tools and workshop equipment required
♦ padlock -T40262/1-

WARNING
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) re-energise the high-voltage system.

– Re-energise high-voltage system using ⇒ Vehicle diagnostic

tester.
– Select and start “ODIS-Service” mode.
– Select “Special functions” tab and select following options
one after the other:
♦ High Voltage
♦ 0051 - High-volt restart
– You will be requested to plug in maintenance connector for
high-voltage system TW while running through program.
– Remove padlock -T40262/1- from maintenance connector
for high-voltage system -TW- -1-.

– Release retainer -3- with a small screwdriver -arrow A-.

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– Press down release mechanism -2- -arrow B- and push

maintenance connector for high-voltage system -TW- -1- in
until it engages -arrow C-.

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12 Potential equalisation lines

12.1 General notes - potential equalisation

lines
♦ The contact surfaces of the potential equalisation lines must
be checked prior to installation.
♦ The contact surfaces must be clean and free of corrosion
and grease.
♦ If this is not the case, clean the contact surfaces using the
contact surface cleaning set -VAS 6410- ⇒ Electrical system;
Rep. gr. 97; Cleaning contact surfaces.

12.2 Potential equalisation measurement

A potential equalisation measurement must be performed on
the high-voltage components affected after installation of high-
voltage components or potential equalisation lines.
Important
• 12 V and high-voltage connections not yet connected to
high-voltage components.
• Potential equalisation line installed correctly and connected
to high-voltage components.
Procedure
– Use ⇒ Vehicle diagnostic tester to perform potential equali‐
sation measurement:
– Select and start “ODIS-Service” mode.
– Select “Special functions” tab and select following options
one after the other:
♦ High Voltage
♦ Potential equalisation measurement on high-voltage compo‐
nents

12.3 Overview of fitting locations - potential

equalisation lines

12.3.1 Overview of fitting locations - potential equalisation lines (front)

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1 - Potential equalisation line

for charging unit 1 for high-
voltage battery -AX4-
2 - Nut
❑ 8 Nm
3 - Potential equalisation line
for electrical air conditioner
compressor -V470-
4 - Bolt
❑ 8 Nm
5 - Nut
❑ 20 Nm
6 - Nut
❑ 20 Nm
7 - Nut
❑ 20 Nm
8 - Potential equalisation line
to vehicle body
9 - Bolt
❑ 8 Nm
10 - Bolt
❑ 8 Nm
11 - Nut
❑ 9.5 Nm
12 - Potential equalisation line
for high-voltage battery charg‐
ing socket 1 -UX4-
13 - Bolt
❑ 20 Nm
14 - Potential equalisation line
❑ For voltage converter for 800 V, 400 V, 48 V, 12 V -A48- and power contactor with boost function
-J1178-
15 - Bolt
❑ 20 Nm
16 - Potential equalisation line for high-voltage battery charging socket 2 -UX5-
17 - Nut
❑ 9.5 Nm
18 - Wiring harness with potential equalisation line
19 - Bracket for power contactor with boost function
20 - Bolt
❑ 8 Nm
21 - Nut
❑ 20 Nm
22 - Wiring harness with potential equalisation line
23 - Nut
❑ 8 Nm

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24 - Potential equalisation line for electric drive control unit for front axle -J1234-
25 - Nut
❑ 8 Nm
26 - Nut
❑ 8 Nm
27 - Potential equalisation line for high-voltage heater (linear) -Z189-
28 - Bolt
❑ On charging unit 1 for high-voltage battery -AX4-
❑ 20 Nm

12.3.2 Overview of fitting locations - potential equalisation lines (rear)

Overview of fitting locations - potential equalisation lines (rear)

1 - Nut
❑ 8 Nm
2 - Potential equalisation line
for high-voltage battery 1 -
AX2-
3 - Nut
❑ 8 Nm
4 - Nut
❑ 8 Nm
5 - Potential equalisation line
❑ For electric drive con‐
trol unit for rear axle -
J1235-
6 - Bolt
❑ 20 Nm

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13 Charging socket

13.1 Exploded view - charging socket, left-

hand drive vehicles

13.1.1 Assembly overview - charging socket

1 - Nut
❑ Tightening torque
⇒ Rep. gr. 93; Over‐
view of fitting locations
- potential equalisation
lines
2 - High-voltage battery
charging socket 1 -UX4-
❑ Depending on vehicle
equipment
❑ ⇒ Rep. gr. 93; Remov‐
ing and installing high-
voltage battery charg‐
ing socket 1 UX4
3 - Nut
❑ 2x
❑ 8 Nm
4 - Mounting for high-voltage
battery charging socket
5 - Bolt
❑ 4x
❑ 9 Nm
6 - Bolt
❑ 4.5 Nm
7 - Manual release cable
8 - Actuator for high-voltage
charging socket lock 1 -F498-
❑ ⇒ a13.11.1 nd instal‐
ling actuator for high-
voltage charging socket
lock F498”, page 287
9 - Bolt
❑ 2x
❑ 1.5 Nm

13.2 Exploded view - charging socket, right-

hand drive vehicles

13.2.1 Assembly overview - charging socket

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1 - Bolt
❑ 2x
❑ 1.5 Nm
2 - Actuator for high-voltage
charging socket lock 1 -F498-
❑ ⇒ a13.11.1 nd instal‐
ling actuator for high-
voltage charging socket
lock F498”, page 287
3 - Manual release cable
4 - High-voltage battery
charging socket 1 -UX4-
❑ Depending on vehicle
equipment
❑ ⇒ Rep. gr. 93; Remov‐
ing and installing high-
voltage battery charg‐
ing socket 1 UX4
5 - Mounting for high-voltage
battery charging socket
6 - Bolt
❑ 4.5 Nm
7 - Bolt
❑ 4x
❑ 9 Nm
8 - Nut
❑ 2x
❑ 8 Nm
9 - Nut
❑ Tightening torque
⇒ Rep. gr. 93; Over‐
view of fitting locations
- potential equalisation lines

13.3 Exploded view - charging socket 2, left-

hand drive vehicles

13.3.1 Assembly overview - charging socket 2

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1 - Bolt
❑ 2x
❑ 1.5 Nm
2 - Actuator for high-voltage
charging socket lock 2 -F499-
❑ ⇒ a13.11.2 nd instal‐
ling actuator for high-
voltage charging socket
lock F499”, page 290
3 - Manual release cable
4 - High-voltage battery
charging socket 2 -UX5-
❑ ⇒ Rep. gr. 93; Remov‐
ing and installing high-
voltage battery charg‐
ing socket 2 UX5
5 - Bolt
❑ 4.5 Nm
6 - Bolt
❑ 4x
❑ 9 Nm
7 - Mounting for high-voltage
battery charging socket
8 - Nut
❑ 2x
❑ 8 Nm
9 - Nut
❑ Tightening torque
⇒ Rep. gr. 93; Over‐
view of fitting locations
- potential equalisation
lines

13.4 Exploded view - charging socket 2,

right-hand drive vehicles

13.4.1 Assembly overview - charging socket 2

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1 - Nut
❑ Tightening torque
⇒ Rep. gr. 93; Over‐
view of fitting locations
- potential equalisation
lines
2 - Nut
❑ 2x
❑ 8 Nm
3 - Mounting for high-voltage
battery charging socket
4 - Bolt
❑ 4x
❑ 9 Nm
5 - Bolt
❑ 4.5 Nm
6 - High-voltage battery
charging socket 2 -UX5-
❑ ⇒ Rep. gr. 93; Remov‐
ing and installing high-
voltage battery charg‐
ing socket 2 UX5
7 - Manual release cable
8 - Bolt
❑ 2x
❑ 1.5 Nm
9 - Actuator for high-voltage
charging socket lock 2 -F499-
❑ ⇒ a13.11.2 nd instal‐
ling actuator for high-
voltage charging socket
lock F499”, page 290

13.5 Removing and installing high-voltage

battery charging socket 1 UX4 - left-
hand drive vehicles

13.5.1 Removing and installing high-voltage

battery charging socket 1 UX4
Removing

DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) de-energise the high-voltage system.

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

energising high-voltage system; De-energising high-voltage
system.
– Switch off ignition. Deposit vehicle key and other drive au‐
thorisation systems (e.g. smartphone) outside vehicle.
– Remove plenum chamber cover ⇒ General body repairs,
exterior; Rep. gr. 50; Bulkhead; Removing and installing ple‐
num chamber cover.
– Remove body brace ⇒ Running gear, axles, steering; Rep.
gr. 40; Suspension strut, upper links; Removing and instal‐
ling body brace.
– Remove fresh air intake ⇒ Heating, ventilation, air condition‐
ing system; Rep. gr. 87; Air duct system; Removing and
installing fresh air intake.
– Remove body brace (front) ⇒ Running gear, axles, steering;
Rep. gr. 40; Suspension strut, upper links; Removing and
installing body brace (front).
– Remove battery ⇒ Electrical system; Rep. gr. 27; Battery;
Removing and installing battery.
– Remove bolt -arrow- and move potential equalisation line -1-
clear.

– Take connector housing -3- out of mounting -arrow-.

– Unplug electrical connectors -1-, -2-, -4-.

– Move wiring harness clear.
– To avoid malfunctions caused by interchanging electrical
connectors, mark connectors before unplugging them.

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– Unplug electrical connectors -1-, -2-.

– Move wiring harness clear.
– Unscrew nut -5-.
– Release fasteners -arrow A- and detach electronics box in
luggage compartment (front) -4- from brackets -arrow B-.
– Unplug high-voltage connectors -1-, -5- ⇒ Motor; Rep.
gr. 93; High-voltage wires; Unplugging high-voltage connec‐
tors.

– Move high-voltage wires -4- clear.

– Remove wheel housing liner ⇒ General body repairs, exteri‐
or; Rep. gr. 66; Wheel housing liners; Exploded view - wheel
housing liner (front).
– Remove charging flap unit ⇒ General body repairs, exteri‐
or; Rep. gr. 55; Charging flap unit; Removing and installing
charging flap unit.
– Remove nut -arrow- and move potential equalisation lines
-1- clear.

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– Unplug electrical connector -3-.

– Move connector housing -2- and wiring harness clear.
– Mark fitting location of bolts on mounting for charging socket
for re-installation.

– Remove bolts -arrows-.

– Move charging socket -1- clear at mounting -2-.
– Move manual release cable -4- for charging socket clear at
control motor -3-.
– Move high-voltage wires -5-, -6- clear.
– Guide out charging socket; at the same time, guide high-
voltage wire by hand.
Installing
Installation is carried out in reverse order; note the following:
– Perform a potential equalisation measurement on the high-
voltage components affected after installation of high-voltage
components or potential equalisation lines ⇒ Rep. gr. 93;
Potential equalisation measurement.

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WARNING
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) re-energise the high-voltage system.

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

energising high-voltage system; Re-energising high-voltage
system.
Tightening torques
♦ ⇒ Motor; Rep. gr. 93; Charging socket; Exploded view -
charging socket
♦ ⇒ Motor; Rep. gr. 93; Potential equalisation lines; Overview
of fitting locations - potential equalisation lines
♦ ⇒ Electrical system; Rep. gr. 97; Relay carriers, fuse carri‐
ers, electronics boxes; Exploded view - relay carriers, fuse
carriers, electronics boxes

13.6 Removing and installing high-voltage

battery charging socket 1 UX4 - right-
hand drive vehicles

13.6.1 Removing and installing high-voltage

battery charging socket 1 UX4
Removing

DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) de-energise the high-voltage system.

– De-energise high-voltage system ⇒ Rep. gr. 93; De-energis‐

ing high-voltage system.
– Switch off ignition. Deposit vehicle key and other drive au‐
thorisation systems (e.g. smartphone) outside vehicle.
– Remove plenum chamber cover ⇒ General body repairs,
exterior; Rep. gr. 50; Bulkhead; Removing and installing ple‐
num chamber cover.
– Remove body brace ⇒ Running gear, axles, steering; Rep.
gr. 40; Suspension strut, upper links; Removing and instal‐
ling body brace.
– Remove fresh air intake ⇒ Heating, ventilation, air condition‐
ing system; Rep. gr. 87; Air duct system; Removing and
installing fresh air intake.
– Remove body brace (front) ⇒ Running gear, axles, steering;
Rep. gr. 40; Suspension strut, upper links; Removing and
installing body brace (front).
– Remove battery ⇒ Electrical system; Rep. gr. 27; Battery;
Removing and installing battery.

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– Take connector housing -3- out of mounting -arrow-.

– Unplug electrical connectors -1-, -2-, -4-.

– Release catch -2- -arrow- and push maintenance connector
for high-voltage system -TW- -1- downwards out of mount‐
ing.

– Take connector housing -1- out of bracket -2- and unplug

electrical connector -3-.

– Release securing clip -2- -arrows A- and remove it.

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– Release fasteners -arrows B- and detach bracket -1-.

– Unplug electrical connector -3-.
– Move wiring harness clear.
– Remove high-voltage heater and move to side with coolant
hoses connected ⇒ Heating, ventilation, air conditioning sys‐
tem ; Rep. gr. 87; Coolant circuit; Removing and installing
high-voltage heater (linear) Z189.
– Unplug high-voltage connectors -1-, -3- ⇒ Rep. gr. 93; Un‐
plugging high-voltage connectors.

– Move high-voltage wires -2-, -4- clear.

– Remove wheel housing liner ⇒ General body repairs, exteri‐
or; Rep. gr. 66; Wheel housing liners; Assembly overview -
wheel housing liner (front).
– Remove charging flap unit ⇒ General body repairs, exteri‐
or; Rep. gr. 55; Charging flap unit; Removing and installing
charging flap unit.
– Remove nut -arrow-.

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– Push bracket -5- with valve unit slightly to one side.

– Move brake lines -3- clear at retainer -4-.
– Move high-voltage wires -1-, -2- clear.
– Remove nut -arrow- and move potential equalisation line -1-
clear.

– Unplug electrical connector -2-.

– Move connector housing -3- and wiring harness clear.
– Mark fitting location of bolts on mounting for charging socket
for re-installation.

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– Remove bolts -arrows-.

– Move charging socket -6- clear at mounting -3-.
– Move manual release cable -4- for charging socket clear at
control motor -5-.
– Move high-voltage wires -1-, -2- clear.
– Guide out charging socket; at the same time, guide high-
voltage wires by hand.
Installing
Installation is carried out in reverse order; note the following:
– Perform a potential equalisation measurement on the high-
voltage components affected after installation of high-voltage
components or potential equalisation lines ⇒ Rep. gr. 93;
Potential equalisation measurement.

WARNING
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) re-energise the high-voltage system.

– Re-energise high-voltage system ⇒ Rep. gr. 93; Re-energis‐

ing high-voltage system.
Tightening torques
♦ ⇒ Rep. gr. 93; Assembly overview - charging socket, right-
hand drive vehicles
♦ ⇒ Rep. gr. 93; Overview of fitting locations - potential equali‐
sation lines

13. Charging socket 279

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13.7 Removing and installing high-voltage

battery charging socket 2 UX5 - left-
hand drive vehicles

13.7.1 Removing and installing high-voltage

battery charging socket 2 UX5
Removing

DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) de-energise the high-voltage system.

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

energising high-voltage system; De-energising high-voltage
system.
– Remove windscreen wiper motor ⇒ Electrical system; Rep.
gr. 92; Windscreen wiper system; Removing and installing
windscreen wiper motor Vxx.
– Remove bracket for power contactor with boost function ⇒
a15.4 nd installing bracket for power contactor with boost
function”, page 312 .
– Remove heat exchanger for high-voltage battery ⇒ Heating,
ventilation, air conditioning system; Rep. gr. 87; Refrigerant
circuit; Removing and installing heat exchanger for high-volt‐
age battery.
– Unfasten hose clips -1-, -4- and detach coolant hoses.

– Release fastener -3- and detach coolant line -2- from brack‐
et.
– Remove bolts -arrows-.

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– Move refrigerant line -2- clear at retainer -1-.

– Move refrigerant line clear with wire guide -3-.
– Move brake lines -2- clear at retainer -1-.

– Move high-voltage wire -3- clear.

– Remove wheel housing liner ⇒ General body repairs, exteri‐
or; Rep. gr. 66; Wheel housing liners; Exploded view - wheel
housing liner (front).
– Remove charging flap unit ⇒ General body repairs, exteri‐
or; Rep. gr. 55; Charging flap unit; Removing and installing
charging flap unit.
– Remove nut -arrow- and move potential equalisation line -1-
clear.

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– Unplug electrical connector -2-.

– Move connector housing -3- and wiring harness clear.
– Mark fitting location of bolts on mounting for charging socket
for re-installation.

– Remove bolts -arrows-.

– Move charging socket -5- clear at mounting -4-.
– Move manual release cable -2- for charging socket clear at
control motor -3-.
– Move high-voltage wire -1- clear.
– Guide out charging socket; at the same time, guide high-
voltage wire by hand.
Installing
Installation is carried out in reverse order; note the following:
– Perform a potential equalisation measurement on the high-
voltage components affected after installation of high-voltage
components or potential equalisation lines ⇒ Rep. gr. 93;
Potential equalisation measurement.
Tightening torques
♦ ⇒ Motor; Rep. gr. 93; Charging socket; Exploded view -
charging socket 2
♦ ⇒ Motor; Rep. gr. 93; Potential equalisation lines; Overview
of fitting locations - potential equalisation lines

13.8 Removing and installing high-voltage

battery charging socket 2 UX5 - right-
hand drive vehicles

13.8.1 Removing and installing high-voltage

battery charging socket 2 UX5
Removing
– Remove windscreen wiper motor ⇒ Electrical system; Rep.
gr. 92; Windscreen wiper system; Removing and installing
windscreen wiper motor Vxx.

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– Remove bracket for power contactor with boost function ⇒

a15.4 nd installing bracket for power contactor with boost
function”, page 312 .
– Remove refrigerant lines with internal heat exchanger
⇒ Heating, air conditioning; Rep. gr. 87; Refrigerant circuit;
Removing and installing refrigerant lines with internal heat
exchanger.
– Remove wheel housing liner ⇒ General body repairs, exteri‐
or; Rep. gr. 66; Wheel housing liners; Exploded view - wheel
housing liner (front).
– Remove charging flap unit ⇒ General body repairs, exteri‐
or; Rep. gr. 55; Charging flap unit; Removing and installing
charging flap unit.
– Remove nut -arrow- and move potential equalisation lines
-1- clear.

– Unplug electrical connector -3-.

– Move connector housing -2- and wiring harness clear.
– Mark fitting location of bolts on mounting for charging socket
for re-installation.

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– Remove bolts -arrows-.

– Move charging socket -1- clear at mounting -2-.
– Move manual release cable -4- for charging socket clear at
control motor -3-.
– Move high-voltage wire -5- clear.
– Guide out charging socket; at the same time, guide high-
voltage wire by hand.
Installing
Installation is carried out in reverse order; note the following:
– Perform a potential equalisation measurement on the high-
voltage components affected after installation of high-voltage
components or potential equalisation lines ⇒ Rep. gr. 93;
Potential equalisation measurement.
Tightening torques
♦ ⇒ Rep. gr. 93; Exploded view - charging socket 2, right-hand
drive vehicles
♦ ⇒ Rep. gr. 93; Overview of fitting locations - potential equali‐
sation lines

13.9 e-tron charging system

The e-tron charging system comprises the following compo‐
nents:

-1- = Charging cable with connector for industrial power sock‐

ets: charging cable for high-voltage charging system, mains
connection -P88-
-2- = Charging cable with connector for domestic power sock‐
ets: charging cable for high-voltage charging system, mains
connection -P88-
-3- = Operating unit for high-voltage charging system -E943-
Operating unit: universal charging cable, basic (PR no. NW1)
(compact)
Operating unit: universal charging cable, high (PR no. NW2)
(connect)
-4- = Charging cable with vehicle connector

13.10 Diagnosis of e-tron charging system

Special tools and workshop equipment required
♦ Diagnosis adapter for high-voltage charge system -VAS 611
009-
♦ vehicle diagnostic tester

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Procedure
♦ On the e-tron compact and connect charging systems, it is
possible to perform independent diagnosis with ODIS Serv‐
ice using the diagnostic adapter -VAS 611 009-, i.e. without
performing in-car diagnosis.
♦ As the e-tron compact and connect charging systems are
external components, it is not possible to read out the vehi‐
cle identification number (VIN) when performing diagnosis;
there are therefore a few particular points which must be
noted.
♦ The steps described below should be followed when starting
diagnosis of the e-tron compact and connect charging sys‐
tems.

– Disconnect operating unit for high-voltage charging system

-E943- from power outlet.
– Disconnect charging cable (vehicle end).
– Connect diagnostic adapter for high-voltage charging system
-VAS 611 009- -item 1- between charging cable for high-
voltage charging system, mains connection -P88- -item 2-
and operating unit for high-voltage charging system -E943-
-item 3-.

– Connect vehicle diagnostic tester to diagnostic adapter for

high-voltage charging system -VAS 611 009-.
– Connect diagnostic adapter for high-voltage charging system
-VAS 611 009- to power outlet.
– Switch on operating unit for high-voltage charging system
-E943-.
Depending on the ODIS version, it may be necessary to enter
AUDILADEKABELMINI for PR no. NW1 or AUDILADEKABEL‐
MAXI for PR no. NW2 instead of the vehicle identification num‐
ber when the program is started.
– Select ODIS Service and start Diagnosis mode.

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Indicated on display:
1- VIN not found. Check ignition/diagnostic interface
2- Press Continue button.
Indicated on display:
1- An error occurred during automatic identification of the
vehicle. Please identify the vehicle manually.
2- Press OK button.
– In the “Vehicle identification” line:

1- Activate “manual”
– In the “VIN” line, enter the following:
2 - “AUDILADEKABELMINI for PR no. NW1”
– If the brand is not already present in the “Manufacturer” line,
select “Audi”.
– In the “Model” line, enter the following:
3 - “All external components”
– “Model year”, “Version”, “Engine” lines can be disregarded.
– Check the “Work with Guided Fault Finding” line:
4 - must be activated
– To continue to the next step:
5 - Press Apply.

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– If possible, enter vehicle identification number -arrow- of ve‐

hicle with which customer is using affected e-tron compact
or connect charging system.

– Work through test programs entered in test plan.

13.11 Removing and installing actuator for

high-voltage charging socket lock

13.11.1 Removing and installing actuator for

high-voltage charging socket lock F498
Special tools and workshop equipment required
♦ Cable loom repair set -VAS 1978B-
♦ Hot air blower -VAS 1978/14A-
Removing

DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) de-energise the high-voltage system.

– De-energise high-voltage system ⇒ Rep. gr. 93; De-energis‐

ing high-voltage system.
– Switch off ignition. Deposit vehicle key and other drive au‐
thorisation systems (e.g. smartphone) outside vehicle.
– Remove front wheel housing liner ⇒ General body repairs,
exterior; Rep. gr. 66; Wheel housing liners; Assembly over‐
view - front wheel housing liner.
– Remove charging flap unit ⇒ General body repairs, exteri‐
or; Rep. gr. 55; Charging flap unit; Removing and installing
charging flap unit.
– Remove nut -arrow- and move potential equalisation lines
-1- clear.

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– Unplug electrical connector -3-.

– Move connector housing -2- and wiring harness clear.
Left-hand drive vehicles
– Mark fitting location of bolts on mounting for charging socket
for re-installation.

– Remove bolts -arrows-.

– Move charging socket -1- clear at mounting -2-.
– Move manual release cable -4- for charging socket clear at
control motor -3-.
– Move high-voltage wires -5-, -6- clear.
– Take charging socket out of mounting.
Right-hand drive vehicles
– Mark fitting location of bolts on mounting for charging socket
for re-installation.

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– Remove bolts -arrows-.

– Move charging socket -1- clear at mounting -2-.
– Move manual release cable -4- for charging socket clear at
control motor -3-.
– Move high-voltage wire -5- clear.
– Take charging socket out of mounting.
All vehicles (continued)
– Remove bolts -1, 3-.

– Detach actuator -2-.

– Cut through wiring harness 20 mm from actuator -arrow-.
Installing
Installation is carried out in reverse order; note the following:
– Connect new actuator to vehicle wiring harness according
to up-to-date current flow diagram ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
– Shorten wires at new actuator to 90 mm.
– Strip ends of wires on vehicle wiring harness and actuator.
– Connect suitable crimp connector from wiring harness repair
set -VAS 1978B- to ends of wires so that they are offset from
each other ⇒ Electrical system; General information; Rep.

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gr. 97; Repairing wiring harnesses and connectors; Repair‐

ing wiring harnesses.
– Guide crimping pliers from wiring harness repair set -VAS
1978B- upwards through wheel housing from below and fas‐
ten crimp connector.
– Heat up crimp connector using hot air blower -VAS
1978/14A- until it is completely sealed and adhesive emerg‐
es at ends.

WARNING
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) re-energise the high-voltage system.

– Re-energise high-voltage system ⇒ Rep. gr. 93; Re-energis‐

ing high-voltage system.
Tightening torques
♦ ⇒ Motor; Rep. gr. 93; Charging socket; Assembly overview -
charging socket 2

13.11.2 Removing and installing actuator for

high-voltage charging socket lock F499
Special tools and workshop equipment required
♦ Cable loom repair set -VAS 1978B-
♦ Hot air blower -VAS 1978/14A-
Removing

DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) de-energise the high-voltage system.

– De-energise high-voltage system ⇒ Rep. gr. 93; De-energis‐

ing high-voltage system.
– Switch off ignition. Deposit vehicle key and other drive au‐
thorisation systems (e.g. smartphone) outside vehicle.
– Remove front wheel housing liner ⇒ General body repairs,
exterior; Rep. gr. 66; Wheel housing liners; Assembly over‐
view - front wheel housing liner.
– Remove charging flap unit ⇒ General body repairs, exteri‐
or; Rep. gr. 55; Charging flap unit; Removing and installing
charging flap unit.
– Remove nut -arrow- and move potential equalisation line -1-
clear.

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– Unplug electrical connector -2-.

– Move connector housing -3- and wiring harness clear.
Left-hand drive vehicles
– Mark fitting location of bolts on mounting for charging socket
for re-installation.

– Move charging socket -5- clear at mounting -4-.

– Move manual release cable -2- for charging socket clear at
control motor -3-.
– Move high-voltage wire -1- clear.
– Take charging socket out of mounting.
Right-hand drive vehicles
– Mark fitting location of bolts on mounting for charging socket
for re-installation.

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– Move charging socket -6- clear at mounting -3-.

– Move manual release cable -4- for charging socket clear at
control motor -5-.
– Move high-voltage wires -1-, -2- clear.
– Take charging socket out of mounting.
All vehicles (continued)
– Remove bolts -1, 3-.

– Detach actuator -2-.

– Cut through wiring harness approx. 20 mm from actuator
-arrow-.
Installing
Installation is carried out in reverse order; note the following:
– Connect new actuator to vehicle wiring harness according
to up-to-date current flow diagram ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
– Shorten wire at new actuator to approx. 90 mm.
– Strip ends of wires on vehicle wiring harness and actuator.
– Connect suitable crimp connector from wiring harness repair
set -VAS 1978B- to ends of wires so that they are offset from
each other ⇒ Electrical system; General information; Rep.
gr. 97; Repairing wiring harnesses and connectors; Repair‐
ing wiring harnesses.

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– Guide crimping pliers from wiring harness repair set -VAS

1978B- upwards through wheel housing from below and fas‐
ten crimp connector.
– Heat up crimp connector using hot air blower -VAS
1978/14A- until it is completely sealed and adhesive emerg‐
es at ends.

WARNING
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) re-energise the high-voltage system.

– Re-energise high-voltage system ⇒ Rep. gr. 93; Re-energis‐

ing high-voltage system.
Tightening torques
♦ ⇒ Motor; Rep. gr. 93; Charging socket; Assembly overview -
charging socket

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14 Charging unit for high-voltage bat‐

tery

14.1 Exploded view - charging unit 1 for high-voltage battery

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1 - Potential equalisation line

2 - Bolt
❑ Tightening torque
⇒ Rep. gr. 93; Over‐
view of fitting locations
- potential equalisation
lines
3 - Nut
❑ 2x
❑ 8 Nm
4 - Bolt
❑ 2x
❑ 8 Nm
5 - Bracket (right)
6 - Charging flap unit (right-
side)
7 - Module for battery charge
selector buttons -EX32-
❑ With LED module for
charging socket 1 -
L263-
❑ ⇒ a14.4 nd installing
charging process dis‐
play unit”, page 298
8 - Bolt
❑ 2x
❑ 1.5 Nm
9 - Front cross member
10 - Bolt
❑ 2x
❑ 1.5 Nm
11 - Module 2 for battery charge selector buttons -EX40-
❑ With LED module for charging socket 2 -L264-
❑ ⇒ a14.4 nd installing charging process display unit”, page 298
12 - Charging flap unit (left-side)
13 - Bolt
❑ 2x
❑ 8 Nm
14 - Nut
❑ 2x
❑ 8 Nm
15 - Bracket (left)
16 - Charging unit 1 for high-voltage battery -AX4-
❑ With control unit for high-voltage battery charging unit -J1050-
❑ ⇒ Rep. gr. 93; Removing and installing charging unit 1 for high-voltage battery AX4
17 - Coolant hose
❑ Connection “G”
18 - Coolant hose

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❑ Connection “F”

14.2 Removing and installing charging unit

1 for high-voltage battery AX4
Removing
If control unit is renewed, test plan for renewal of control unit
must be performed:
– Perform “Replace control module” function with ⇒ Vehicle
diagnostic tester ⇒ Rep. gr. 00; Starting diagnosis.
Continued

DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) de-energise the high-voltage system.

– De-energise high-voltage system ⇒ Rep. gr. 93; De-energis‐

ing high-voltage system.
– Remove high-voltage heater (linear) -Z189- ⇒ Heating, venti‐
lation, air conditioning system ; Rep. gr. 87; Coolant circuit;
Removing and installing high-voltage heater (linear) Z189.
– Unplug high-voltage connectors -3-, -4- ⇒ Motor; Rep.
gr. 93; High-voltage wires; Unplugging high-voltage connec‐
tors.

– Move high-voltage wire -5- clear.

– Remove bolt -arrow- and move potential equalisation line -1-
clear.
– Unplug electrical connector -2-.
– Move electrical wiring harness -2- clear.

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– Lift retaining clips -1- and disconnect coolant hoses.

– Remove charging unit 1 for high-voltage battery -AX4- -3-.
Installing
Installation is carried out in reverse order; note the following:
– A potential equalisation measurement must be performed
on the high-voltage components affected after installation
of high-voltage components or potential equalisation lines
⇒ Rep. gr. 93; Potential equalisation measurement.
– First plug high-voltage connectors -3-, -4- into charging unit
1 for high-voltage battery -AX4- (already installed) ⇒ Motor;
Rep. gr. 93; High-voltage wires; Unplugging high-voltage
connectors.

– Then plug in electrical connector -2-.

WARNING
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) re-energise the high-voltage system.

– Re-energise high-voltage system ⇒ Rep. gr. 93; Re-energis‐

ing high-voltage system.
Tightening torques
♦ ⇒ Motor; Rep. gr. 93; Charging unit for high-voltage battery;
Assembly overview - charging unit for high-voltage battery

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14.3 Removing and installing bracket for

charging unit for high-voltage battery
Removing
– Remove charging unit 1 for high-voltage battery -AX4- ⇒ Mo‐
tor; Rep. gr. 93; Charging unit for high-voltage battery; Re‐
moving and installing charging unit 1 for high-voltage battery
AX4.
– Remove bolts -arrows-.

– Remove brackets -1-, -3- on charging unit -2-.

Installing
Installation is carried out in reverse sequence.
Tightening torques
♦ ⇒ Motor; Rep. gr. 93; Charging unit for high-voltage battery;
Exploded view - charging unit for high-voltage battery

14.4 Removing and installing charging proc‐

ess display unit
Removing
– Remove charging flap unit ⇒ General body repairs, exteri‐
or; Rep. gr. 55; Charging flap unit; Removing and installing
charging flap unit.
– Remove bolts -arrows-.

– Detach module for battery charge selector buttons -EX32-/

LED module for charging socket 1 -L263- -1-.
Installing
Installation is carried out in reverse sequence.

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Tightening torques
♦ ⇒ Motor; Rep. gr. 93; Charging unit for high-voltage battery;
Exploded view - charging unit for high-voltage battery

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15 Voltage converter

15.1 Exploded view - voltage converter

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1 - Bolt
❑ 2x
❑ 8 Nm
2 - Support bracket (right-
side)
3 - Insulating mat
4 - Bolt
❑ 2x
❑ 8 Nm
5 - Nut
❑ Tightening torque
⇒ Rep. gr. 93; Over‐
view of fitting locations
- potential equalisation
lines
6 - Potential equalisation line
❑ ⇒ Rep. gr. 93; Over‐
view of fitting locations
- potential equalisation
lines
7 - High-voltage wiring har‐
ness
❑ ⇒ Rep. gr. 93; Over‐
view of fitting locations
- high-voltage wires
8 - Bolt
❑ Tightening torque
⇒ Rep. gr. 93; Over‐
view of fitting locations
- potential equalisation
lines
9 - Wiring harness with poten‐
tial equalisation line
❑ ⇒ Rep. gr. 93; Overview of fitting locations - potential equalisation lines
10 - Bolt
❑ 2x
❑ 8 Nm
11 - Bracket
12 - Nut
❑ Tightening torque ⇒ Rep. gr. 93; Overview of fitting locations - potential equalisation lines
13 - Bolt
❑ Tightening torque ⇒ Rep. gr. 93; Overview of fitting locations - potential equalisation lines
14 - Bolt
❑ Tightening torque ⇒ Rep. gr. 93; Overview of fitting locations - potential equalisation lines
15 - Positive wire to 12 V battery
❑ ⇒ Electrical system; Rep. gr. 27; Battery; Exploded view - battery
16 - Potential equalisation line
❑ ⇒ Rep. gr. 93; Overview of fitting locations - potential equalisation lines
17 - Voltage converter for 800 V, 400 V, 48 V, 12 V -A48-
❑ ⇒ Rep. gr. 93; Removing and installing voltage converter

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18 - Coolant lines
19 - Bolt
❑ 4x
❑ 8 Nm
20 - Nut
❑ 2x
❑ 20 Nm
21 - Power contactor with boost function -J1178-
❑ ⇒ a15.3 nd installing power contactor with boost function”, page 306
22 - Bolt
❑ 4x
❑ 8 Nm
23 - Bracket for power contactor with boost function
❑ ⇒ a15.4 nd installing bracket for power contactor with boost function”, page 312
24 - Support bracket (left-side)
25 - Bolt
❑ 2x
❑ 8 Nm
26 - Clip
❑ 4x

15.2 Removing and installing voltage con‐

verter
Removing
If control unit is renewed, test plan for renewal of control unit
must be performed:
– Perform “Replace control module” function with ⇒ Vehicle
diagnostic tester ⇒ Rep. gr. 00; Starting diagnosis.
Continued

DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) de-energise the high-voltage system.

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

energising high-voltage system; De-energising high-voltage
system.
– Drain coolant ⇒ Motor; Rep. gr. 19; Cooling system/coolant;
Draining cooling system.
– Switch off ignition. Deposit vehicle key and other drive au‐
thorisation systems (e.g. smartphone) outside vehicle.
Left-hand drive vehicles
– Disconnect battery ⇒ Electrical system; Rep. gr. 27; Battery;
Disconnecting and connecting battery.

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Right-hand drive vehicles

– Remove battery ⇒ Electrical system; Rep. gr. 27; Battery;
Removing and installing battery.
All vehicles (continued)
– Remove windscreen wiper motor ⇒ Electrical system; Rep.
gr. 92; Windscreen wiper system; Removing and installing
windscreen wiper motor Vxx.
– Remove plenum chamber partition panel ⇒ General body
repairs, exterior; Rep. gr. 50; Bulkhead; Removing and in‐
stalling plenum chamber partition panel.
– Remove strut brace (front) ⇒ Running gear, axles, steering;
Rep. gr. 40; Suspension strut, upper links; Removing and
installing strut brace (front).
Left-hand drive vehicles
– Remove positive terminal cover -1- from positive connection
terminal.

– Release catch -2- and remove positive terminal cover -3-

upwards.
– Remove nut and move positive wire clear.
All vehicles (continued)
– Unplug high-voltage connectors -1-, -5- ⇒ Motor; Rep.
gr. 93; High-voltage wiring; Unplugging high-voltage connec‐
tors.

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– Unplug electrical connector -3- and move wiring harness -4-

clear.
– Remove bolt -arrow- and place potential equalisation line -2-
to one side.
– Place absorbent material underneath to catch escaping cool‐
ant.

– Release hose clips -2- and detach coolant hoses.

– Remove bolts -arrows-.
– Remove voltage converter -1-.
Renewing voltage converter - left-hand drive vehicles
– Release catches -arrows- and lift off cover -1-.

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– Open protective cap -1-.

– Unscrew nut -arrow- and remove positive wire -2-.

– Remove plastic cover from voltage converter housing and
slide onto new voltage converter.
Renewing voltage converter - right-hand drive vehicles
– Release catches -arrows- and lift off cover -1-.

– Open protective cap -2-.

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– Remove nut -arrow-.

– Move positive cable -1- clear and detach.
– Remove plastic cover from voltage converter housing and
slide onto new voltage converter.
All vehicles (continued)
Installing
Installation is carried out in reverse order; note the following:
– Perform a potential equalisation measurement on the high-
voltage components affected after installation of high-voltage
components or potential equalisation lines ⇒ Rep. gr. 93;
Potential equalisation measurement.
– Fill cooling system ⇒ Motor; Rep. gr. 19; Cooling sys‐
tem/coolant; Filling cooling system.

WARNING
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) re-energise the high-voltage system.

– Re-energise high-voltage system ⇒ Rep. gr. 93; Re-energis‐

ing high-voltage system.
Tightening torques
♦ ⇒ Motor; Rep. gr. 93; Voltage converter; Assembly overview
- voltage converter
♦ ⇒ Motor; Rep. gr. 93; Potential equalisation lines; Overview
of fitting locations - potential equalisation lines

15.3 Removing and installing power contac‐

tor with boost function
Removing
If control unit is renewed, test plan for renewal of control unit
must be performed:
– Perform “Replace control module” function with ⇒ Vehicle
diagnostic tester ⇒ Rep. gr. 00; Starting diagnosis.

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Continued

DANGER
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) de-energise the high-voltage system.

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

energising high-voltage system; De-energising high-voltage
system.
– Drain coolant ⇒ Motor; Rep. gr. 19; Cooling system/coolant;
Draining cooling system.
– Switch off ignition. Deposit vehicle key and other drive au‐
thorisation systems (e.g. smartphone) outside vehicle.
Left-hand drive vehicles
– Disconnect battery ⇒ Electrical system; Rep. gr. 27; Battery;
Disconnecting and connecting battery.
Right-hand drive vehicles
– Remove strut brace ⇒ Running gear, axles, steering; Rep.
gr. 40; Suspension strut, upper links; Removing and instal‐
ling strut brace.
– Remove battery ⇒ Electrical system; Rep. gr. 27; Battery;
Removing and installing battery.
All vehicles (continued)
– Remove windscreen wiper motor ⇒ Electrical system; Rep.
gr. 92; Windscreen wiper system; Removing and installing
windscreen wiper motor Vxx.
– Remove plenum chamber partition panel ⇒ General body
repairs, exterior; Rep. gr. 50; Bulkhead; Removing and in‐
stalling plenum chamber partition panel.
– Remove strut brace (front) ⇒ Running gear, axles, steering;
Rep. gr. 40; Suspension strut, upper links; Removing and
installing strut brace (front).
Left-hand drive vehicles
– Remove positive terminal cover -1- from positive connection
terminal.

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– Release catch -2- and remove positive terminal cover -3-

upwards.
– Remove nut and move positive wire clear.
Right-hand drive vehicles
– Release catches -arrows- and lift off cover -1-.

– Open protective cap -2-.

– Remove nut -arrow-.

– Move positive cable -1- clear and detach.

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All vehicles (continued)

– Unplug high-voltage connectors -1-, -5- ⇒ Motor; Rep.
gr. 93; High-voltage wires; Unplugging high-voltage connec‐
tors.

– Unplug electrical connector -3- and move wiring harness -4-

clear.
– Remove nut -6- and bolts -1-, -4-.

– Move potential equalisation lines -2-, -3-, -5- clear.

– Unplug high-voltage connectors -1-, -2-, -3- ⇒ Motor; Rep.
gr. 93; High-voltage wires; Unplugging high-voltage connec‐
tors.

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– Remove bolts -arrows-.

– Disconnect wiring harness.
– Unplug electrical connector -5-.
Right-hand drive vehicles
– Unplug electrical connector -arrow-.

All vehicles (continued)

– Place absorbent material underneath to catch escaping cool‐
ant.

– Release hose clips -2- and detach coolant hoses.

– Lift retaining clips -1- and disconnect coolant hoses.

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– Disconnect high-voltage wiring harness -2- ⇒ Motor; Rep.

gr. 93; High-voltage wires; Unplugging high-voltage connec‐
tors.

– Remove nuts -arrows-.

Important
• Second mechanic required
– Lift out power contactor with boost function -J1178- -1-.
Right-hand drive vehicles
– Tilt power contactor with boost function -J1178- upwards at
rear to lift it out.
Note
Do not attempt to bend brake line to a different shape.
Renewing power contactor with boost function
– Remove bolt -3- and move potential equalisation line -2-
clear.

– Remove bolts -arrows-.

– Lift voltage converter -4- off power contactor with boost func‐
tion -1-.
All vehicles (continued)
Installing
Installation is carried out in reverse order; note the following:
– Fill cooling system ⇒ Motor; Rep. gr. 19; Cooling sys‐
tem/coolant; Filling cooling system.
– Perform a potential equalisation measurement on the high-
voltage components affected after installation of high-voltage
components or potential equalisation lines ⇒ Rep. gr. 93;
Potential equalisation measurement.

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WARNING
High voltage can cause fatal injury.
Danger of severe or fatal injuries from electric shock or elec‐
tric arcs.
– Have a high-voltage technician (HVT) or a high-voltage
expert (HVE) re-energise the high-voltage system.

– Re-energise high-voltage system ⇒ Rep. gr. 93; Re-energis‐

ing high-voltage system.
Tightening torques
♦ ⇒ Motor; Rep. gr. 93; Voltage converter; Assembly overview
- voltage converter
♦ ⇒ Motor; Rep. gr. 93; Potential equalisation lines; Overview
of fitting locations - potential equalisation lines

15.4 Removing and installing bracket for

power contactor with boost function
Removing
– Remove power contactor with boost function -J1178- ⇒
a15.3 nd installing power contactor with boost function”,
page 306 .
Left-hand drive vehicles
– Remove battery ⇒ Electrical system; Rep. gr. 27; Battery;
Removing and installing battery.
All vehicles (continued)
– Remove charging unit ⇒ Motor; Rep. gr. 93; Charging unit
for high-voltage battery; Removing and installing charging
unit 1 for high-voltage battery AX4.
– To avoid malfunctions caused by interchanging electrical
connectors, mark connectors before unplugging them.

– Move clear and unplug electrical connectors -2-.

– Unplug electrical connector -3- and move clear.
– Detach coupling point -1-.
– Remove nuts -arrows-.

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– Move potential equalisation lines -1- to -4- clear.

– Remove bolts -arrows-.

– Detach bracket -1- at high-voltage wiring harness -2-.

– Move electrical wire -3- and high-voltage wiring harness
clear.
Right-hand drive vehicles
– Remove bolts -arrows-.

– Detach battery tray -1-.

All vehicles (continued)
– Remove bolts -1-, -4-, -7-, -8-.

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– Lift bracket -3- slightly at front, release wire guide -2- for
high-voltage wiring harness and move wire guide clear.
– Release fasteners and move high-voltage wire -6- clear.
– Move high-voltage wire under bracket clear -arrows-.
– Guide bracket out towards front. To do so, press heat ex‐
changer -5- for high-voltage battery slightly upwards.
Installing
Installation is carried out in reverse order; note the following:
– Perform a potential equalisation measurement on the high-
voltage components affected after installation of high-voltage
components or potential equalisation lines ⇒ Rep. gr. 93;
Potential equalisation measurement.
Tightening torques
♦ ⇒ Motor; Rep. gr. 93; Voltage converter; Exploded view -
voltage converter
♦ ⇒ Motor; Rep. gr. 93; Potential equalisation lines; Overview
of fitting locations - potential equalisation lines

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16 Engine sound generation

16.1 Overview of fitting locations - vehicle noise/engine sound

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1 - Actuator 4 for engine

sound generator -R355-
❑ Secured with spreader
rivet and nut
❑ ⇒ Rep. gr. 93; Remov‐
ing and installing actua‐
tor for engine sound
generator (GM3)
❑ Nut, 8 Nm
2 - Bracket for engine sound
generator control unit 2 -
J1167-
❑ Secured with spreader
rivet and nut
❑ Nut, 3 Nm
3 - Engine sound generator
control unit 2 -J1167-
❑ ⇒ Rep. gr. 93; Remov‐
ing and installing en‐
gine sound generator
control unit (GM4)
❑ ⇒ Rep. gr. 93; Remov‐
ing and installing en‐
gine sound generator
control unit (GM3)
❑ Bolt, 4 Nm
4 - Mid-range loudspeaker
with additional internal loud‐
speaker, rear left -R358-
(GM3)
❑ ⇒ a16.6 nd installing in‐
ternal loudspeaker for
engine sound generator
(GM3)”, page 325
❑ Bolt, 1.5 Nm
5 - Actuator 3 for engine sound generator -R348-
❑ ⇒ Rep. gr. 93; Removing and installing actuator for engine sound generator (GM4)
❑ ⇒ Rep. gr. 93; Removing and installing actuator for engine sound generator (GM3)
❑ Tightening torque and sequence ⇒ page 316
6 - Mid-range loudspeaker with additional internal loudspeaker, rear right -R359-
❑ ⇒ a16.6.2 nd installing mid-range loudspeaker with additional internal loudspeaker, rear right R359”,
page 326
❑ Bolt, 1.5 Nm
7 - Engine sound generator control unit 3 -J1177-
❑ ⇒ Rep. gr. 93; Removing and installing engine sound generator control unit (GM3)
❑ Bolt, 4 Nm
8 - Bracket for engine sound generator control unit 3 -J1177-
❑ Secured with spreader rivet and nut
❑ Nut, 8 Nm

Actuator 3 for engine sound generator -R348- - tightening tor‐

que and sequence

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Bolts Tightening torque

1, 3, 2 2.6 Nm

16.2 Removing and installing engine sound

generator control unit (GM4)

16.2.1 Removing and installing engine sound

generator control unit 2 J1167
Removing
– Switch off ignition. Deposit vehicle key and other drive au‐
thorisation systems (e.g. smartphone) outside vehicle.
– Detach luggage compartment side trim (left-side) and press
to side ⇒ General body repairs, interior; Rep. gr. 70; Lug‐
gage compartment trim panels; Removing and installing lug‐
gage compartment side trim.
– Move wiring harness -3- clear.

– Remove spreader rivet -2-.

– Press insulating mat -1- to side.
– Remove nuts -arrows-.
– Move bracket clear with engine sound generator control unit
2 -J1167-.

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– Unplug electrical connectors -1-, -2-.

– Remove bracket -3- and control unit.

– Remove bolts -arrows-.

– Detach control unit -1- from bracket -2-.

Installing
Installation is carried out in reverse sequence.
Tightening torques
♦ ⇒ Motor; Rep. gr. 93; Engine sound generation; Overview of
fitting locations - engine sound generation

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16.3 Removing and installing engine sound

generator control unit (GM3)

16.3.1 Removing and installing engine sound

generator control unit 2 J1167
Removing
– Switch off ignition. Deposit vehicle key and other drive au‐
thorisation systems (e.g. smartphone) outside vehicle.
– Detach luggage compartment side trim (left-side) and press
to side ⇒ General body repairs, interior; Rep. gr. 70; Lug‐
gage compartment trim panels; Removing and installing lug‐
gage compartment side trim.
– Move wiring harness -3- clear.

– Remove spreader rivet -2-.

– Press insulating mat -1- to side.
– Remove nuts -arrows-.
– Move bracket clear with engine sound generator control unit
2 -J1167-.
– Unplug electrical connectors -1-, -2-.

– Remove bracket -3- and control unit.

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– Remove bolts -arrows-.

– Detach control unit -1- from bracket -2-.

Installing
Installation is carried out in reverse sequence.
Tightening torques
♦ ⇒ Motor; Rep. gr. 93; Engine sound generation; Overview of
fitting locations - engine sound generation

16.3.2 Removing and installing engine sound

generator control unit 3 J1177
Removing
– Switch off ignition. Deposit vehicle key and other drive au‐
thorisation systems (e.g. smartphone) outside vehicle.
– Detach luggage compartment side trim (right-side) and press
to side ⇒ General body repairs, interior; Rep. gr. 70; Lug‐
gage compartment trim panels; Removing and installing lug‐
gage compartment side trim.
– Remove spreader rivet -2-.

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– Press insulating mat -4- to side.

– Remove nuts -arrows-.
– Move bracket -1- clear with engine sound generator control
unit 3 -J1177-.
– Unplug electrical connector -3-.
– Remove bracket and control unit.
– Remove bolts -arrows-.

– Detach control unit -2- from bracket -1-.

Installing
Installation is carried out in reverse sequence.
Tightening torques
♦ ⇒ Motor; Rep. gr. 93; Engine sound generation; Overview of
fitting locations - engine sound generation

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16.4 Removing and installing actuator for

engine sound generator (GM4)

16.4.1 Removing and installing actuator 3 for

engine sound generator R348
Removing
– Switch off ignition. Deposit vehicle key and other drive au‐
thorisation systems (e.g. smartphone) outside vehicle.
– Remove luggage compartment pan ⇒ General body repairs,
interior; Rep. gr. 70; Luggage compartment trim panels; Re‐
moving and installing luggage compartment pan (front).
– Remove bolts -1-, -2-, -3-.

– Remove impact bar (bottom) ⇒ General body repairs, exte‐

rior; Rep. gr. 63; Bumper (front); Removing and installing
impact bar.
– Release fasteners -arrow- all around and detach air duct -1-.

– Unplug electrical connector -2-.

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– Guide actuator 3 for engine sound generator -R348- -1- out

towards right.
Installing
Installation is carried out in reverse sequence.
Tightening torques
♦ ⇒ Motor; Rep. gr. 93; Engine sound generation; Overview of
fitting locations - engine sound generation

16.5 Removing and installing actuator for

engine sound generator (GM3)

16.5.1 Removing and installing actuator 3 for

engine sound generator R348
Removing
– Switch off ignition. Deposit vehicle key and other drive au‐
thorisation systems (e.g. smartphone) outside vehicle.
– Remove luggage compartment pan ⇒ General body repairs,
interior; Rep. gr. 70; Luggage compartment trim panels; Re‐
moving and installing luggage compartment pan (front).
– Remove bolts -1-, -2-, -3-.

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– Remove impact bar (bottom) ⇒ General body repairs, exte‐

rior; Rep. gr. 63; Bumper (front); Removing and installing
impact bar.
– Release fasteners -arrow- all around and detach air duct -1-.

– Unplug electrical connector -2-.

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– Guide actuator 3 for engine sound generator -R348- -1- out

towards right.
Installing
Installation is carried out in reverse sequence.
Tightening torques
♦ ⇒ Motor; Rep. gr. 93; Engine sound generation; Overview of
fitting locations - engine sound generation

16.5.2 Removing and installing actuator 4 for

engine sound generator R355
Removing
– Switch off ignition. Deposit vehicle key and other drive au‐
thorisation systems (e.g. smartphone) outside vehicle.
– Remove rear bumper cover ⇒ General body repairs, exte‐
rior; Rep. gr. 63; Bumper (rear); Removing and installing
bumper cover.
– Unplug electrical connector -1-.

– Remove nuts -arrows-.

– Detach actuator 4 for engine sound generator -R355- -2-
towards rear.
Installing
Installation is carried out in reverse sequence.
Tightening torques
♦ ⇒ Motor; Rep. gr. 93; Engine sound generation; Overview of
fitting locations - engine sound generation

16.6 Removing and installing internal loud‐

speaker for engine sound generator
(GM3)

16.6.1 Removing and installing mid-range

loudspeaker with additional internal
loudspeaker, rear left R358
Removing
– Switch off ignition. Deposit vehicle key and other drive au‐
thorisation systems (e.g. smartphone) outside vehicle.

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– Remove door trim (rear left) ⇒ General body repairs, interior;

Rep. gr. 70; Door trim (rear); Removing and installing door
trim (rear).
– Unplug electrical connector -1-.

– Remove bolts -arrows-.

– Detach mid-range loudspeaker with additional internal loud‐
speaker, rear left -R358- -2-.
Installing
Installation is carried out in reverse sequence.
Tightening torques
♦ ⇒ Motor; Rep. gr. 93; Engine sound generation; Overview of
fitting locations - engine sound generation

16.6.2 Removing and installing mid-range

loudspeaker with additional internal
loudspeaker, rear right R359
The procedure for removing and installing is the same as
for the left side; the arrangement is symmetrically opposite ⇒
a16.6.1 nd installing mid-range loudspeaker with additional in‐
ternal loudspeaker, rear left R358”, page 325 .

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17 Accelerator mechanism

17.1 Exploded view - accelerator pedal module

1 - Bolt
❑ 8 Nm
2 - Electrical connector
❑ Ensure item is engaged
securely
3 - Accelerator pedal module
-GX2-
❑ Accelerator position
sender -G79-/accelera‐
tor position sender 2 -
G185-
❑ ⇒ Motor; Rep.
gr. 93; Accelerator
mechanism; Removing
and installing accelera‐
tor pedal module GX2

17.2 Removing and installing accelerator

pedal module GX2
Removing
– Switch off ignition. Deposit vehicle key and other drive au‐
thorisation systems (e.g. smartphone) outside vehicle.
– Remove bolt -1-.

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– Lift accelerator pedal module -3- slightly off mounting and

detach it upwards -arrow-.
– Unplug electrical connector -2-.
Installing
Installation is carried out in reverse sequence.
Tightening torques
♦ ⇒ Electric drive motor 0EG; Rep. gr. 93; Accelerator mecha‐
nism; Exploded view - accelerator pedal module

328 Rep. gr.93 - Electric drive systems