Service

Workshop Manual
Q6 e-tron 2024 ➤
Electric drive motor 0EL, 0EN
Edition 07.2024

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 © 2024 Audi AG, Ingolstadt D4D80B4C4ED

 Q6 e-tron 2024 ➤
Electric drive motor 0EL, 0EN - Edition 07.2024

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.1 Motor number/motor data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1 Safety and repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2 Removing and installing motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1 Removing motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Securing motor to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.3 Installing motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3 Removing and installing rear motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.1 Removing rear motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.2 Securing motor to engine and gearbox support - rear motor . . . . . . . . . . . . . . . . . . . . . . . . 23
3.3 Installing rear motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4 Assembly mountings (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.1 Assembly overview - assembly mountings (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.2 Removing and installing motor mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.3 Removing and installing motor carriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5 Rear assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.1 Assembly overview - rear assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.2 Removing and installing motor mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1 Safety and repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.2 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.1 Assembly overview - coolant expansion tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.2 Removing and installing coolant expansion tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.3 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.4 Filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.5 Draining coolant - all-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.6 Draining coolant - rear-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.7 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3 Coolant pump/thermostat assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.1 Overview of fitting locations - coolant pump/thermostat assembly . . . . . . . . . . . . . . . . . . . . 73
3.2 Assembly overview - electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3.3 Assembly overview - coolant temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.4 Removing and installing coolant pump for high-voltage battery V590 - all-wheel drive . . . . 76
3.5 Removing and installing coolant pump for high-voltage battery V590 - rear-wheel drive . . 78
3.6 Removing and installing thermal management coolant pump 4 V620 . . . . . . . . . . . . . . . . 79

Contents i
 Q6 e-tron 2024 ➤
Electric drive motor 0EL, 0EN - Edition 07.2024

3.7 Removing and installing coolant changeover valve 2 N633 . . . . . . . . . . . . . . . . . . . . . . . . 80

3.8 Removing and installing changeover and mixing valve 4 for thermal management V653 . . 81
3.9 Removing and installing coolant temperature sender 1 for high-voltage battery G898 . . . . 81
3.10 Removing and installing coolant temperature sender 2 for high-voltage battery G899 . . . . 83
3.11 Removing and installing coolant temperature sender 5 for thermal management G906 . . 85
3.12 Removing and installing coolant temperature sender 6 for thermal management G907 . . 87
3.13 Removing and installing coolant temperature sender 7 for thermal management G908 . . 89
3.14 Removing and installing coolant temperature sender 8 for thermal management G968 - all-
wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3.15 Removing and installing coolant temperature sender 8 for thermal management G968 -
rear-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.16 Removing and installing coolant temperature sender 10 for thermal management G1018 . . 95
4 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.1 Assembly overview - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.2 Removing and installing coolant distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.3 Removing and installing coolant manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
5 Radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5.1 Assembly overview - radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5.2 Assembly overview - radiator blind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
5.3 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
5.4 Removing and installing radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
5.5 Removing and installing radiator blind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5.6 Removing and installing radiator blind control motor V544 . . . . . . . . . . . . . . . . . . . . . . . . 111
5.7 Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
5.8 Removing and installing radiator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
5.9 Removing and installing air guide (front) for radiator blind . . . . . . . . . . . . . . . . . . . . . . . . . . 114
5.10 Removing and installing air guide (side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

93 - Electric drive systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

1 Safety and repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.2 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
2 High-voltage components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2.1 Overview of fitting locations - high-voltage components . . . . . . . . . . . . . . . . . . . . . . . . . . 117
3 Warning labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
3.1 Checking warning stickers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
4 High-voltage battery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
4.1 Assembly overview - high-voltage battery (installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
4.2 Assembly overview - switching unit for high-voltage battery . . . . . . . . . . . . . . . . . . . . . . . . 127
4.3 Inspecting and classifying high-voltage battery 1 AX2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
4.4 Diagnosis of removed high-voltage battery 1 AX2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
4.5 Determining mean cell voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
4.6 Charging and discharging battery modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
4.7 Leak test for high-voltage battery 1 AX2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.8 Leak test for cooling system for high-voltage battery 1 AX2 . . . . . . . . . . . . . . . . . . . . . . . . 138
4.9 Checking high-voltage battery for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
4.10 Removing and installing high-voltage battery 1 AX2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
4.11 Voltage and insulation measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
4.12 Lifting high-voltage battery 1 AX2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
4.13 Opening high-voltage battery 1 AX2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
4.14 Closing high-voltage battery 1 AX2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
4.15 Removing and installing battery regulation control unit J840 . . . . . . . . . . . . . . . . . . . . . . . . 168
4.16 Removing and installing switching unit for high-voltage battery SX6 . . . . . . . . . . . . . . . . . . 170
5 High-voltage battery components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
5.1 Overview of fitting locations - battery modules, 100 kWh . . . . . . . . . . . . . . . . . . . . . . . . . . 183

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5.2 Overview of fitting locations - battery modules, 83 kWh . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

5.3 Overview of fitting locations - battery modules control units, 100 kWh . . . . . . . . . . . . . . . . 186
5.4 Overview of fitting locations - battery modules control units, 83 kWh . . . . . . . . . . . . . . . . 187
5.5 Overview of fitting locations - battery connectors, 100 kWh . . . . . . . . . . . . . . . . . . . . . . . . 188
5.6 Overview of fitting locations - battery connectors, 83 kWh . . . . . . . . . . . . . . . . . . . . . . . . . . 190
5.7 Assembly overview - high-voltage battery (removed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
5.8 Assembly overview - battery modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
5.9 Assembly overview - wiring harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
5.10 Marking battery modules, battery connectors and control units . . . . . . . . . . . . . . . . . . . . . . 195
5.11 Removing battery module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
5.12 Installing battery module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
5.13 Removing and installing battery modules control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
5.14 Removing and installing wiring harness for high-voltage battery 1 AX2 . . . . . . . . . . . . . . 212
5.15 Visually inspecting and classifying battery module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
5.16 Provisional energisation of high-voltage battery 1 AX2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
6 Power and control electronics for electric drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
6.1 Assembly overview - power and control electronics for electric drive (front) . . . . . . . . . . . . 218
6.2 Assembly overview - power and control electronics for electric drive (rear) . . . . . . . . . . . . 218
6.3 Removing and installing power and control electronics for electric drive (front) . . . . . . . . 218
6.4 Removing and installing power and control electronics for electric drive (rear) . . . . . . . . . . 221
7 Electric drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
7.1 Assembly overview - electric drive motor, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
7.2 Assembly overview - electric drive motor, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
7.3 Removing and installing front drive motor rotor position sender . . . . . . . . . . . . . . . . . . . . 230
7.4 Removing and installing rear drive motor rotor position sender . . . . . . . . . . . . . . . . . . . . . . 231
7.5 Removing and installing front drive motor temperature sender . . . . . . . . . . . . . . . . . . . . . . 232
7.6 Removing and installing rear drive motor temperature sender . . . . . . . . . . . . . . . . . . . . . . 235
7.7 Removing and installing front oil temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
7.8 Removing and installing rear oil temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
8 Motor control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
8.1 Removing and installing motor control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
9 High-voltage wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
9.1 Overview of fitting locations - high-voltage wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
9.2 Removing and installing high-voltage wiring harness for drive motor . . . . . . . . . . . . . . . . 241
9.3 Removing and installing high-voltage wire from switching unit for high-voltage battery to
coupling point (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
9.4 Removing and installing high-voltage wiring harness from switching unit for high-voltage
battery to high-voltage central box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
9.5 Removing and installing high-voltage wire for electrical air conditioner compressor . . . . . . 245
9.6 Removing and installing high-voltage wire for high-voltage heater . . . . . . . . . . . . . . . . . . 249
9.7 Unplugging high-voltage connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
10 De-energising high-voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
10.1 De-energising high-voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
11 Re-energising high-voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
11.1 Re-energising high-voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
12 Potential equalisation lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
12.1 General notes - potential equalisation lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
12.2 Overview of fitting locations - potential equalisation lines . . . . . . . . . . . . . . . . . . . . . . . . . . 260
12.3 Potential equalisation measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
13 Charging socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
13.1 Assembly overview - charging socket, EU, NAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
13.2 Assembly overview - charging socket, China, Japan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
13.3 Assembly overview - charging socket 2, EU, NAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
13.4 Assembly overview - charging socket 2, China, Japan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
13.5 Removing and installing high-voltage battery charging socket 1 UX4 - EU, NAR . . . . . . . . 271

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13.6 Removing and installing high-voltage battery charging socket 1 UX4 - China, Japan . . . . 275
13.7 Removing and installing high-voltage battery charging socket 2 UX5 . . . . . . . . . . . . . . . . 278
13.8 Removing and installing actuator for high-voltage charging socket lock - EU, NAR . . . . . . 282
13.9 Removing and installing actuator for high-voltage charging socket lock - China, Japan . . 291
13.10 Removing and installing control unit 1 for activation of charging flap and charging socket
J1245 - EU, NAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
13.11 Removing and installing control unit 1 for activation of charging flap and charging socket
J1245 - China, Japan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
13.12 Removing and installing control unit 2 for activation of charging flap and charging socket
J1246 - EU, NAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
14 High-voltage central box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
14.1 Assembly overview - high-voltage central box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
14.2 Removing and installing high-voltage central box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
15 Charging unit for high-voltage battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
15.1 Charging unit for high-voltage battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
16 Voltage converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
16.1 Voltage converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
17 Engine sound generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
17.1 Overview of fitting locations - engine sound generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
17.2 Assembly overview - engine sound generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
17.3 Removing and installing engine sound generator control unit J943 . . . . . . . . . . . . . . . . . . 308
17.4 Removing and installing actuator for engine sound generator . . . . . . . . . . . . . . . . . . . . . . 309
18 Accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
18.1 Assembly overview - accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
18.2 Assembly overview - accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
18.3 Removing and installing accelerator pedal module GX2 . . . . . . . . . . . . . . . . . . . . . . . . . . 314

iv Contents
 Q6 e-tron 2024 ➤
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00 – Technical data
1 Safety precautions
10007K94P626.004.1 - 07.2024

1.1 Safety information

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

1. Safety precautions 1
 Q6 e-tron 2024 ➤
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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

 Q6 e-tron 2024 ➤
Electric drive motor 0EL, 0EN - Edition 07.2024

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 vehi‐ tion and re-
near high-voltage cles 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
Power and control ⇒ Rep. gr. 93 ; Remov‐ HVT
electronics 2 for ing and installing power
electric drive - JX4- and control electronics 2
for electric drive JX4
Three-phase cur‐ ⇒ Rep. gr. 10 ; Remov‐ De-energisa‐
rent drive 2 - VX97- ing front motor tion and re-
with electric drive energisation
motor 2 - V717- by HVT, work
when system
is de-ener‐
gised by EIP
Power and control ⇒ Rep. gr. 93 ; Remov‐ HVT
electronics for elec‐ ing and installing power
tric drive - JX1- and control electronics
for electric drive JX1
Three-phase cur‐ ⇒ Rep. gr. 10 ; Remov‐ De-energisa‐
rent drive - VX54- ing rear motor tion and re-
with electric drive energisation
motor - V141- by HVT, work
when system
is de-ener‐
gised by EIP
High-voltage bat‐ ⇒ Rep. gr. 93 ; Remov‐ De-energisa‐
tery 1 - AX2- ing and installing high- tion and re-
voltage battery 1 AX2 energisation
by HVT, work
when system
is de-ener‐
gised by EIP

3. Assessing high-voltage system risk level 3

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Component Operation Qualification

High-voltage cen‐ ⇒ Rep. gr. 93 ; Remov‐ De-energisa‐
tral box - JX6- ing and installing high- tion and re-
voltage central box energisation
by HVT, work
when system
is de-ener‐
gised by EIP
High-voltage bat‐ ⇒ Rep. gr. 93 ; Remov‐ De-energisa‐
tery charging sock‐ ing and installing high- tion and re-
et 1 - UX4- voltage battery charging energisation
socket 1 UX4 by HVT, work
when system
is de-ener‐
gised by EIP
High-voltage bat‐ ⇒ Rep. gr. 93 ; Remov‐ De-energisa‐
tery charging sock‐ ing and installing high- tion and re-
et 2 - UX5- voltage battery charging energisation
socket 2 UX5 by HVT, work
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
Air conditioner ⇒ Heating, air condition‐ De-energisa‐
compressor - ing; Rep. gr. 87 ; Air tion and re-
VX81- conditioner compressor; energisation
Removing and installing by HVT, work
air conditioner compres‐ when system
sor VX81 is de-ener‐
gised by EIP
High-voltage heater ⇒ Heating, air condi‐ De-energisa‐
(PTC) - ZX17- tioning; Rep. gr. 87 ; tion and re-
Front heater and air con‐ energisation
ditioning unit; Removing by HVT, work
and installing high-volt‐ when system
age heater (PTC) ZX17 is de-ener‐
gised by EIP
High-voltage wiring ⇒ Rep. gr. 93 ; Remov‐ De-energisa‐
harness for front ing and installing high- tion and re-
drive motor/high- voltage wiring harness for energisation
voltage wiring har‐ drive motor by HVT, work
ness for front drive when system
motor is de-ener‐
gised by EIP
High-voltage wire ⇒ “9.3 Removing and in‐ De-energisa‐
from switching unit stalling high-voltage wire tion and re-
for high-voltage from switching unit for energisation
battery to coupling high-voltage battery to by HVT, work
point (front) coupling point (front)”, when system
page 244 is de-ener‐
gised by EIP
High-voltage wir‐ ⇒ “9.4 Removing and in‐ De-energisa‐
ing harness from stalling high-voltage wir‐ tion and re-
switching unit for ing harness from switch‐ energisation
high-voltage battery ing unit for high-voltage by HVT, work
to high-voltage cen‐ battery to high-voltage when system
tral box central box”, page 244 is de-ener‐
gised by EIP

4 Rep. gr.00 - Technical data

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Component Operation Qualification

High-voltage wire ⇒ Rep. gr. 93 ; Remov‐ De-energisa‐
for electrical air ing and installing high- tion and re-
conditioner com‐ voltage wire for electrical energisation
pressor air conditioner compres‐ by HVT, work
sor when system
is de-ener‐
gised by EIP
High-voltage wire ⇒ Rep. gr. 93 ; Remov‐ De-energisa‐
for high-voltage ing and installing high- tion and re-
heater voltage wire for high-volt‐ energisation
age heater by HVT, work
when system
is de-ener‐
gised by EIP
Subframe with ⇒ Running gear, axles, De-energisa‐
steering rack steering; Rep. gr. 40 ; tion and re-
Subframe; Removing and energisation
installing subframe with by HVT, work
steering rack when system
is de-ener‐
gised by EIP
Subframe with mo‐ ⇒ Running gear, axles, De-energisa‐
tor steering; Rep. gr. 40 ; tion and re-
Subframe; Removing and energisation
installing subframe with by HVT, work
motor when system
is de-ener‐
gised by EIP

3. Assessing high-voltage system risk level 5

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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 high-voltage central box - JX6-
♦ 6. Renewing power and control electronics 2 for electric
drive - JX4-
♦ 7. Renewing power and control electronics for electric drive -
JX1-
♦ 8. Renewing battery regulation control unit - J840-
♦ 9. Classification of high-voltage battery 1 - AX2-
♦ 10. Classifying battery module
♦ 11. Determining mean cell voltage
♦ 12. Renewing drive motor rotor position sender 1 - G713-
♦ 13. Renewing rotor position sender 1 for drive motor 2 -
G1147-
♦ 14. Calibrating electric drive motor
♦ 15. Leak test for battery housing of high-voltage battery 1 -
AX2-
♦ 16. Leak test for coolant circuit of high-voltage battery 1 -
AX2-
♦ 17. Renewing control unit 1 for activation of charging flap
and charging socket - J1245-
♦ 18. Renewing control unit 2 for activation of charging flap
and charging socket - J1246-
♦ 19. Starting up
♦ 20. Module balancer VAS 6910A
1. Adapting end stops for radiator blind
♦ Diagnostic capable systems
♦ 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 systems
♦ 00C5 - Thermal Management Control Module -J1024-
♦ 00C5 - Thermal Management Control Module -J1024-, func‐
tions

6 Rep. gr.00 - Technical data

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♦ 00C5 - Basic setting

♦ 00C5 - Drain, fill coolant circuits
3. Opening electrically actuated valves in cooling system after
discharging and charging
♦ Diagnostic capable systems
♦ 00C5 - Thermal Management Control Module -J1024-
♦ 00C5 - Thermal Management Control Module -J1024-, func‐
tions
♦ 00C5 - Basic setting
♦ 00C5 - Stop - drain, fill coolant circuits
4. Bleeding cooling system
♦ Diagnostic capable systems
♦ 00C5 - Thermal Management Control Module -J1024-
♦ 00C5 - Thermal Management Control Module -J1024-, func‐
tions
♦ 00C5 - Basic setting
♦ 00C5 - Bleed cooling system
5. Renewing high-voltage central box - JX6-
♦ Diagnostic capable systems
♦ 813B - High-voltage central box - JX6
♦ 813B - Functions
♦ 813B - Replace control module
6. Renewing power and control electronics 2 for electric drive -
JX4-
♦ Diagnostic capable systems
♦ 00CE - Electric drive 2
♦ 00CE - Electric drive 2, functions
♦ 00CE - Replace control module
7. Renewing power and control electronics for electric drive -
JX1-
♦ Diagnostic capable systems
♦ 0051 - Electric drive
♦ 0051 - Electric Drive, functions
♦ 0051 - Replace control module
8. Renewing battery regulation control unit - J840-
♦ Diagnostic capable systems
♦ 008C - Hybrid Battery Energy Management -J840
♦ 008C - Hybrid Battery Energy Management, functions
♦ 008C - J840 - Battery Regulation Control Module
♦ 008C - Replace control module
9. Classification of high-voltage battery 1 - AX2-
♦ Special functions
♦ High Voltage

4. Electrical components 7
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♦ 008C - Classification of high-voltage battery

10. Classifying battery module
♦ Diagnostic capable systems
♦ 008C - Hybrid Battery Energy Management -J840
♦ 008C - Hybrid Battery Energy Management - functions
♦ 008C - Classification of battery module
11. Determining mean cell voltage
♦ Diagnostic capable systems
♦ 008C - Hybrid Battery Energy Management -J840
♦ 008C - Hybrid Battery Energy Management - functions
♦ 008C - Determine mean cell voltage
12. Renewing drive motor rotor position sender 1 - G713-
♦ Diagnostic capable systems
♦ 0051 - Electric drive power and control electronics - JX1-
♦ 0051 - Electric Drive - functions
♦ 0051 - Basic setting
13. Renewing rotor position sender 1 for drive motor 2 - G1147-
♦ Diagnostic capable systems
♦ 00CE - Electric drive power and control electronics 2 - JX4-
♦ 00CE - Electric drive 2 - functions
♦ 00CE - Basic setting
14. Calibrating electric drive motor
Three-phase current drive 2 - VX97-
♦ Diagnostic capable systems
♦ 00CE - Electric drive power and control electronics 2 - JX4-
♦ 00CE - Electric drive 2 - functions
♦ 00CE - Basic setting
Three-phase current drive - VX54-
♦ Diagnostic capable systems
♦ 0051 - Electric drive power and control electronics - JX1-
♦ 0051 - Electric Drive - functions
♦ 0051 - Basic setting
15. Leak test for battery housing of high-voltage battery 1 -
AX2-
♦ Diagnostic capable systems
♦ 008C - Hybrid Battery Energy Management -J840
♦ 008C - Hybrid Battery Energy Management - functions
♦ 008C - High-voltage battery leak test
16. Leak test for coolant circuit of high-voltage battery 1 - AX2-
♦ Diagnostic capable systems
♦ 008C - Hybrid Battery Energy Management -J840

8 Rep. gr.00 - Technical data

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♦ 008C - Hybrid Battery Energy Management - functions

♦ 008C - High-voltage battery leak test
17. Renewing control unit 1 for activation of charging flap and
charging socket - J1245-
♦ Diagnostic capable systems
♦ 813C - Control Module for Charge Door and Charging Sock‐
et Activation 1
♦ 813C - Functions
♦ 813C - Replace control module
18. Renewing control unit 2 for activation of charging flap and
charging socket - J1246-
♦ Diagnostic capable systems
♦ 813D - Control Module for Charge Door and Charging Sock‐
et Activation 2
♦ 813D - Functions
♦ 813D - Replace control module
19. Starting up
♦ Diagnostic capable systems
♦ 008C - Hybrid Battery Energy Management -J840
♦ 008C - Hybrid Battery Energy Management - functions
♦ 008C - start up operations
20. Module balancer VAS 6910A
♦ Diagnostic capable systems
♦ 008C - Hybrid Battery Energy Management -J840
♦ 008C - Hybrid Battery Energy Management, functions
♦ Module balancer VAS 6910A

4. Electrical components 9
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5 Identification

5.1 Motor number/motor data

Motor number
♦ Motor numbers (motor code and serial number) are en‐
graved on housing.
♦ The first three characters of the motor code stand for the
mechanical construction and design.
♦ The fourth character is not included.
♦ The four-character motor code is shown on the type plate
(depending on country) and the vehicle data sticker.
Transmission unit code
♦ The transmission unit code is not stamped on the housing.
♦ The transmission unit code is shown on the label on the
power and control electronics
♦ The different motor and transmission unit combinations are
listed below.
Front electric drive motor
A - Motor information - on bottom right of motor mounting
1 - Model code
2 - Motor code with serial number
B - Label on power and control electronics 2 for electric drive -
JX4-
3 - Part number of power and control electronics 2 for electric
drive - JX4- ⇒ Electronic parts catalogue
4 - Characters 4 to 6: transmission unit code, e.g. UJG
Motor code ECFA
Designation for electrical com‐ Electric drive motor 2 - V717-
ponent
Designation EIA210-2.0/100
Max. output [kW] 140
Design Asynchronous motor
Motor type 0ENA
Transmission unit code UJG

10 Rep. gr.00 - Technical data

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Rear electric drive motor

A - Motor information - on left side of stator housing
1 - Model code
2 - Motor code with serial number
B - Label on power and control electronics for electric drive -
JX1-
3 - Part number of power and control electronics for electric
drive - JX1- ⇒ Electronic parts catalogue
4 - Characters 4 to 6: transmission unit code, e.g. UJN
Motor code ECCA
Designation for electrical com‐ Electric drive motor - V141-
ponent
Designation EIP210-2.0/200
Max. output [kW] 280
Design Permanently excited synchro‐
nous motor
Motor type 0ELD
Transmission unit code UJN

5. Identification 11
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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 .

12 Rep. gr.10 - Removing and installing engine

 Q6 e-tron 2024 ➤
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2 Removing and installing motor

2.1 Removing motor

Special tools and workshop equipment required
♦ Pin - VAS 501 027-2-
♦ Pin - VAS 501 027-3-
♦ Pin - VAS 501 027-4-
♦ Pin - VAS 501 027-5-
♦ lifting device - VAS 501 027-
♦ workshop hoist - VAS 6100-

Removing
– Remove drive shafts (left and right) ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Drive shaft; Removing and installing
drive shaft .

– Remove subframe together with motor ⇒ Running gear,

axles, steering; Rep. gr. 40 ; Subframe; Removing and in‐
stalling subframe with motor; Removing and installing sub‐
frame .

– Unplug electrical connector -1-.

– Remove bolt -arrow- for potential equalisation line.
– Move electrical wiring harness clear.

2. Removing and installing motor 13

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

– Move electrical wiring harness clear.

– Secure lifting device - VAS 501 027- to motor.

♦ Insert pins -A, B, E, G- in housing.
♦ Align pins with holes according to markings (e.g. A to A).
♦ Insert and tighten bolts.
Pin Marking
Pin - VAS 501 027-2- -A-
Pin - VAS 501 027-3- -B-
Pin - VAS 501 027-4- -E-
Pin - VAS 501 027-5- -G-
– Secure lifting device - VAS 501 027- to workshop hoist -
VAS 6100- .
– Take up weight of motor with workshop hoist - VAS 6100- .

– Remove bolts -arrows-.

14 Rep. gr.10 - Removing and installing engine

 Q6 e-tron 2024 ➤
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– Remove bolt -1-.

Important
• To unscrew bolt -1-, clamp motor carrier -2-.
– Remove bolt -3-.
– Detach motor carrier -2-.
– Repeat procedure on opposite side of vehicle.

– Lift motor out with workshop hoist - VAS 6100- .

2.2 Securing motor to engine and gearbox

support
Special tools and workshop equipment required
♦ engine and gearbox support - VAS 6095A-
♦ lifting device - VAS 501 023-
♦ lifting device - VAS 501 027-
♦ workshop hoist - VAS 6100-

Procedure
– ⇒ Rep. gr. 10 ; Remove motor .

– Carefully set motor down.

– Separate lifting device - VAS 501 027- and workshop hoist -
VAS 6100- .
– Detach lifting device - VAS 501 027- from motor.

– Insert lifting device - VAS 501 023- -A- in holes -arrows a-.
– Screw spindle into hole -arrow b- hand-tight.
– Attach workshop hoist - VAS 6100- to lifting device - VAS
501 023- -A-.
– Lift motor with workshop hoist - VAS 6100- .

2. Removing and installing motor 15

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– Fit lifting device - VAS 501 023- -A- on engine and gearbox
support - VAS 6095A- -B-.
– Fit and tighten bolts -arrows-.

2.3 Installing motor

Special tools and workshop equipment required
♦ Pin - VAS 501 027-2-
♦ Pin - VAS 501 027-3-
♦ Pin - VAS 501 027-4-
♦ Pin - VAS 501 027-5-
♦ engine and gearbox support - VAS 6095A-
♦ lifting device - VAS 501 023-
♦ lifting device - VAS 501 027-
♦ workshop hoist - VAS 6100-

16 Rep. gr.10 - Removing and installing engine

 Q6 e-tron 2024 ➤
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Installing
– Attach lifting device - VAS 501 023- -A- to workshop hoist -
VAS 6100- .
– Take up weight of motor slightly with workshop hoist - VAS
6100- .
– Loosen bolts -arrows-.
– Detach lifting device - VAS 501 023- -A- from engine and
gearbox support - VAS 6095A- -B-.

– Carefully set motor down.

– Separate lifting device - VAS 501 023- and workshop hoist -
VAS 6100- .
– Detach lifting device - VAS 501 023- from motor.

– Secure lifting device - VAS 501 027- to motor.

♦ Insert pins -A, B, E, G- in housing.
♦ Align pins with holes according to markings (e.g. A to A).
♦ Insert and tighten bolts.
Pin Marking
Pin - VAS 501 027-2- -A-
Pin - VAS 501 027-3- -B-
Pin - VAS 501 027-4- -E-
Pin - VAS 501 027-5- -G-
– Secure lifting device - VAS 501 027- to workshop hoist -
VAS 6100- .

– Lift motor into installation position with workshop hoist - VAS

6100- .

2. Removing and installing motor 17

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– Fit motor carrier -2-.

– Tighten bolt -3-.
– Tighten bolt -1-.
Important
• To tighten bolt -1-, clamp motor carrier -2-.
– Repeat procedure on opposite side of vehicle.

– Tighten bolts -arrows-.

– Detach workshop hoist - VAS 6100- and lifting device - VAS

501 027- from motor.

– Route electrical wiring harness on motor and secure.

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

18 Rep. gr.10 - Removing and installing engine

 Q6 e-tron 2024 ➤
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– Route electrical wiring harness on motor and secure.

– Tighten bolt -arrow- for potential equalisation line.
– Plug in electrical connector -1-.

– Install motor with subframe ⇒ Running gear, axles, steering;

Rep. gr. 40 ; Subframe; Removing and installing subframe
with motor; Removing and installing subframe .

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

steering; Rep. gr. 40 ; Drive shaft; Removing and installing
drive shaft .

– 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 .

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-energising high-voltage system

If three-phase current drive 2 - VX97- has been renewed:

– Perform “Calibrate electric drive motor” function ⇒ Rep.
gr. 00 ; Starting diagnosis .

2. Removing and installing motor 19

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Continued
Tightening torques
♦ ⇒ Rep. gr. 10 ; Assembly overview - assembly mountings
(front)
♦ ⇒ Rep. gr. 93 ; Assembly overview - electric drive motor

20 Rep. gr.10 - Removing and installing engine

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3 Removing and installing rear motor

3.1 Removing rear motor

Special tools and workshop equipment required
♦ Pin - VAS 501 027-2-
♦ Pin - VAS 501 027-6-
♦ Pin - VAS 501 027-7-
♦ Pin - VAS 501 027-8-
♦ lifting device - VAS 501 027-
♦ workshop hoist - VAS 6100-

Removing
– Remove drive shafts (left and right) ⇒ Running gear, axles,
steering; Rep. gr. 42 ; Drive shaft; Removing and installing
drive shaft .

– Remove subframe together with motor ⇒ Running gear,

axles, steering; Rep. gr. 42 ; Subframe; Removing and in‐
stalling subframe .

– Loosen hose clips -arrows-.

– Disconnect coolant hoses -1-.

3. Removing and installing rear motor 21

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– Remove bolt -1- for potential equalisation line.

– Unplug electrical connectors -2- to -5-.
– Move electrical wiring harness clear.

– Unplug electrical connectors -1- and -2-.

– Move electrical wiring harness clear.

– Remove bolt -arrow-.

– Release retaining clip -2-.
– Carefully push coolant line -1- to the side.

22 Rep. gr.10 - Removing and installing engine

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– Secure lifting device - VAS 501 027- to motor.

♦ Insert pins -A, C, D, F- in housing.
♦ Note installation position of pin -C-.
♦ Align pins with holes according to markings (e.g. A to A).
♦ Insert and tighten bolts.
Pin Marking
Pin - VAS 501 027-2- -A-
Pin - VAS 501 027-6- -C-
Pin - VAS 501 027-7- -D-
Pin - VAS 501 027-8- -F-
– Secure lifting device - VAS 501 027- to workshop hoist -
VAS 6100- .
– Take up weight of motor with workshop hoist - VAS 6100- .

– Unscrew threaded connection -1- and remove.

– Remove bolts -2- and -3-.
– Lift power unit -4- out with workshop hoist - VAS 6100- .

3.2 Securing motor to engine and gearbox

support - rear motor
Special tools and workshop equipment required
♦ engine and gearbox support - VAS 6095A-
♦ lifting device - VAS 501 023-
♦ lifting device - VAS 501 027-
♦ workshop hoist - VAS 6100-

Procedure
– ⇒ Rep. gr. 10 ; Removing rear motor

– Carefully set motor down.

– Separate lifting device - VAS 501 027- and workshop hoist -
VAS 6100- .

3. Removing and installing rear motor 23

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– Detach lifting device - VAS 501 027- from motor.

– Insert lifting device - VAS 501 023- -A- in holes -arrows a-.
– Screw spindle into hole -arrow b- hand-tight.
– Attach workshop hoist - VAS 6100- to lifting device - VAS
501 023- -A-.
– Lift motor with workshop hoist - VAS 6100- .

– Fit lifting device - VAS 501 023- -A- on engine and gearbox
support - VAS 6095A- -B-.
– Tighten bolts -arrows-.

3.3 Installing rear motor

Special tools and workshop equipment required
♦ Pin - VAS 501 027-2-
♦ Pin - VAS 501 027-6-
♦ Pin - VAS 501 027-7-
♦ Pin - VAS 501 027-8-
♦ engine and gearbox support - VAS 6095A-
♦ lifting device - VAS 501 023-
♦ lifting device - VAS 501 027-
♦ workshop hoist - VAS 6100-

24 Rep. gr.10 - Removing and installing engine

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Installing
– Attach lifting device - VAS 501 023- -A- to workshop hoist -
VAS 6100- .
– Take up weight of motor slightly with workshop hoist - VAS
6100- .
– Loosen bolts -arrows-.
– Detach lifting device - VAS 501 023- -A- from engine and
gearbox support - VAS 6095A- -B-.

– Carefully set motor down.

– Separate lifting device - VAS 501 023- and workshop hoist -
VAS 6100- .
– Detach lifting device - VAS 501 023- from motor.

– Secure lifting device - VAS 501 027- to motor.

♦ Insert pins -A, C, D, F- in housing.
♦ Note installation position of pin -C-.
♦ Align pins with holes according to markings (e.g. A to A).
♦ Insert and tighten bolts.
Pin Marking
Pin - VAS 501 027-2- -A-
Pin - VAS 501 027-6- -C-
Pin - VAS 501 027-7- -D-
Pin - VAS 501 027-8- -F-
– Secure lifting device - VAS 501 027- to workshop hoist -
VAS 6100- .

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– Lift motor -4- into installation position with workshop hoist -

VAS 6100- .
– Insert and tighten threaded connection -1-.
– Tighten bolts -2- and -3-.

– Detach workshop hoist - VAS 6100- and lifting device - VAS

501 027- from motor.

– Bring coolant line -1- into position.

– Fasten retaining clip -2-.
– Tighten bolt -arrow-.

– Route electrical wiring harness on motor and secure.

– Plug in electrical connectors -1- and -2-.

26 Rep. gr.10 - Removing and installing engine

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– Route electrical wiring harness on motor and secure.

– Tighten bolt -1- for potential equalisation line.
– Plug in electrical connectors -2- to -5-.

– Fit coolant lines -1-.

– Fit clips -arrows-.

– Install motor together with subframe ⇒ Running gear, axles,

steering; Rep. gr. 42 ; Subframe; Removing and installing
subframe .

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

steering; Rep. gr. 42 ; Drive shaft; Removing and installing
drive shaft .

– 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 .

3. Removing and installing rear motor 27

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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.

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

If three-phase current drive - VX54- has been renewed:

– Perform “Calibrate electric drive motor” function ⇒ Rep.
gr. 00 ; Starting diagnosis .

Continued
Tightening torques
♦ ⇒ Rep. gr. 10 ; Assembly overview - rear assembly mount‐
ings
♦ ⇒ Rep. gr. 93 ; Assembly overview - electric drive motor,
rear

28 Rep. gr.10 - Removing and installing engine

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4 Assembly mountings (front)

4.1 Assembly overview - assembly mountings (front)

4. Assembly mountings (front) 29

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1 - Motor carrier (right-side)

❑ ⇒ “4.3.2 Removing and
installing motor carriers
(rear)”, page 37
2 - Bolt
❑ Secures motor carrier
to subframe
❑ 20 Nm
3 - Bolt
❑ For motor mounting
(right-side)
❑ 160 Nm
4 - Bolt
❑ Secures motor carrier
to body
❑ 100 Nm
5 - Motor mounting (front)
❑ Renew after removing
❑ ⇒ Rep. gr. 10 ; Re‐
moving and installing
motor mountings
6 - Bolt
❑ For motor mounting
(front)
❑ 2x
❑ 100 Nm
7 - Motor mounting (right-
side)
❑ Renew after removing
❑ ⇒ Rep. gr. 10 ; Re‐
moving and installing
motor mountings
8 - Motor mounting (left-side)
❑ Renew after removing
❑ ⇒ Rep. gr. 10 ; Removing and installing motor mountings
9 - Motor carrier (left-side)
❑ ⇒ “4.3.2 Removing and installing motor carriers (rear)”, page 37
10 - Bolt
❑ Secures motor carrier to body
❑ 100 Nm
11 - Bolt
❑ Secures motor carrier to subframe
❑ 20 Nm
12 - Bolt
❑ For motor mounting (left-side)
❑ 160 Nm
13 - Bolt
❑ For steering rack
❑ ⇒ Running gear, axles, steering; Rep. gr. 48 ; Steering rack; Assembly overview - steering rack

30 Rep. gr.10 - Removing and installing engine

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14 - Bolt
❑ For steering rack
❑ ⇒ Running gear, axles, steering; Rep. gr. 48 ; Steering rack; Assembly overview - steering rack
15 - Nut
❑ For steering rack
❑ ⇒ Running gear, axles, steering; Rep. gr. 48 ; Steering rack; Assembly overview - steering rack
16 - Motor carrier (front)
❑ ⇒ “4.3.1 Removing and installing motor carriers (front)”, page 37

4.2 Removing and installing motor mount‐

ings
Special tools and workshop equipment required
♦ Bell - T40458/1-
♦ Clamping nut - T40458/13-
♦ Foot pump - VAS 6179-
♦ Half moon - T40458/5-
♦ Hydraulic cylinder - VAS 6178-
♦ Nut - T40458/8-
♦ Pressure gauge with connection line - VAS 6179/1-
♦ Sleeve - T40458/6-
♦ Spindle M12 - T40458/14-
♦ Spindle M14 - T40458/15-
♦ Thrust piece - T40458/3-
♦ Thrust piece - T40458/4-
♦ fork - T40458/10-

Servicing
Important
• A second person is required for the following steps.

Preparations
– ⇒ Rep. gr. 10 ; Secure motor to engine and gearbox sup‐
port .

4. Assembly mountings (front) 31

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– Set up special tools as shown:

♦ -1- Hydraulic cylinder - VAS 6178-
♦ -2- Pressure gauge with connection line - VAS 6179/1-
♦ -3- Foot pump - VAS 6179-

– Pull control knob on pressure relief valve of foot pump - VAS

6179- to position -1-.
– To protect against components falling down, hold hydraulic
cylinder securely during pressing operation.

Renewing motor mounting (front)

– Secure fork - T40458/10- -B- to mounting -1- with bolt -A-.
– Screw spindle M14 - T40458/15- -C- into fork - T40458/10-
-B-.

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– Fit tools in centre as shown.

♦ -A- Sleeve - T40458/6-
♦ -B- Hydraulic cylinder - VAS 6178-
♦ -C- Nut - T40458/8-
♦ -D- Spindle M14 - T40458/15-
– Pull mounting out.

– Note installation position of motor mounting -1- shown.

Important
• Recess -2- faces marking -arrow- on housing.

– Fit tools in centre as shown.

♦ -A- Hydraulic cylinder - VAS 6178-
♦ -B- Bell - T40458/1-
♦ -C- Thrust piece - T40458/3-
♦ -1- Mounting
♦ -D- Half moon - T40458/5-
– Press mounting -1- into housing so it is flush.

4. Assembly mountings (front) 33

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Renewing motor mounting (left-side)

– Screw spindle M14 - T40458/15- -A- into mounting -1-.

– Fit tools in centre as shown.

♦ -A- Spindle M14 - T40458/15-
♦ -B- Nut - T40458/8-
♦ -C- Hydraulic cylinder - VAS 6178-
♦ -D- Sleeve - T40458/6-
– Pull mounting out.

– Screw spindle M12 - T40458/14- -A- into thread -arrow-.

34 Rep. gr.10 - Removing and installing engine

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– Note installation position of motor mounting -1- shown.

Important
• Recess -2- faces marking -arrow- on housing.

– Fit tools in centre as shown.

♦ -A- Spindle M12 - T40458/14-
♦ -B- Clamping nut - T40458/13-
♦ -C- Thrust piece - T40458/4-
♦ -1- Mounting
– Press mounting -1- into housing so it is flush.

Renewing motor mounting (right-side)

– Screw spindle M14 - T40458/15- -A- into mounting -1-.

4. Assembly mountings (front) 35

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– Fit tools in centre as shown.

♦ -A- Sleeve - T40458/6-
♦ -B- Hydraulic cylinder - VAS 6178-
♦ -C- Nut - T40458/8-
♦ -D- Spindle M14 - T40458/15-
– Pull mounting out.

– Screw spindle M12 - T40458/14- into thread -arrow-.

– Note installation position of motor mounting -1- shown.

Important
• Recesses -2- face markings -arrows- on housing.

36 Rep. gr.10 - Removing and installing engine

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– Fit tools in centre as shown.

♦ -A- Spindle M12 - T40458/14-
♦ -B- Clamping nut - T40458/13-
♦ -C- Thrust piece - T40458/4-
♦ -1- Mounting
– Press mounting -1- into housing so it is flush.

4.3 Removing and installing motor carriers

4.3.1 Removing and installing motor carriers

(front)
Removing
– ⇒ Rep. gr. 10 ; Remove motor .

– Unscrew threaded connections -2- and remove.

– Unscrew threaded connections -3-.
– Pull motor carrier -1- out upwards.

Installing
Installation is carried out in reverse sequence.

Tightening torques
♦ ⇒ Running gear, axles, steering; Rep. gr. 48 ; Steering
rack; Assembly overview - steering rack

4.3.2 Removing and installing motor carriers

(rear)
Special tools and workshop equipment required
♦ Pin - VAS 501 027-2-
♦ Pin - VAS 501 027-3-
♦ Pin - VAS 501 027-4-

4. Assembly mountings (front) 37

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♦ Pin - VAS 501 027-5-

♦ lifting device - VAS 501 027-
♦ workshop hoist - VAS 6100-

Installing
The removal and installation procedures are described for the
(left/right) side of the vehicle as an example.

– Remove subframe together with motor ⇒ Running gear,

axles, steering; Rep. gr. 40 ; Subframe; Removing and in‐
stalling subframe with motor; Removing and installing sub‐
frame .

– Secure lifting device - VAS 501 027- to motor.

♦ Insert pins -A, B, E, G- in housing.
♦ Align pins with holes according to markings (e.g. A to A).
♦ Insert and tighten bolts.
Pin Marking
Pin - VAS 501 027-2- -A-
Pin - VAS 501 027-3- -B-
Pin - VAS 501 027-4- -E-
Pin - VAS 501 027-5- -G-
– Secure lifting device - VAS 501 027- to workshop hoist -
VAS 6100- .
– Take up weight of motor slightly with workshop hoist - VAS
6100- .

– Remove bolt -1-.

Important
• To unscrew bolt -1-, clamp motor carrier -2-.
– Remove bolt -3-.
– Detach motor carrier -2-.

38 Rep. gr.10 - Removing and installing engine

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Installing
Installation is carried out in reverse order.

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

4. Assembly mountings (front) 39

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5 Rear assembly mountings

5.1 Assembly overview - rear assembly mountings

1 - Motor mounting (right-

side)
❑ Renew after removing
❑ ⇒ Rep. gr. 10 ; Re‐
moving and installing
motor mountings
2 - Motor mounting (rear)
❑ Renew after removing
❑ ⇒ Rep. gr. 10 ; Re‐
moving and installing
motor mountings
3 - Nut
❑ For motor mounting
(rear)
4 - Bolt
❑ For motor mounting
(rear)
❑ 100 Nm
5 - Bolt
❑ For motor mounting
(left-side)
❑ 100 Nm
6 - Bolt
❑ For motor mounting
(right-side)
❑ 100 Nm
7 - Motor mounting (left-side)
❑ Renew after removing
❑ ⇒ Rep. gr. 10 ; Re‐
moving and installing
motor mountings

5.2 Removing and installing motor mount‐

ings
Special tools and workshop equipment required
♦ Bell - T40458/2-
♦ Counter-support - T40458/12-
♦ Disc - T40458/11-
♦ Foot pump - VAS 6179-
♦ Hydraulic cylinder - VAS 6178-
♦ Nut - T40458/9-
♦ Pressure gauge with connection line - VAS 6179/1-
♦ Sleeve - T40458/7-

40 Rep. gr.10 - Removing and installing engine

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♦ Spindle M12 - T40458/14-

♦ Thrust piece - T40458/4-

Servicing
Important
• A second person is required for the following steps.

Preparations
– ⇒ Rep. gr. 10 ; Secure motor to engine and gearbox sup‐
port .

– Set up special tools as shown:

♦ -1- Hydraulic cylinder - VAS 6178-
♦ -2- Pressure gauge with connection line - VAS 6179/1-
♦ -3- Foot pump - VAS 6179-

– Pull control knob on pressure relief valve of foot pump - VAS

6179- to position -1-.
– To protect against components falling down, hold hydraulic
cylinder securely during pressing operation.

5. Rear assembly mountings 41

 Q6 e-tron 2024 ➤
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Renewing motor mounting (rear)

– Fit tools in centre as shown.
♦ -A- Spindle M12 - T40458/14-
♦ -B- Nut - T40458/9-
♦ -C- Hydraulic cylinder - VAS 6178-
♦ -D- Sleeve - T40458/7-
♦ -E- Disc - T40458/11-
– Pull mounting out.

– Note installation position of motor mounting -1- shown.

Important
• Groove -2- faces right.
• Recess -3- faces marking -arrow- on housing.

– Fit tools in centre as shown.

♦ -A- Hydraulic cylinder - VAS 6178-
♦ -B- Bell - T40458/2-
♦ -C- Thrust piece - T40458/4-
♦ -1- Mounting
– Press mounting -1- into housing so it is flush.

42 Rep. gr.10 - Removing and installing engine

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Renewing motor mounting (left-side)

– Fit tools in centre as shown.
♦ -A- Spindle M12 - T40458/14-
♦ -B- Nut - T40458/9-
♦ -C- Hydraulic cylinder - VAS 6178-
♦ -D- Sleeve - T40458/7-
♦ -E- Disc - T40458/11-
– Pull mounting out.

– Note installation position of motor mounting -1- shown.

Important
• Recesses -2- face markings -arrows- on housing.

– Fit tools in centre as shown.

♦ -A- Hydraulic cylinder - VAS 6178-
♦ -B- Bell - T40458/2-
♦ -C- Thrust piece - T40458/4-
♦ -1- Mounting
– Press mounting -1- into housing so it is flush.

5. Rear assembly mountings 43

 Q6 e-tron 2024 ➤
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Renewing motor mounting (right-side)

– Fit tools in centre as shown.
♦ -A- Spindle M12 - T40458/14-
♦ -B- Nut - T40458/9-
♦ -C- Hydraulic cylinder - VAS 6178-
♦ -D- Sleeve - T40458/7-
♦ -E- Disc - T40458/11-
– Pull mounting out.

– Note installation position of motor mounting -1- shown.

Important
• Groove -2- faces right.
• Recess -3- faces marking -arrow- on housing.

– Fit tools in centre as shown.

♦ -A- Spindle M12 - T40458/14-
♦ -B- Nut - T40458/9-
♦ -C- Hydraulic cylinder - VAS 6178-
♦ -D- Thrust piece - T40458/4-
♦ -1- Mounting
♦ -E- Counter-support - T40458/12-
– Press mounting -1- into housing so it is flush.

44 Rep. gr.10 - Removing and installing engine

 Q6 e-tron 2024 ➤
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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 .

1. Safety and repair instructions 45

 Q6 e-tron 2024 ➤
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2 Cooling system/coolant

2.1 Assembly overview - coolant expansion tank

1 - Bleeder valve
2 - Bolt
❑ 3.5 Nm
3 - O-ring
❑ Renew if damaged
4 - Cap
❑ Check opening pres‐
sure ⇒ Rep. gr. 19 ;
Checking cooling sys‐
tem for leaks
5 - Warning label
❑ Fit sealing tag with
warning label on filler
cap of coolant expan‐
sion tank ⇒ Rep.
gr. 19 ; Filling cooling
system
6 - Sealing tag
❑ Fit sealing tag with
warning label on filler
cap of coolant expan‐
sion tank ⇒ Rep.
gr. 19 ; Filling cooling
system
7 - Bolt
❑ 8 Nm
8 - Coolant expansion tank
❑ With coolant shortage
indicator sender 2 -
G837-
❑
9 - Coolant hose
10 - Rubber bush
11 - Coolant bleeder hose
12 - Coolant bleeder hose

2.2 Removing and installing coolant ex‐

pansion tank
Special tools and workshop equipment required
♦ cooling system service device - VAS 531 011-
♦ hose clamps up to 25mm - 3094-

46 Rep. gr.19 - Cooling

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Vehicles with front luggage compartment pan:

– Remove front luggage compartment pan ⇒ General body
repairs, interior; Rep. gr. 70 ; Luggage compartment trim
panels; Removing and installing front luggage compartment
pan .

All vehicles (continued)

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.

– Cut through ring of sealing tag -2-.

– Open filler cap -1-.
– Extract coolant from coolant expansion tank with cooling
system service device - VAS 531 011- .

– Unplug electrical connector -4-.

– Remove bolt -2-.
– Release catch -arrow- and detach coolant expansion tank
-3- upwards.
– Clamp off coolant hoses with hose clamps up to 25mm -
3094- -A-.
– Release hose clips -1- and detach coolant hoses.
– Release hose clip -5- and detach coolant hose.
– Detach coolant expansion tank -3-.

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

2. Cooling system/coolant 47
 Q6 e-tron 2024 ➤
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– ⇒ Rep. gr. 19 ; Fill cooling system .

Tightening torques
♦ ⇒ Rep. gr. 19 ; Assembly overview - coolant expansion
tank

2.3 Connection diagram - coolant hoses

48 Rep. gr.19 - Cooling

 Q6 e-tron 2024 ➤
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1 - High-voltage central box -

JX6-
2 - Three-phase current drive
- VX54-
3 - Restrictor
4 - Power and control elec‐
tronics for electric drive - JX1-
5 - Control unit 1 for automa‐
ted driving - J1274-
6 - Power and control elec‐
tronics 2 for electric drive -
JX4-
❑ Vehicles with all-wheel
drive
7 - Restrictor
❑ Vehicles with all-wheel
drive
8 - Coolant temperature send‐
er 10 for thermal manage‐
ment - G1018-
9 - Thermal management
coolant pump 4 - V620-
10 - Coolant temperature
sender 8 for thermal manage‐
ment - G968-
11 - Non-return valve
12 - Heat exchanger for high-
voltage battery with refriger‐
ant expansion valve 2 - N637-
13 - Coolant temperature
sender 7 for thermal manage‐
ment - G908-
14 - Coolant temperature sender 2 for high-voltage battery - G899-
15 - Changeover and mixing valve 4 for thermal management - V653-
16 - Coolant pump for high-voltage battery - V590-
17 - Coolant temperature sender 6 for thermal management - G907-
18 - Coolant temperature sender 1 for high-voltage battery - G898-
19 - Radiator
20 - High-voltage battery 1 - AX2-
21 - Coolant changeover valve 2 - N633-
22 - Non-return valve
23 - Non-return valve
24 - Bleeder valve
25 - Coolant expansion tank
26 - Coolant temperature sender 5 for thermal management - G906-
27 - Filler cap
28 - Three-phase current drive 2 - VX97-

2. Cooling system/coolant 49
 Q6 e-tron 2024 ➤
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❑ Vehicles with all-wheel drive

2.4 Filling cooling system

Special tools and workshop equipment required
♦ cooling system service device - VAS 531 011-
Important
• The procedure “Filling cooling system without cooling sys‐
tem service device VAS 531 011” is only permitted if one of
the components listed in the table is renewed.
• The procedure “Filling cooling system with cooling system
service device VAS 531 011” must be used if a component
that is not listed in the table is replaced, if several compo‐
nents of the cooling system are replaced at the same time,
or if an undefined amount of coolant has escaped (e.g. due
to damage caused by animal bites).
Component Note
Front axle drive -
Front transmission unit: gear -
oil cooler
Rear transmission unit: gear -
oil cooler
Radiator -
Heat exchanger for high-volt‐ -
age battery
Rear final drive -
High-voltage central box - -
JX6-
Control unit 1 for automated -
driving - J1274-
Power and control electronics -
2 for electric drive - JX4-
Coolant distributor with ther‐ -
mal management coolant
pump 4 - V620-
Thermal management coolant -
pump 4 - V620-
Coolant expansion tank -
High-voltage battery 1 - AX2- -
and high-voltage central box -
JX6-
Coolant temperature sender Prerequisite: < 100 ml of cool‐
ant escaped when renewing
component

Filling cooling system without cooling system service device -

VAS 531 011-
– Perform function “Opening electrically actuated valves in
cooling system for discharging and charging” with ⇒ Vehicle
diagnostic tester ⇒ Rep. gr. 00 ; Starting diagnosis .

50 Rep. gr.19 - Cooling

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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.

– Cut through ring of sealing tag -2-.

– Open filler cap -1-.

– Turn bleeder valve -1- to “OPEN” position.

Important
• Marking on bleeder valve -1- must align with marking for
“OPEN” position.

– Fill coolant expansion tank up to “max.” marking with coolant

(mixed according to recommended ratio) ⇒ Safety and re‐
pair instructions; Rep. gr. 00 ; Repair instructions; Replace‐
ment parts, servicing materials and consumables .
– Perform function “Opening electrically actuated valves in
cooling system after discharging and charging” with ⇒ Vehi‐
cle diagnostic tester ⇒ Rep. gr. 00 ; Starting diagnosis .
– Monitor coolant level while performing function “Bleeding
cooling system” and add coolant if necessary.
Important
• Coolant level must not drop below “min.” marking during
bleeding routine.
– Perform function “Bleeding cooling system” using ⇒ Vehicle
diagnostic tester ⇒ Rep. gr. 00 ; Starting diagnosis .

2. Cooling system/coolant 51
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– After successfully completing function “Bleeding cooling sys‐

tem”, turn bleeder valve -1- to “CLOSED” position.
Important
• Marking on bleeder valve -1- must align with marking for
“CLOSED” position.

– Check coolant level and correct it if necessary.

Important
• Coolant level must be at max. marking -1-.

– Close filler cap -1-.

– Thread open end of sealing tag -4- through filler cap -1-,
coolant expansion tank -2-, warning label -3- and sealing tag
-4- as shown in illustration and pull it closed.

Filling cooling system with cooling system service device - VAS

531 011-
Important
• Follow operating instructions for cooling system service de‐
vice - VAS 531 011- .

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– ⇒ Rep. gr. 19 ; Drain coolant .

– Perform function “Opening electrically actuated valves in

cooling system for discharging and charging” with ⇒ Vehicle
diagnostic tester ⇒ Rep. gr. 00 ; Starting diagnosis .

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.

– Cut through ring of sealing tag -2-.

– Open filler cap -1-.

– Turn bleeder valve -1- to “OPEN” position.

Important
• Marking on bleeder valve -1- must align with marking for
“OPEN” position.

– Fill “NEW” container of cooling system service device -

VAS 531 011- with sufficient coolant (mixed according to
recommended ratio) ⇒ Safety and repair instructions; Rep.

2. Cooling system/coolant 53
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gr. 00 ; Repair instructions; Replacement parts, servicing

materials and consumables
– Ensure that all coolant hoses are connected.
– Connect cooling system service device.
– Select “Vehicle maintenance” in main menu.
– Select “Pressure test” in menu and perform hydraulic leak
test.
♦ Test duration: 10 seconds
♦ Max. Delta P: 100 mbar
♦ Test pressure: 2700 mbar
♦ Refer to notes on display.
♦ The result of the test will be shown when the test is com‐
plete.
– Select “Vacuum phase” in menu and perform hydraulic leak
test.
♦ Test duration: 240 seconds
♦ Specified pressure: 40 mbar
♦ Max. Delta P: 10 mbar
♦ Test duration: 5 seconds
♦ 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 14000 g; this corresponds to
14 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 the instructions on the display and do not interrupt
the process.
♦ The result of the test will be shown when the test is com‐
plete.
♦ Repeat procedure if necessary.

– Perform function “Opening electrically actuated valves in

cooling system after discharging and charging” with ⇒ Vehi‐
cle diagnostic tester ⇒ Rep. gr. 00 ; Starting diagnosis .
– Perform function “Bleeding cooling system” using ⇒ Vehicle
diagnostic tester ⇒ Rep. gr. 00 ; Starting diagnosis .

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– After successfully completing function “Bleeding cooling sys‐

tem”, turn bleeder valve -1- to “CLOSED” position.
Important
• Marking on bleeder valve -1- must align with marking for
“CLOSED” position.

– Check coolant level and correct it if necessary.

Important
• Coolant level must be at max. marking -1-.

– Close filler cap -1-.

– Thread open end of sealing tag -4- through filler cap -1-,
coolant expansion tank -2-, warning label -3- and sealing tag
-4- as shown in illustration and pull it closed.

2.5 Draining coolant - all-wheel drive

Special tools and workshop equipment required
♦ Coolant hose, e.g. 06B 121 101 E or hose with external
diameter of 16 mm
♦ compressed air gun
♦ cooling system service device - VAS 531 011-
♦ hose clamp up to 40mm - 3093-

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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
• Observe operating instructions for cooling system service
device - VAS 531 011- .

Preparations
– Ensure that DRAIN container of cooling system service de‐
vice - VAS 531 011- has space for 14 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 .

Vehicles with front luggage compartment pan:

– Pull cover -1- off upwards -arrow-.

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All vehicles (continued)

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.

– Cut through ring of sealing tag -2-.

– Open filler cap -1-.

– Remove front underbody cladding ⇒ General body repairs,

exterior; Rep. gr. 66 ; Underbody cladding; Removing and
installing front underbody cladding .
– Detach rear section of front right wheel housing liner and
press it towards front ⇒ General body repairs, exterior; Rep.
gr. 66 ; Wheel housing liners; Removing and installing front
wheel housing liner .
– Turn front wheels all the way to the left.

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Draining coolant from rear of vehicle

– Clamp off coolant hoses -2- and -3- using hose clamp up to
40mm - 3093- .
– Place cooling system service device - VAS 531 011- under
coupling point to catch coolant.
– Detach coolant hose -3- and immediately connect angled
coolant hose to coolant pipe -4-.
Note
To make draining off easier, hold an angled coolant hose
against coolant pipe (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.
– Detach coolant hose -2-.
– Insert compressed air gun in coolant pipe -1-, seal with a
cleaning cloth and blow coolant out.
Important
• Coolant must not escape in quantities larger than drops.

Draining coolant from front of vehicle

– Connect cooling system service device - VAS 531 011- to
coolant expansion tank.

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

“Drain system”.
– Start “discharging procedure”.
– Hold coolant hoses -1- and -2- in funnel of cooling system
service device - VAS 531 011- .
– Detach hose clamp up to 40mm - 3093- and allow coolant to
drain.
– Select process “Discharging with pressure”.
– Follow the instructions on the display and blow the coolant
out.
Important
• Coolant must not escape in quantities larger than drops.
– If necessary, restart process “Discharging with pressure”.

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Draining coolant from battery

– Disconnect coolant hoses -1- and -2- and hold in funnel of
cooling system service device - VAS 531 011- .

– Attach angled coolant hose (e.g. 06B 121 101 E) to coolant

pipe -1-.
– Insert compressed air gun in coolant pipe -2-, seal with a
cleaning cloth and blow coolant out.
Important
• Coolant must not escape in quantities larger than drops.

Final steps
– Connect coolant hoses.
– ⇒ Rep. gr. 19 ; Fill cooling system .

2.6 Draining coolant - rear-wheel drive

Special tools and workshop equipment required
♦ Coolant hose, e.g. 06B 121 101 E or hose with external
diameter of 16 mm
♦ compressed air gun
♦ cooling system service device - VAS 531 011-

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.

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Procedure

Important
• Observe operating instructions for cooling system service
device - VAS 531 011- .

Preparations
– Ensure that DRAIN container of cooling system service de‐
vice - VAS 531 011- has space for 14 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 .

Vehicles with front luggage compartment pan:

– Pull cover -1- off upwards -arrow-.

60 Rep. gr.19 - Cooling

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All vehicles (continued)

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.

– Cut through ring of sealing tag -2-.

– Open filler cap -1-.

– Remove front underbody cladding ⇒ General body repairs,

exterior; Rep. gr. 66 ; Underbody cladding; Removing and
installing front underbody cladding .

Draining coolant from rear of vehicle

– Place cooling system service device - VAS 531 011- under
coupling point to catch coolant.
– Disconnect coolant hoses -1- and -4- and drain off coolant.
– Hold coolant hose -1- in funnel of cooling system service
device - VAS 531 011- .
– Insert compressed air gun in coolant hose -4-, seal with a
cleaning cloth and blow coolant out.
Important
• Coolant must not escape in quantities larger than drops.

Draining coolant from front of vehicle

– Connect cooling system service device - VAS 531 011- to
coolant expansion tank.

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

“Drain system”.
– Start “discharging procedure”.
– Attach angled coolant hose (e.g. 06B 121 101 E) to coolant
pipes -1- and -2-. Position funnel of cooling system service
device - VAS 531 011- underneath.
– Select process “Discharging with pressure”.
– Follow the instructions on the display and blow the coolant
out.
Important
• Coolant must not escape in quantities larger than drops.
– If necessary, restart process “Discharging with pressure”.

Draining coolant from battery

– Disconnect coolant hoses -1- and -2- and hold in funnel of
cooling system service device - VAS 531 011- .

– Attach angled coolant hose (e.g. 06B 121 101 E) to coolant

pipe -1-.
– Insert compressed air gun in coolant pipe -2-, seal with a
cleaning cloth and blow coolant out.
Important
• Coolant must not escape in quantities larger than drops.

Final steps
– Connect coolant hoses.
– ⇒ Rep. gr. 19 ; Fill cooling system .

2.7 Checking cooling system for leaks

Special tools and workshop equipment required

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♦ Cooling system service device - VAS 531 011-

♦ Cooling system tester - V.A.G 1274B-
♦ adapter - VAS 691 005/5-
♦ adapter for cooling system tester - V.A.G 1274/9-
♦ closure cap - VAS 691 005/2-
♦ junction - VAS 691 005/1-
♦ test adapter - VAS 691 005/4-
♦ turbocharger tester - V.A.G 1397A-

WARNING
Internal leak in a high-voltage component.
Risk of fire in high-voltage battery.
– Avoid performing unnecessary pressure tests on the cool‐
ing system if an internal leak is suspected in a high-voltage
component.

Procedure
If there is a loss of coolant without an obvious leak, there may
be internal leaks which can cause coolant to enter the high-volt‐
age battery.
If such damage occurs, coolant may flow from one high-voltage
component to another via the high-voltage wires.
Final steps must be performed after test is completed ⇒ page
71 .

– Check underbody for obvious loss of coolant.

– Check whether any active warning lamps related to the high-

voltage system are shown in the dash panel insert.
– Check event memory of high-voltage components ⇒ Vehicle
diagnostic tester.

Event memory of high-voltage system contains faults and warn‐

ing lamp active:
– Check and repair high-voltage system ⇒ Vehicle diagnostic
tester.
Note
Event memory contains faults related to insulation resistance,
for example.

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Continued
High-voltage system OK:

Vehicles with front luggage compartment pan:

– Pull cover -1- off upwards -arrow-.
All vehicles (continued)

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.

– Cut through ring of sealing tag -2-.

– Open filler cap -1-.

– Check pressure relief valve in filler cap ⇒ page 70 .

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– Turn bleeder valve -1- to “OPEN” position.

Important
• Marking on bleeder valve -1- must align with marking for
“OPEN” position.

– Perform function “Opening electrically actuated valves in

cooling system for discharging and charging” with ⇒ Vehicle
diagnostic tester ⇒ Rep. gr. 00 ; Starting diagnosis .

– Perform vacuum test ⇒ page 65 .

Vacuum test with cooling system service device - VAS 531 011-
– Connect cooling system service device - VAS 531 011- (re‐
fer to operating instructions).
– Select “Vehicle maintenance” in main menu.
– Select “Vacuum phase” in menu and perform hydraulic leak
test.
♦ Time for vacuum: 240 seconds
♦ Specified pressure: 100 mbar
♦ Max. Delta P: 50 mbar
♦ Test duration: 120 seconds
♦ Refer to notes on display.
♦ The result of the test will be shown when the test is com‐
plete.
Important
• To prevent air from entering the cooling system, the cooling
system must be filled using the service device immediately
after the pressure test while it is still under vacuum.
• If the vacuum is released by opening the coolant expansion
tank, the cooling system must be bled.
– Select “Charge system” from the menu and perform process.
♦ Filling quantity: enter mass of 10000 g; this corresponds to
10 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.

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♦ Follow the instructions on the display and do not interrupt

the process.

Vacuum test OK:

– Perform pressure test with cooling system service device -
VAS 531 011- ⇒ page 66 .

Continued
Vacuum test not OK:
– Perform checks ⇒ page 67 .

Pressure test with cooling system service device - VAS 531

011-
Important
• Cooling system service device - VAS 531 011- connected to
vehicle.
– 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.
– Release pressure in cooling system immediately.

Pressure test OK:

– Top up coolant to max mark and document it.

Continued
Pressure test not OK:
– Perform checks ⇒ page 67 .

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Vacuum/pressure test not OK:

– Remove front underbody cladding ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody cladding; Removing and
installing front underbody cladding .
– Remove rear underbody cladding ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody cladding; Removing and
installing rear underbody cladding .

Vehicles with front luggage compartment pan:

– Remove front luggage compartment pan ⇒ General body
repairs, interior; Rep. gr. 70 ; Luggage compartment trim
panels; Removing and installing front luggage compartment
pan .

All vehicles (continued)

Pressure test not OK:
– Check cooling system for external leaks.

Continued
Vacuum test not OK:
– Check cooling system for external leaks (cooling system
must be under vacuum when doing so).
Important
• Repeat vacuum test. ⇒ page 65

Continued
External leak identified in cooling system:
– Repair cooling system.
Note
If an external leak is identified, the pressure test can be started
again with the cooling system service device - VAS 531 011- to
enable the leak to be localised ⇒ page 66 .

2. Cooling system/coolant 67
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Continued
No external leaks identified in cooling system:
– Fit test adapter - VAS 691 005/4- on connection “B” on junc‐
tion - VAS 691 005/1- .
– Fit cleaning nozzle -D- on connection “A” on junction - VAS
691 005/1- .
– Open shut-off tap “A” on junction - VAS 691 005/1- .
– Close shut-off tap “C” on junction - VAS 691 005/1- .
– Hold connection “B” so that it is facing upwards and use
compressed air gun to blow air into test adapter - VAS 691
005/4- until coolant is removed.
– Remove test adapter - VAS 691 005/4- and cleaning nozzle
-D-.

– Seal off test adapter - VAS 691 005/4- with closure cap -
VAS 691 005/2- .
– Connect connection “A” on junction - VAS 691 005/1- to
connection “II” on turbocharger tester - V.A.G 1397A- .
– Connect hand pump of cooling system tester - V.A.G 1274B-
to connection “C” on junction - VAS 691 005/1- .
– Open shut-off taps “A”, “C” on junction - VAS 691 005/1- .
– Switch on turbocharger tester - V.A.G 1397A- . Select set‐
ting “II”.
– Generate pressure using hand pump until turbocharger test‐
er - V.A.G 1397A- shows a value of between 300 and
350 mbar.
– Close shut-off tap “C” on junction - VAS 691 005/1- .
– Wait one minute (settling time), then write down value shown
on turbocharger tester - V.A.G 1397A- .
– Wait 30 seconds, then check drop in pressure on turbo‐
charger tester - V.A.G 1397A- .
Important
• Maximum drop in pressure: below 5 mbar

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– Screw adapter - VAS 691 005/5- -3- onto coolant expansion

tank -4-.
– Connect adapter - VAS 691 005/5- -3- to junction - VAS 691
005/1- -2- at connection “B”.
– Open shut-off taps “A” and “C” on junction - VAS 691 005/1-
-2-.
– Switch on turbocharger tester - V.A.G 1397A- -1-. Select
setting “II”.
– Generate pressure using hand pump -5- until turbocharger
tester - V.A.G 1397A- -1- shows a value of approx. 0.5 mbar.
– Close shut-off valve “C” on junction - VAS 691 005/1- -2-
and immediately write down value shown.
Note
Check cooling system for external leaks during pressure test.
– Write down value shown on turbocharger tester - V.A.G
1397A- -1- after waiting for 5 minutes (settling time).
Important
• Pressure must not drop by more than 0.1 bar; otherwise this
indicates that there are leaks in the cooling system.
– Check drop in pressure on turbocharger tester - V.A.G
1397A- -1- after waiting a further 10 minutes.
Important
• Pressure must not drop by more than 0.05 bar; otherwise
there are leaks in the cooling system.
– Release pressure in cooling system immediately.

– Check whether any active warning lamps related to the high-

voltage system are shown in the dash panel insert.
– Check event memory of high-voltage components ⇒ Vehicle
diagnostic tester.

If result of pressure loss test is not OK and no external leaks

are identified or if an event memory entry is logged for the
high-voltage system during the pressure loss test:

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.

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

– Repair high-voltage system ⇒ Vehicle diagnostic tester.
– Check event memory of high-voltage system and check for
coolant in high-voltage wires ⇒ page 70 .

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Continued
If result of pressure loss test is not OK and external leaks are
identified:
– Repair cooling system and then perform vacuum test ⇒ page
65 .

Checking for coolant in high-voltage wires

– Unplug high-voltage wires from the following components
and check for moisture.

Checking pressure relief valve in filler cap

Important
• Cooling system tester - V.A.G 1274B- checked for leaks.

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.

– Cut through ring of sealing tag -2-.

– Open filler cap -1-.

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

adapter for cooling system tester - V.A.G 1274/9- -2- with
filler cap -3-.
– Operate hand pump -1- to build up pressure.
Important
• The pressure relief valve should open at a pressure of be‐
tween 0.7 and 0.9 bar.
– Renew filler cap -3- if pressure relief valve does not open as
described.

Final steps
– Check coolant level and correct it if necessary.
Important
• Coolant level must be at max. marking -1-.

– Close filler cap -1-.

– Thread open end of sealing tag -4- through filler cap -1-,
coolant expansion tank -2-, warning label -3- and sealing tag
-4- as shown in illustration and pull it closed.

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– Turn bleeder valve -1- to “CLOSED” position.

Important
• Marking on bleeder valve -1- must align with marking for
“CLOSED” position.

– 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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3 Coolant pump/thermostat assembly

3.1 Overview of fitting locations - coolant pump/thermostat assembly

Overview of fitting locations - coolant pumps, coolant valves

1 - Coolant pump for high-

voltage battery - V590-
❑ ⇒ Rep. gr. 19 ; Re‐
moving and installing
coolant pump for high-
voltage battery V590
2 - Changeover and mixing
valve 4 for thermal manage‐
ment - V653-
❑ Combined as one unit
with coolant manifold
❑ ⇒ Rep. gr. 19 ; Re‐
moving and installing
coolant manifold
3 - Coolant changeover valve
2 - N633-
❑ Combined as one unit
with coolant distributor
❑ ⇒ Rep. gr. 19 ; Re‐
moving and installing
coolant distributor
4 - Thermal management
coolant pump 4 - V620-
❑ ⇒ Rep. gr. 19 ; Re‐
moving and installing
thermal management
coolant pump 4 V620

Overview of fitting locations - coolant temperature senders

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1 - Coolant temperature send‐

er 1 for high-voltage battery -
G898-
❑ ⇒ Rep. gr. 19 ;
Removing and instal‐
ling coolant tempera‐
ture sender 1 for high-
voltage battery G898
2 - Coolant temperature send‐
er 2 for high-voltage battery -
G899-
❑ ⇒ Rep. gr. 19 ;
Removing and instal‐
ling coolant tempera‐
ture sender 2 for high-
voltage battery G899
3 - Coolant temperature send‐
er 7 for thermal management
- G908-
❑ ⇒ Rep. gr. 19 ;
Removing and instal‐
ling coolant tempera‐
ture sender 7 for ther‐
mal management G908
4 - Coolant temperature send‐
er 8 for thermal management
- G968-
❑ ⇒ Rep. gr. 19 ;
Removing and instal‐
ling coolant tempera‐
ture sender 8 for ther‐
mal management G968
5 - Coolant temperature send‐
er 10 for thermal manage‐
ment - G1018-
❑ ⇒ Rep. gr. 19 ; Re‐
moving and installing
coolant temperature sender 10 for thermal management G1018
6 - Coolant temperature sender 5 for thermal management - G906-
❑ ⇒ Rep. gr. 19 ; Removing and installing coolant temperature sender 5 for thermal management G906
7 - Coolant temperature sender 6 for thermal management - G907-
❑ ⇒ Rep. gr. 19 ; Removing and installing coolant temperature sender 6 for thermal management G907

3.2 Assembly overview - electric coolant pump

74 Rep. gr.19 - Cooling

 Q6 e-tron 2024 ➤
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1 - Bolt
❑ 8 Nm
2 - Rubber bush
3 - Bracket
4 - Spacer sleeve
5 - Bracket
6 - Nuts
❑ 8 Nm
7 - Coolant distributor
8 - Thermal management
coolant pump 4 - V620-
❑ ⇒ Rep. gr. 19 ; Re‐
moving and installing
thermal management
coolant pump 4 V620
9 - Retaining bracket
10 - Bolt
❑ 2x
❑ 4.2 Nm
11 - Flange nut
❑ 2x
❑ 8 Nm
12 - Rubber bush
❑ 2x
13 - Retaining bracket
❑ Must engage audibly
14 - Coolant pump for high-
voltage battery - V590-
❑ ⇒ Rep. gr. 19 ; Removing and installing coolant pump for high-voltage battery V590

3.3 Assembly overview - coolant temperature sender

3. Coolant pump/thermostat assembly 75

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1 - Mounting for coolant tem‐

perature sender
❑ Example
2 - Bolt
❑ G906, G907: 4.5 Nm
❑ G908, G968: 5.5 Nm
❑ G1018, G898, G899:
5 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
coolant temperature
sender
5 - O-ring
❑ Renew after removing

3.4 Removing and installing coolant pump

for high-voltage battery V590 - all-
wheel drive
Special tools and workshop equipment required
♦ Socket, 9 mm
♦ socket, 9 mm

Removing
– ⇒ Rep. gr. 19 ; Drain coolant .

76 Rep. gr.19 - Cooling

 Q6 e-tron 2024 ➤
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– Unplug electrical connector -4-.

– Move coolant hoses clear at retaining clips -arrows-.
– Unfasten hose clips -3- and detach coolant hoses.
– Remove bolts -1-.

– Move coolant hose clear at retaining clips -arrows-.

– Unfasten hose clips -1- and detach coolant hoses.
– Move connection -2- to side.

– Unplug electrical connector -1- and move it clear.

– Release fasteners with socket, 9 mm -arrows-, and disen‐
gage retaining bracket -2- and put it to side.
– Loosen hose clip -5- and detach coolant hose.
– Detach coolant pump for high-voltage battery - V590- -3-
with coolant hoses.
– Unfasten hose clips -4- and detach coolant hoses.

3. Coolant pump/thermostat assembly 77

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

– ⇒ Rep. gr. 19 ; Fill cooling system .

Tightening torques
♦ ⇒ Rep. gr. 19 ; Assembly overview - coolant pipes

3.5 Removing and installing coolant pump

for high-voltage battery V590 - rear-
wheel drive
Special tools and workshop equipment required
♦ hose clamps (up to 25 mm) - 3094-

Removing

Vehicles with front luggage compartment pan:

– Pull cover -1- off upwards -arrow-.

All vehicles (continued)

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.

78 Rep. gr.19 - Cooling

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– Cut through ring of sealing tag -2-.

– Open filler cap -1- briefly to release pressure in cooling sys‐
tem and then tighten cap again.

– Remove front underbody cladding ⇒ General body repairs,

exterior; Rep. gr. 66 ; Underbody cladding; Removing and
installing front underbody cladding .

– Unplug electrical connector -1-.

– Clamp off coolant hoses -2- and -4- with hose clamps (up to
25 mm) - 3094- -A-.
– Loosen hose clips -3- and detach coolant hoses -2- and -4-.
– Release fasteners -arrows-, disengage retaining bracket -5-
and place to one side.
– Detach coolant pump for high-voltage battery - V590- -6-.

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

– ⇒ Rep. gr. 19 ; Fill cooling system .

Tightening torques
♦ ⇒ Rep. gr. 19 ; Assembly overview - coolant pipes

3.6 Removing and installing thermal man‐

agement coolant pump 4 V620
Special tools and workshop equipment required
♦ hose clamps up to 25mm - 3094-

3. Coolant pump/thermostat assembly 79

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Removing
– Remove front left wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liners; Remov‐
ing and installing front wheel housing liner .

– Unplug electrical connector -2-.

– Remove bolts -arrows-.
– Remove retaining bracket -4-.
– Clamp off coolant hoses with hose clamps up to 25mm -
3094- -A-.
– Unfasten hose clips -1- and detach coolant hoses.
– Detach thermal management coolant pump 4 - V620- -3-.

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

– ⇒ Rep. gr. 19 ; Fill cooling system .

Tightening torques
♦ ⇒ Rep. gr. 19 ; Overview of fitting locations - coolant pump/
thermostat assembly
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel hous‐
ing liners; Assembly overview - front wheel housing liner

3.7 Removing and installing coolant

changeover valve 2 N633
Removing
Coolant changeover valve 2 - N633- is renewed together with
coolant distributor.

– Remove coolant distributor ⇒ Rep. gr. 19 ; Removing and

installing coolant distributor .

80 Rep. gr.19 - Cooling

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Installing
Installation is carried out in reverse sequence.

Tightening torques

3.8 Removing and installing changeover

and mixing valve 4 for thermal man‐
agement V653
Removing
Changeover and mixing valve 4 for thermal management -
V653- is renewed together with coolant manifold.

– Remove coolant manifold ⇒ Rep. gr. 19 ; Removing and

installing coolant manifold .

Installing
Installation is carried out in reverse sequence.

3.9 Removing and installing coolant tem‐

perature sender 1 for high-voltage bat‐
tery G898
Removing
Important
• Catch escaping coolant and determine volume which has
escaped.
• If more than 100 ml of coolant has escaped, drain and refill
cooling system at end of process.

– End high-voltage charging process.

– Remove front underbody cladding ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody cladding; Removing and
installing front underbody cladding .

3. Coolant pump/thermostat assembly 81

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Vehicles with front luggage compartment pan:

– Pull cover -1- off upwards -arrow-.

All vehicles (continued)

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.

– Cut through ring of sealing tag -2-.

– Open filler cap -1- briefly to release pressure in cooling sys‐
tem and then tighten cap again.

– Unplug electrical connector -2-.

– Remove bolt -3-.
– Pull out coolant temperature sender 1 for high-voltage bat‐
tery - G898- -1- and insert new coolant temperature sender
immediately.

82 Rep. gr.19 - Cooling

 Q6 e-tron 2024 ➤
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Installing
Installation is carried out in reverse order; note the following:

If more than 100 ml of coolant has escaped:

– ⇒ Rep. gr. 19 ; Drain coolant.
– ⇒ Rep. gr. 19 ; Fill cooling system.

Continued
– Add coolant and bleed cooling system ⇒ Rep. gr. 19 ;
Filling cooling system .

Tightening torques
♦ ⇒ Rep. gr. 19 ; Assembly overview - coolant temperature
sender

3.10 Removing and installing coolant tem‐

perature sender 2 for high-voltage bat‐
tery G899
Removing
Important
• Catch escaping coolant and determine volume which has
escaped.
• If more than 100 ml of coolant has escaped, drain and refill
cooling system at end of process.

– End high-voltage charging process.

– Remove front underbody cladding ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody cladding; Removing and
installing front underbody cladding .

3. Coolant pump/thermostat assembly 83

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Vehicles with front luggage compartment pan:

– Pull cover -1- off upwards -arrow-.

All vehicles (continued)

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.

– Cut through ring of sealing tag -2-.

– Open filler cap -1- briefly to release pressure in cooling sys‐
tem and then tighten cap again.

– Unplug electrical connector -2-.

– Remove bolt -3-.
– Pull out coolant temperature sender 2 for high-voltage bat‐
tery - G899- -1- and insert new coolant temperature sender
immediately.

84 Rep. gr.19 - Cooling

 Q6 e-tron 2024 ➤
Electric drive motor 0EL, 0EN - Edition 07.2024

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

If more than 100 ml of coolant has escaped:

– ⇒ Rep. gr. 19 ; Drain coolant.
– ⇒ Rep. gr. 19 ; Fill cooling system.

Continued
– Add coolant and bleed cooling system ⇒ Rep. gr. 19 ;
Filling cooling system .

Tightening torques
♦ ⇒ Rep. gr. 19 ; Assembly overview - coolant temperature
sender

3.11 Removing and installing coolant tem‐

perature sender 5 for thermal manage‐
ment G906
Removing
Important
• Catch escaping coolant and determine volume which has
escaped.
• If more than 100 ml of coolant has escaped, drain and refill
cooling system at end of process.

– End high-voltage charging process.

– Remove front left wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liners; Remov‐
ing and installing front wheel housing liner .

3. Coolant pump/thermostat assembly 85

 Q6 e-tron 2024 ➤
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Vehicles with front luggage compartment pan:

– Pull cover -1- off upwards -arrow-.

All vehicles (continued)

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.

– Cut through ring of sealing tag -2-.

– Open filler cap -1- briefly to release pressure in cooling sys‐
tem and then tighten cap again.

– Unplug electrical connector -2-.

– Remove bolt -3-.
– Pull out coolant temperature sender 5 for thermal manage‐
ment - G906- -1- and insert new coolant temperature sender
immediately.

86 Rep. gr.19 - Cooling

 Q6 e-tron 2024 ➤
Electric drive motor 0EL, 0EN - Edition 07.2024

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

If more than 100 ml of coolant has escaped:

– ⇒ Rep. gr. 19 ; Drain coolant.
– ⇒ Rep. gr. 19 ; Fill cooling system.

Continued
– Add coolant and bleed cooling system ⇒ Rep. gr. 19 ;
Filling cooling system .

Tightening torques
♦ ⇒ Rep. gr. 19 ; Assembly overview - coolant temperature
sender

3.12 Removing and installing coolant tem‐

perature sender 6 for thermal manage‐
ment G907
Removing
Important
• Catch escaping coolant and determine volume which has
escaped.
• If more than 100 ml of coolant has escaped, drain and refill
cooling system at end of process.

– End high-voltage charging process.

– Remove front left wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liners; Remov‐
ing and installing front wheel housing liner .

3. Coolant pump/thermostat assembly 87

 Q6 e-tron 2024 ➤
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Vehicles with front luggage compartment pan:

– Pull cover -1- off upwards -arrow-.

All vehicles (continued)

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.

– Cut through ring of sealing tag -2-.

– Open filler cap -1- briefly to release pressure in cooling sys‐
tem and then tighten cap again.

– Unplug electrical connector -2-.

– Remove bolt -3-.
– Pull out coolant temperature sender 6 for thermal manage‐
ment - G907- -1- and insert new coolant temperature sender
immediately.

88 Rep. gr.19 - Cooling

 Q6 e-tron 2024 ➤
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Installing
Installation is carried out in reverse order; note the following:

If more than 100 ml of coolant has escaped:

– ⇒ Rep. gr. 19 ; Drain coolant.
– ⇒ Rep. gr. 19 ; Fill cooling system.

Continued
– Add coolant and bleed cooling system ⇒ Rep. gr. 19 ;
Filling cooling system .

Tightening torques
♦ ⇒ Rep. gr. 19 ; Assembly overview - coolant temperature
sender

3.13 Removing and installing coolant tem‐

perature sender 7 for thermal manage‐
ment G908
Removing
Important
• Catch escaping coolant and determine volume which has
escaped.
• If more than 100 ml of coolant has escaped, drain and refill
cooling system at end of process.

– End high-voltage charging process.

Vehicles with all-wheel drive:

– Remove bracket for air conditioner compressor ⇒ Heating,
air conditioning; Rep. gr. 87 ; Air conditioner compressor;
Removing and installing bracket for air conditioner compres‐
sor .

Left-hand drive vehicles:

– Detach intermediate steering shaft from steering rack and
move clear by telescoping together ⇒ Running gear, axles,
steering; Rep. gr. 48 ; Steering column; Removing and in‐
stalling intermediate steering shaft .

3. Coolant pump/thermostat assembly 89

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All vehicles (continued)

Vehicles with rear-wheel drive:
– Remove front underbody cladding ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody cladding; Removing and
installing front underbody cladding .

All vehicles (continued)

Vehicles with front luggage compartment pan:
– Pull cover -1- off upwards -arrow-.

All vehicles (continued)

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.

– Cut through ring of sealing tag -2-.

– Open filler cap -1- briefly to release pressure in cooling sys‐
tem and then tighten cap again.

90 Rep. gr.19 - Cooling

 Q6 e-tron 2024 ➤
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– Move breather pipe -1- clear and press to one side.

– Unplug electrical connector -4-.
– Remove bolt -2-.
– Pull out coolant temperature sender 7 for thermal manage‐
ment - G908- -3- and insert new coolant temperature sender
immediately.

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

If more than 100 ml of coolant has escaped:

– ⇒ Rep. gr. 19 ; Draining coolant
– ⇒ Rep. gr. 19 ; Filling cooling system

Continued
– Add coolant and bleed cooling system ⇒ Rep. gr. 19 ;
Filling cooling system .

Tightening torques
♦ ⇒ Rep. gr. 19 ; Assembly overview - coolant temperature
sender

3.14 Removing and installing coolant tem‐

perature sender 8 for thermal manage‐
ment G968 - all-wheel drive
Removing
Important
• Catch escaping coolant and determine volume which has
escaped.
• If more than 100 ml of coolant has escaped, drain and refill
cooling system at end of process.

– End high-voltage charging process.

3. Coolant pump/thermostat assembly 91

 Q6 e-tron 2024 ➤
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Vehicles with front luggage compartment pan:

– Remove front luggage compartment pan ⇒ General body
repairs, interior; Rep. gr. 70 ; Luggage compartment trim
panels; Removing and installing front luggage compartment
pan .

All vehicles (continued)

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.

– Cut through ring of sealing tag -2-.

– Open filler cap -1- briefly to release pressure in cooling sys‐
tem and then tighten cap again.

Right-hand drive vehicles:

– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Removing and installing battery .

All vehicles (continued)

– Unplug electrical connector -2-.
– Remove bolt -3-.
– Pull out coolant temperature sender 8 for thermal manage‐
ment - G968- -1- and insert new coolant temperature sender
immediately.

92 Rep. gr.19 - Cooling

 Q6 e-tron 2024 ➤
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Installing
Installation is carried out in reverse order; note the following:

If more than 100 ml of coolant has escaped:

– ⇒ Rep. gr. 19 ; Draining coolant
– ⇒ Rep. gr. 19 ; Filling cooling system

Continued
– Add coolant and bleed cooling system ⇒ Rep. gr. 19 ;
Filling cooling system .

Tightening torques
♦ ⇒ Rep. gr. 19 ; Assembly overview - coolant temperature
sender

3.15 Removing and installing coolant tem‐

perature sender 8 for thermal manage‐
ment G968 - rear-wheel drive
Removing
Important
• Catch escaping coolant and determine volume which has
escaped.
• If more than 100 ml of coolant has escaped, drain and refill
cooling system at end of process.

– End high-voltage charging process.

Vehicles with front luggage compartment pan:

– Pull cover -1- off upwards -arrow-.

3. Coolant pump/thermostat assembly 93

 Q6 e-tron 2024 ➤
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All vehicles (continued)

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.

– Cut through ring of sealing tag -2-.

– Open filler cap -1- briefly to release pressure in cooling sys‐
tem and then tighten cap again.

– Remove front underbody cladding ⇒ General body repairs,

exterior; Rep. gr. 66 ; Underbody cladding; Removing and
installing front underbody cladding .

– Unplug electrical connector -1-.

– Remove bolt -2-.
– Pull out coolant temperature sender 8 for thermal manage‐
ment - G968- -3- and insert new coolant temperature sender
immediately.

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

94 Rep. gr.19 - Cooling

 Q6 e-tron 2024 ➤
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If more than 100 ml of coolant has escaped:

– ⇒ Rep. gr. 19 ; Draining coolant
– ⇒ Rep. gr. 19 ; Filling cooling system

Continued
– Add coolant and bleed cooling system ⇒ Rep. gr. 19 ;
Filling cooling system .

Tightening torques
♦ ⇒ Rep. gr. 19 ; Assembly overview - coolant temperature
sender

3.16 Removing and installing coolant tem‐

perature sender 10 for thermal man‐
agement G1018
Removing
Important
• Catch escaping coolant and determine volume which has
escaped.
• If more than 100 ml of coolant has escaped, drain and refill
cooling system at end of process.

– End high-voltage charging process.

Vehicles with front luggage compartment pan:

– Pull cover -1- off upwards -arrow-.

3. Coolant pump/thermostat assembly 95

 Q6 e-tron 2024 ➤
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All vehicles (continued)

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.

– Cut through ring of sealing tag -2-.

– Open filler cap -1- briefly to release pressure in cooling sys‐
tem and then tighten cap again.

– Remove wheel actuator (left-side) ⇒ General body repairs,

exterior; Rep. gr. 50 ; Lock carrier; Removing and installing
wheel actuator .

– Unplug electrical connector -2-.

– Remove bolt -3-.
– Pull out coolant temperature sender 10 for thermal manage‐
ment - G1018- -1- and insert new coolant temperature send‐
er immediately.

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

If more than 100 ml of coolant has escaped:

– ⇒ Rep. gr. 19 ; Drain coolant.

96 Rep. gr.19 - Cooling

 Q6 e-tron 2024 ➤
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– ⇒ Rep. gr. 19 ; Fill cooling system.

Continued
– Add coolant and bleed cooling system ⇒ Rep. gr. 19 ;
Filling cooling system .

Tightening torques
♦ ⇒ Rep. gr. 19 ; Assembly overview - coolant temperature
sender

3. Coolant pump/thermostat assembly 97

 Q6 e-tron 2024 ➤
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4 Coolant pipes

4.1 Assembly overview - coolant pipes

Assembly overview - coolant pipes (front)

1 - Retaining clip
2 - Retaining clip
3 - Bolt
❑ 2x
❑ 8 Nm
4 - Coolant hose
5 - Seal
6 - Retaining clip
7 - Coolant hose
8 - Coolant hose
9 - Seal
10 - Retaining clip
11 - Coolant hose
12 - Coolant hose
13 - Coolant hose
14 - Coolant hose
❑ Allocation ⇒ page 101
15 - Seal
❑ Renew after removing
16 - Seal
❑ Renew after removing
17 - Seal
❑ Renew after removing
18 - Coolant hose
19 - Retaining clip
20 - Seal
❑ Renew after removing
21 - Seal
❑ Renew after removing
22 - Coolant hose
23 - Breather line
24 - Breather line
25 - Seal
26 - Coolant hose

Assembly overview - coolant pipes (rear)

98 Rep. gr.19 - Cooling

 Q6 e-tron 2024 ➤
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1 - Retaining clip
2 - Coolant pipe
3 - Coolant hose
4 - Seal
❑ Renew after removing
5 - Coolant hose
6 - Retaining clip
7 - Bolt
❑ 8 Nm
8 - Retainer
❑ For coolant hoses
9 - Coolant hose
10 - Retaining clip
11 - Coolant hose
12 - Seal
❑ Renew after removing
13 - Coolant pipe

Assembly overview - coolant distributor/coolant manifold

4. Coolant pipes 99
 Q6 e-tron 2024 ➤
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1 - Retaining clip
2 - Coolant manifold
❑ With integrated
changeover and mixing
valve 4 for thermal
management - V653-
❑ ⇒ Rep. gr. 19 ; Re‐
moving and installing
coolant manifold
3 - Coolant hose
❑ 3x
❑ Allocation ⇒ page 101
4 - O-ring
❑ Renew after removing
5 - Bolt
❑ 2x
❑ 8 Nm
6 - Rubber bush
❑ 2x
7 - Spacer sleeve
❑ 2x
8 - Coolant distributor
❑ With integrated coolant
changeover valve 2 -
N633-
❑ ⇒ Rep. gr. 19 ; Re‐
moving and installing
coolant distributor
9 - Coolant hose
10 - Coolant hose
11 - Spacer sleeve
❑ 2x
12 - Rubber bush
❑ 2x
13 - Bolt
❑ 2x
❑ 8 Nm
14 - Rubber bush
❑ 3x
15 - Flange nut
❑ 3x
❑ 8 Nm

100 Rep. gr.19 - Cooling

 Q6 e-tron 2024 ➤
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Allocation of coolant hoses

Coolant hose Coolant manifold
A A
B B
C C
D D
E E
F F

4.2 Removing and installing coolant distrib‐

utor
Special tools and workshop equipment required
♦ hose clamps up to 25mm - 3094-

Removing
– Remove wheel actuator (left-side) ⇒ General body repairs,
exterior; Rep. gr. 50 ; Lock carrier; Removing and installing
wheel actuator .

– Clamp off coolant hoses -1- with hose clamps up to 25mm -

3094- -A-.

4. Coolant pipes 101

 Q6 e-tron 2024 ➤
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– Unplug electrical connector -1- and move it clear.

– Starting from top, detach coolant hoses -2- by turning them
anti-clockwise -arrow-.

– Unplug electrical connectors -3-.

– Release retaining clip -5- and move coolant hose -4- clear.
– Turn coolant hose -4- anti-clockwise -arrow- and detach it
from coolant distributor -2-.
– Unscrew bolts -1- and remove coolant distributor -2-.

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

If coolant distributor is renewed:

– Remove coolant pump ⇒ Rep. gr. 19 ; Removing and in‐
stalling thermal management coolant pump 4 V620 .
– Remove coolant temperature senders ⇒ Rep. gr. 19 ; Re‐
moving and installing coolant temperature sender 5 for ther‐
mal management G906 , ⇒ Rep. gr. 19 ; Removing and
installing coolant temperature sender 6 for thermal manage‐
ment G907 .

Continued
– ⇒ Rep. gr. 19 ; Fill cooling system .

Tightening torques
♦ ⇒ Rep. gr. 19 ; Assembly overview - coolant pipes

102 Rep. gr.19 - Cooling

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4.3 Removing and installing coolant mani‐

fold
Removing
– ⇒ Rep. gr. 19 ; Drain coolant .

Vehicles with all-wheel drive:

– Remove subframe ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Subframe; Removing and installing subframe with
motor; Removing and installing subframe with motor .

All vehicles (continued)

Vehicles with rear-wheel drive:
– Remove front underbody cladding ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody cladding; Removing and
installing front underbody cladding .
– Remove front left wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liners; Remov‐
ing and installing front wheel housing liner .

Left-hand drive vehicles:

– Detach intermediate steering shaft from steering rack and
move clear by telescoping together ⇒ Running gear, axles,
steering; Rep. gr. 48 ; Steering column; Removing and in‐
stalling intermediate steering shaft .

All vehicles (continued)

– Unplug electrical connectors -6-.
– Move wiring harness clear at coolant manifold -5-.
– Move coolant hose -3- clear at coolant manifold -5-.
– Unfasten hose clips -1-, -2-, -4-, -7- and detach coolant ho‐
ses.
– Unscrew nuts -arrows- and detach coolant manifold -5-.

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

4. Coolant pipes 103

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– ⇒ Rep. gr. 19 ; Fill cooling system .

Tightening torques
♦ ⇒ Rep. gr. 19 ; Assembly overview - coolant pipes

104 Rep. gr.19 - Cooling

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5 Radiator/radiator fan

5.1 Assembly overview - radiator/radiator fan

5. Radiator/radiator fan 105

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1 - Radiator fan - V7-

❑ ⇒ Rep. gr. 19 ; Re‐
moving and installing
radiator fan V7
2 - Radiator cowl
❑ ⇒ Rep. gr. 19 ; Re‐
moving and installing
radiator cowl
3 - Air guide
4 - Bolt
❑ 5x
❑ 4.2 Nm
5 - Bolt
❑ 2x
❑ 4.2 Nm
6 - Speed nut
❑ 3x
7 - Air duct
8 - Spreader rivet
❑ 2x
9 - Air duct
10 - Bolt
❑ 3x
❑ 5 Nm
11 - Elastomer bush
❑ Insert in lower part
of retaining frame -24-
first, then insert bracket
-12-
12 - Bracket
❑ Insert elastomer bush -11- in lower part of retaining frame -24- first, then insert bracket
13 - Bolt
❑ ⇒ General body repairs, exterior; Rep. gr. 63 ; Front bumper; Assembly overview - bumper carrier
14 - O-ring
❑ Check for damage
15 - Coolant hose
16 - Coolant hose
17 - Upper part of retaining frame
18 - Bolt
❑ 5x
❑ 4.2 Nm
19 - Radiator
❑ ⇒ Rep. gr. 19 ; Removing and installing radiator
20 - Condenser
❑ ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit; Removing and installing condenser
21 - Elastomer bush
❑ Insert in lower part of retaining frame -24- first, then insert bracket -23-

106 Rep. gr.19 - Cooling

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22 - Bolt
❑ Tightening torque ⇒ General body repairs, exterior; Rep. gr. 50 ; Lock carrier; Assembly overview -
lock carrier
23 - Bracket
❑ Insert elastomer bush -21- in lower part of retaining frame -24- first, then insert bracket
24 - Lower part of retaining frame

5.2 Assembly overview - radiator blind

1 - Air guide (side, right)

❑ ⇒ “5.10 Removing
and installing air guide
(side)”, page 115
2 - Air duct (side, left)
❑ ⇒ “5.10 Removing
and installing air guide
(side)”, page 115
3 - Radiator blind
❑ ⇒ Rep. gr. 19 ; Re‐
moving and installing
radiator blind
4 - Radiator blind control mo‐
tor - V544-
❑ ⇒ Rep. gr. 19 ; Re‐
moving and installing
radiator blind control
motor V544
5 - Bracket
6 - Bolt
❑ 4 Nm
7 - Adaptive cruise control
unit
8 - Air guide (front)
❑ ⇒ “5.9 Removing and
installing air guide
(front) for radiator
blind”, page 114
9 - Bolt
❑ Tightening torque
⇒ Driver assist sys‐
tems; Rep. gr. 98 ;
Adaptive cruise control;
Assembly overview - adaptive cruise control
❑ 3x
10 - Bolt
❑ 6x
❑ 6 Nm

5.3 Removing and installing radiator

Special tools and workshop equipment required

5. Radiator/radiator fan 107

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♦ drip tray for workshop hoist - VAS 6208-

♦ hose clamps up to 25mm - 3094-

Removing
– Remove radiator blind ⇒ Rep. gr. 19 ; Removing and instal‐
ling radiator blind .

– Remove bolt -1-.

– Remove bolts -2-.

– Release fasteners -arrow- and detach upper part of retaining
frame -1-.

108 Rep. gr.19 - Cooling

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– Clamp off coolant hoses with hose clamps up to 25mm -

3094- -A-.
– Place drip tray for workshop hoist - VAS 6208- underneath.
– Release and detach coolant hose -2-.
– Unfasten hose clips -3- and detach coolant hose.
– Release fastener -arrow- (both sides), swivel radiator -1-
forwards and detach.

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
♦ ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
Assembly overview - refrigerant lines

5.4 Removing and installing radiator fan

V7
Removing
– Remove radiator cowl ⇒ Rep. gr. 19 ; Removing and instal‐
ling radiator cowl .

– Move electrical wire clear.

– Remove bolts -arrows-.
– Detach radiator fan -2- from radiator cowl -1-.

5. Radiator/radiator fan 109

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

Tightening torques
♦ ⇒ Rep. gr. 19 ; Assembly overview - radiator/radiator fan

5.5 Removing and installing radiator blind

Removing
– Remove air guide (front) for radiator blind ⇒ “5.9 Removing
and installing air guide (front) for radiator blind”, page 114 .

Vehicles with front luggage compartment pan:

– Remove front luggage compartment pan ⇒ General body
repairs, interior; Rep. gr. 70 ; Luggage compartment trim
panels; Removing and installing front luggage compartment
pan .

All vehicles (continued)

– Unplug electrical connector -1-.
– Unplug electrical connectors -3-.
– Move wiring harness -2- clear.

– Unplug electrical connector -3- (both sides) and move clear.

– Move electrical wire -4- clear.
– Release fasteners -arrows- and detach air guide (side, left
and right) -1- towards back.
– Detach radiator blind -2-.

110 Rep. gr.19 - Cooling

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Installing
Installation is carried out in reverse sequence.

5.6 Removing and installing radiator blind

control motor V544
Removing
– Remove adaptive cruise control unit - J428- / control unit 2
for adaptive cruise control - J850- ⇒ Driver assist systems;
Rep. gr. 98 ; Senders/sensors/control units; Removing and
installing adaptive cruise control unit J428/J850 .

– Remove bolt -arrow-.

– Swivel bracket -2- downwards and disengage at top of radia‐
tor blind -1- (guide out electrical connectors -3- when doing
so).

– Release fastener and detach radiator blind control motor -

V544- -1- towards right side.
– Unplug electrical connector -2-.

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

– Perform function “Adapting end stops for radiator blind”

⇒ Rep. gr. 00 ; Starting diagnosis .

5. Radiator/radiator fan 111

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Tightening torques
♦ ⇒ Rep. gr. 19 ; Assembly overview - radiator blind

5.7 Removing and installing radiator cowl

Removing
– Move bumper carrier into service position ⇒ General body
repairs, exterior; Rep. gr. 63 ; Front bumper; Moving bump‐
er carrier to and back from service position .

– Unscrew bolts -arrows- and detach air guide -2- from lower
part of retaining frame -1-.

– Move wiring harness clear.

– Carefully release catch -arrow A-.
– Turn radiator cowl -2- clockwise -arrow B- and detach it from
lower part of retaining frame -1-.

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

Tightening torques
♦ ⇒ Rep. gr. 19 ; Assembly overview - radiator/radiator fan

5.8 Removing and installing radiator mod‐

ule
Special tools and workshop equipment required
♦ drip tray for workshop hoist - VAS 6208-

112 Rep. gr.19 - Cooling

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♦ hose clamps up to 25mm - 3094-

Removing
– Disconnect refrigerant lines from condenser ⇒ Heating, air
conditioning; Rep. gr. 87 ; Refrigerant circuit; Detaching and
attaching refrigerant lines at condenser .
– Remove radiator cowl ⇒ Rep. gr. 19 ; Removing and instal‐
ling radiator cowl .
– Remove radiator blind ⇒ Rep. gr. 19 ; Removing and instal‐
ling radiator blind .

– Detach air duct (side) -2- on both sides.

– Unplug electrical connector -4-.

– Clamp off coolant hoses with hose clamps up to 25mm -
3094- -A-.
– Place drip tray for workshop hoist - VAS 6208- underneath.
– Release and detach coolant hoses -2-, -3-.

5. Radiator/radiator fan 113

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– Move electrical wire -4- clear on both sides.

– Detach radiator module -1-.

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

– ⇒ Rep. gr. 19 ; Fill cooling system .

5.9 Removing and installing air guide

(front) for radiator blind
Removing
– Remove bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Bumper (front); Removing and installing bump‐
er cover .

114 Rep. gr.19 - Cooling

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– Remove bolts -3- on both sides.

– Pull radiator blind -2- slightly towards front.
– Release fasteners -arrow- all around and detach air duct -1-.

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

Tightening torques
♦ ⇒ Rep. gr. 19 ; Assembly overview - radiator blind

5.10 Removing and installing air guide

(side)
Removing
– Remove radiator blind ⇒ Rep. gr. 19 ; Removing and instal‐
ling radiator blind .
– Detach air guide (side) towards front.

Installing
Installation is carried out in reverse sequence.

5. Radiator/radiator fan 115

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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 .

116 Rep. gr.93 - Electric drive systems

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2 High-voltage components

2.1 Overview of fitting locations - high-voltage components

2. High-voltage components 117

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1 - High-voltage battery
charging socket 2 - UX5-
❑ ⇒ Rep. gr. 93 ;
Assembly overview -
charging socket 2
❑ ⇒ Rep. gr. 93 ;
Removing and instal‐
ling high-voltage bat‐
tery charging socket 2
UX5
2 - High-voltage central box -
JX6-
❑ ⇒ Rep. gr. 93 ; As‐
sembly overview - high-
voltage central box
❑ ⇒ Rep. gr. 93 ;
Removing and instal‐
ling high-voltage central
box
3 - Power and control elec‐
tronics for electric drive - JX1-
❑ ⇒ Rep. gr. 93 ; As‐
sembly overview - pow‐
er and control electron‐
ics for electric drive,
rear-wheel drive
❑ ⇒ Rep. gr. 93 ; Re‐
moving and installing
power and control elec‐
tronics for electric drive
- rear-wheel drive
4 - High-voltage battery
charging socket 1 - UX4-
❑ ⇒ Rep. gr. 93 ;
Assembly overview -
charging socket
❑ ⇒ Rep. gr. 93 ; Removing and installing high-voltage battery charging socket 1 UX4
5 - Three-phase current drive - VX54-
❑ ⇒ Rep. gr. 93 ; Electric drive motor
❑ ⇒ Rep. gr. 10 ; Removing and installing rear motor
6 - Switching unit for high-voltage battery - SX6-
❑ ⇒ Rep. gr. 93 ; Assembly overview - switching unit for high-voltage battery SX6
❑ ⇒ Rep. gr. 93 ; Removing and installing switching unit for high-voltage battery SX6
7 - High-voltage battery 1 - AX2-
❑ ⇒ Rep. gr. 93 ; Assembly overview - high-voltage battery 1 AX2 (installed)
❑ ⇒ Rep. gr. 93 ; Removing and installing high-voltage battery 1 AX2
8 - Three-phase current drive 2 - VX97-
❑ Vehicles with all-wheel drive
❑ ⇒ Rep. gr. 93 ; Electric drive motor
❑ ⇒ Rep. gr. 10 ; Removing and installing front motor
9 - Power and control electronics 2 for electric drive - JX4-
❑ Vehicles with all-wheel drive
❑ ⇒ Rep. gr. 93 ; Assembly overview - power and control electronics for electric drive, all-wheel drive
❑ ⇒ Rep. gr. 93 ; Removing and installing power and control electronics for electric drive - all-wheel
drive

118 Rep. gr.93 - Electric drive systems

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10 - Air conditioner compressor - VX81-

❑ ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Assembly overview - air
conditioner compressor
11 - High-voltage heater (PTC) - ZX17-
❑ ⇒ Heating, air conditioning; Rep. gr. 87 ; Front heater and air conditioning unit; Assembly overview -
heater and air conditioning unit
❑ ⇒ Heating, air conditioning; Rep. gr. 87 ; Front heater and air conditioning unit; Removing and
installing high-voltage heater (PTC) ZX17

2. High-voltage components 119

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3 Warning labels

3.1 Checking warning stickers

Procedure
♦ Warning stickers are affixed to all high-voltage components.
♦ When performing maintenance work, it is important to en‐
sure that these warning stickers do not get damaged or dirty,
and that they are present on all high-voltage components.
Important
• Renew warning sticker if necessary.
There are warning stickers on the following components:
♦ Emergency label on left side of maintenance connector for
high-voltage system behind coolant expansion tank.

♦ Emergency label inside vehicle behind luggage compart‐

ment side trim (left-side) on fuse carrier

120 Rep. gr.93 - Electric drive systems

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Country-specific version (China)

♦ High-voltage battery charging socket 1 - UX4-

Country-specific version (China)

♦ High-voltage battery charging socket 2 - UX5-

♦ High-voltage heater (PTC) - ZX17-

3. Warning labels 121

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♦ Three-phase current drive 2 - VX97-

♦ Three-phase current drive - VX54-

♦ Air conditioner compressor - VX81-

122 Rep. gr.93 - Electric drive systems

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♦ High-voltage central box - JX6-

♦ Power and control electronics for electric drive - JX1-

♦ Power and control electronics 2 for electric drive - JX4-

♦ High-voltage battery 1 - AX2-

3. Warning labels 123

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♦ Switching unit for high-voltage battery - SX6-

124 Rep. gr.93 - Electric drive systems

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4 High-voltage battery unit

4.1 Assembly overview - high-voltage battery (installed)

4. High-voltage battery unit 125

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1 - Bolt
❑ 10x
❑ 100 Nm
2 - Bolt
❑ 2x
❑ 55 Nm
3 - Potential equalisation line
❑ ⇒ Rep. gr. 93 ; Poten‐
tial equalisation lines
4 - Nut
❑ 3 Nm +45°
5 - Bracket
6 - Bolt
❑ 2x
❑ 8 Nm
7 - Bolt
❑ 2x
❑ 55 Nm
8 - High-voltage battery 1 -
AX2-
❑ ⇒ Rep. gr. 93 ; Re‐
moving and installing
high-voltage battery 1
AX2
9 - Bolt
❑ 2x
❑ Renew after removing
❑ 50 Nm +180°
10 - Skid plate
❑ ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody cladding; Removing and installing skid
plate for high-voltage battery
11 - Bolt
❑ ⇒ General body repairs, exterior; Rep. gr. 66 ; Assembly overview - underbody cladding
12 - Coolant pipe
❑ ⇒ Rep. gr. 19 ; Assembly overview - coolant pipes
13 - Bolt
❑ 8 Nm
14 - Bolt
❑ 2x
❑ Renew after removing
❑ 50 Nm +180°
15 - Bracket
16 - Bracket
17 - Bolt
❑ 8 Nm
18 - Bolt
❑ 2x

126 Rep. gr.93 - Electric drive systems

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❑ Renew after removing

❑ 50 Nm +180°
19 - Bracket
20 - Bolt
❑ 8 Nm
21 - Bracket
22 - Bolt
❑ ⇒ General body repairs, exterior; Rep. gr. 66 ; Assembly overview - underbody cladding

4.2 Assembly overview - switching unit for high-voltage battery

4. High-voltage battery unit 127

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1 - Bolt
❑ 14x
❑ Renew after removing
❑ ⇒ page 130
2 - Battery regulation control
unit - J840-
❑ Renew after removing
❑ ⇒ Rep. gr. 93 ; Re‐
moving and installing
battery regulation con‐
trol unit J840
3 - Cover
❑ Renew after removing
4 - Bolt
❑ 6x
❑ Stage 1: 2.5 Nm
❑ Stage 2: 4.5 Nm
5 - Cover
❑ Renew after removing
6 - Bolt
❑ 8x
❑ Stage 1: 2.5 Nm
❑ Stage 2: 4.5 Nm
7 - Bolt
❑ 8 Nm
8 - Pressure-equalisation ele‐
ment
❑ Apply corrosion protec‐
tion ⇒ page 129
9 - Bolt
❑ 6x
❑ Stage 1: 2.5 Nm
❑ Stage 2: 4.5 Nm
10 - Cover
❑ Renew after removing
11 - Switching unit for high-voltage battery - SX6-
❑ With control unit 1 for high-voltage battery monitor - J1297- and control unit 2 for high-voltage battery
monitor - J1298-
❑ ⇒ Rep. gr. 93 ; Removing and installing switching unit for high-voltage battery SX6
12 - Bolt
❑ 41x
❑ Renew after removing
❑ ⇒ page 129
❑ ⇒ page 129

128 Rep. gr.93 - Electric drive systems

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Bolts securing battery connector to switching unit connection -

tightening torque
Bolts Tightening torque
-Arrows- 8.5 Nm

Switching unit for high-voltage battery SX6 - tightening torque

and sequence
Stage Bolts Tightening torque
1. In tightening se‐ 10 Nm
quence
2. In tightening se‐ 10 Nm + 90°
quence

Applying corrosion protection

1 - Pressure-equalisation element
- Corrosion protection: special lubricant -arrow- ⇒ Electronic
parts catalogue (ETKA)
2 - Bolt
- Corrosion protection: special lubricant -arrow- ⇒ Electronic
parts catalogue (ETKA)

4. High-voltage battery unit 129

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Battery regulation control unit J840 - tightening torque and se‐

quence
Stage Bolts Tightening torque
1. Sequence -1- to -4- 2 Nm
2. Remaining bolts: 2 Nm
clockwise
3. All 4.5 Nm

4.3 Inspecting and classifying high-voltage battery 1 AX2

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

– Put on protective equipment:
♦ Fabric gloves
♦ Safety goggles
♦ Safety shoes with ESD protection
Protective equipment ⇒ Electronic parts catalogue (ETKA)

– Check for the following on high-voltage battery 1 - AX2- :

♦ Cracks in upper or lower part of battery housing.
♦ Deformations in upper or lower part of battery housing.
♦ Temperature-induced discolourations and heat tinting on
battery housing.
♦ Escaping electrolyte.

130 Rep. gr.93 - Electric drive systems

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♦ Damage to high-voltage contacts.

♦ Presence and legibility of information and warning stickers
♦ Correct fitting of potential equalisation line.
♦ Corrosion damage
– After performing visual inspection, perform a classification of
high-voltage battery 1 - AX2- .

If high-voltage battery has been removed:

– Perform diagnosis of removed high-voltage battery ⇒ Rep.
gr. 93 ; Diagnosis of removed high-voltage battery 1 AX2 .

Classification of high-voltage battery:

– Perform “Classification of high-voltage battery” function with
⇒ Vehicle diagnostic tester ⇒ Rep. gr. 00 ; Starting diagno‐
sis .

4.4 Diagnosis of removed high-voltage bat‐

tery 1 AX2
Special tools and workshop equipment required
♦ diagnostic cable - VAS 5581A/18-
♦ diagnostics box - VAS 5581A-

High-voltage battery removed

– Connect diagnostic cable - VAS 5581A/18- to diagnostics
box - VAS 5581A- .

– Connect diagnostic cable - VAS 5581A/18- to 12-volt con‐

nector -1- of high-voltage battery 1 - AX2- .
– Connect black earth clamp of diagnostic cable - VAS
5581A/18- to earth on battery housing -2-.

– Connect ⇒ Vehicle diagnostic tester to diagnostics box -

VAS 5581A- .

4. High-voltage battery unit 131

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Important
• Gateway (GW) mode must be selected on diagnostics box -
VAS 5581A- .
• CAN bus terminal resistor of diagnostics box - VAS 5581A-
is pre-set to 120 Ω and must not be changed.
• Terminal 30 and terminal 15 must be switched on on diag‐
nostics box - VAS 5581A- .
– Perform diagnosis of high-voltage battery using ⇒ Vehicle
diagnostic tester.

If further work is being performed on high-voltage battery:

– Disconnect diagnostics box - VAS 5581A- .

4.5 Determining mean cell voltage

Important
• The mean cell voltage must be determined before a battery
module is renewed.

If high-voltage battery has been removed:

– Perform diagnosis of removed high-voltage battery ⇒ Rep.
gr. 93 ; Diagnosis of removed high-voltage battery 1 AX2 .

Determining mean cell voltage:

– Perform “Determining mean cell voltage” function with ⇒ Ve‐
hicle diagnostic tester ⇒ Rep. gr. 00 ; Starting diagnosis .

4.6 Charging and discharging battery mod‐

ules
Special tools and workshop equipment required
♦ Connecting cable - VAS 6910A/28-
♦ Module balancer - VAS 6910A-
♦ Wire set - VAS 6910A/27-
♦ terminal cover - T40480-
A new battery module must be charged or discharged prior
to installation according to the result of the mean cell voltage
calculation ⇒ “4.5 Determining mean cell voltage”, page 132 .
Module balancer - VAS 6910A- is controlled via ⇒ Vehicle diag‐
nostic tester.
Important
• New battery module unpacked and placed in installation po‐
sition on insert from original packaging.

132 Rep. gr.93 - Electric drive systems

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– Put on protective equipment:

♦ Fabric gloves
♦ Safety goggles
♦ Safety shoes with ESD protection
Protective equipment ⇒ Electronic parts catalogue (ETKA)
– Connect module balancer - VAS 6910A- ⇒ manual for mod‐
ule balancer - VAS 6910A- .
– Perform “Module balancer VAS 6910A” function with ⇒ Vehi‐
cle diagnostic tester ⇒ Rep. gr. 00 ; Starting diagnosis .
– Start selected program and follow instructions on display of
vehicle diagnostic tester.

– After charging or discharging new battery module, fit termi‐

nal cover - T40480- -A- on battery module -1-.

– When new battery module has been charged or discharged

to the calculated voltage, install battery module ⇒ Rep.
gr. 93 ; Installing battery module .

4.7 Leak test for high-voltage battery 1

AX2

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

Sealing off connections on switching unit

4. High-voltage battery unit 133

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1 - Leak-tight connector
❑ Leak-tight connector -
T40481-
2 - Leak-tight test adapter
❑ Leak-tight test adapter -
VAS 691 005/21-
3 - Leak-tight connector
❑ Leak-tight connector -
T40481-
4 - Leak-tight connector
❑ Leak-tight connector -
T40475-
5 - Leak-tight connector
❑ Leak-tight connector -
T40402-
6 - Leak-tight connector
❑ Leak-tight connector -
T40482-
7 - Leak-tight connector
❑ Leak-tight connector -
T40418A-

Setting up equipment

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1 - Junction
❑ Connect junction - VAS
691 005/1- to leak-tight
test adapter - VAS 691
005/21 -
2 - Test instrument box
❑ Test instrument box -
VAS 6356-
3 - Connecting cable
❑ Plug connecting cable
- VAS 5051/66- into
green T/D-1 socket on
test instrument box -
VAS 6356-
4 - Pressure sensor
❑ Pressure sensor - VAS
611 013-
5 - Pressure and vacuum
pump
❑ Pressure and vacuum
pump - VAS 671 005-

4.7.2 Cleaning and checking test tools

Special tools and workshop equipment required
♦ Pressure and vacuum pump - VAS 671 005-
♦ Pressure sensor - V.A.G 1397B-
♦ Test connector set - VAS 6911/3B-
♦ Turbocharger tester - V.A.G 1397A-
♦ adapter - VAS 691 005/4-
♦ cooling system testing set for high-voltage batteries - VAS
691 005-
♦ junction - VAS 691 005/1-
Proceed as follows to ensure that no coolant residue remains in
cooling system testing set for high-voltage batteries - VAS 691
005- :

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

– Fit cleaning nozzle -D- from testing set on outlet -A-.
– Close open outlet -C- with lever.
– Hold outlet -B- upwards and blow through with compressed
air; any coolant present will come out of cleaning nozzle -D-
when you do this.

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Self-test of cooling system testing set for high-voltage batteries

- VAS 691 005- with turbocharger tester - V.A.G 1397A- :
– Assemble the following parts:
1 - Turbocharger tester - V.A.G 1397A-
2 - Test connector set - VAS 6911/3B- attached to junction -
VAS 691 005/1-
3 - Pressure and vacuum pump - VAS 671 005-
– Open shut-off taps “A” and “C” on junction - VAS 691
005/1- .
– Switch on turbocharger tester - V.A.G 1397A- and select
setting “II”.

NOTICE
Battery housing and testing equipment may be damaged if
pressures are too high.
– Observe specified pressures during self-test and leak test.

– Generate pressure using pressure and vacuum pump - VAS

671 005- until turbocharger tester - V.A.G 1397A- shows a
value of 300 … 350 mbar.
– Close shut-off tap “C” on junction - VAS 691 005/1- .
– 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

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All vehicles (continued)

Self-test of cooling system testing set for high-voltage batteries
- VAS 691 005- with pressure sensor - V.A.G 1397B- :
– Assemble the following parts:
1 - Test connector set - VAS 6911/3B- attached to junction -
VAS 691 005/1-
2 - Pressure sensor - V.A.G 1397B-
3 - Pressure and vacuum pump - VAS 671 005-
– Open shut-off taps “A” and “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.

NOTICE
Excessive pressure will damage pressure sensor - V.A.G
1397B- .
– Observe specified pressures during self-test and leak test.

– Generate pressure using pressure and vacuum pump - VAS

671 005- until pressure sensor - V.A.G 1397B- shows a
value of 300 … 350 mbar.
– Close shut-off tap “C” on junction - VAS 691 005/1- .
– 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

4.7.3 Leak test for battery housing

Special tools and workshop equipment required
♦ Diagnostic cable - VAS 5581A/18-
♦ leak-tight connector - T40402-

Important
• Vacuum is used for leak test for high-voltage battery 1 -
AX2- .
• A leak test must always be carried out before opening and
after sealing high-voltage battery 1 - AX2- .
• High-voltage battery 1 - AX2- must be acclimatised.
• The leak test and acclimatisation must be carried out at a
constant ambient temperature.

Setting up test equipment

– ⇒ “4.7.2 Cleaning and checking test tools”, page 135

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– ⇒ “4.7.1 Test equipment layout - leak test for high-voltage

battery”, page 133
– If high-voltage battery has been removed ⇒ Rep. gr. 93 ;
Diagnosis of removed high-voltage battery 1 AX2

Leak test for battery housing:

– Perform “Leak test for battery housing of high-voltage bat‐
tery” function with ⇒ Vehicle diagnostic tester ⇒ Rep.
gr. 00 ; Starting diagnosis .
– Start selected program and follow instructions on display of
vehicle diagnostic tester.
Note
During the test, diagnostic cable - VAS 5581A/18- or connector
on switching unit in vehicle must be replaced with leak-tight
connector - T40402- immediately before building up pressure.
Diagnostic cable - VAS 5581A/18- or connector on switching
unit in vehicle is not sealed.

If leak has been identified:

– Check for leaks ⇒ Rep. gr. 93 ; Checking high-voltage
battery 1 AX2 for leaks .

4.8 Leak test for cooling system for high-

voltage battery 1 AX2
Special tools and workshop equipment required
♦ closure cap - VAS 691 005/20-2-
♦ connecting cable - VAS 5051/66-
♦ cooling system tester - V.A.G 1274B-
♦ junction - VAS 691 005/1-
♦ leak-tight test adapter - VAS 691 005/20-3-
♦ pressure sensor - V.A.G 1397B-
♦ test equipment box - VAS 6356-
Important
• Coolant circuit for high-voltage battery empty ⇒ Rep.
gr. 19 ; Draining coolant

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Setting up test equipment

– Fit closure cap - VAS 691 005/20-2- on connection -A- on
coolant line for high-voltage battery -1-.
– Fit test adapter - VAS 691 005/20-3- on connection -B-.

– Connect junction - VAS 691 005/1- -1- to pressure sensor -

V.A.G 1397B- -4- and cooling system tester - V.A.G 1274B-
-5-.
– Connect pressure sensor - V.A.G 1397B- -4- to test instru‐
ment box - VAS 6356- -2- with connecting cable - VAS
5051/66- -3-.
– Connect junction - VAS 691 005/1- -1- to leak-tight test
adapter - VAS 691 005/20-3- .

If high-voltage battery has been removed

– ⇒ Rep. gr. 93 ; Diagnosis of removed high-voltage battery 1
AX2

Leak test for coolant circuit

– Connect test equipment box - VAS 6356- to ⇒ Vehicle diag‐
nostic tester.
– Perform “Leak test for coolant circuit” function with ⇒ Vehicle
diagnostic tester ⇒ Rep. gr. 00 ; Starting diagnosis .
– If a drop in pressure is identified, localise and repair leak.

4.9 Checking high-voltage battery for leaks

Special tools and workshop equipment required
♦ pressure and vacuum pump - VAS 671 005-
Note
The procedure for localising leaks on high-voltage battery 1 -
AX2- must only be carried out if the leak test under pressure
was failed.

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– Seal off connections on switching unit for high-voltage bat‐

tery - SX6- ⇒ “4.7.1 Test equipment layout - leak test for
high-voltage battery”, page 133 .
– Generate pressure of 50 mbar with pressure and vacuum
pump - VAS 671 005- .
– Use leak detection spray to localise leak. Leaks create bub‐
bles.
– Repair leak.

4.10 Removing and installing high-voltage

battery 1 AX2
Special tools and workshop equipment required
♦ -VAS 6131/10-5-
♦ -VAS 6131/10-7-
♦ -VAS 6131/10-8-
♦ Support - VAS 6131/19-
♦ closure cap - VAS 691 005/20-2-
♦ drip tray for workshop hoist - VAS 6208-
♦ hose clamps up to 25mm - 3094-
♦ insulating mats - VAS 6762/44-
♦ scissor-type assembly platform - VAS 6131A-
♦ support set for Audi - VAS 6131/10-

Removing
Important
• If one or more battery modules need to be renewed after
removing the high-voltage battery, determine mean cell volt‐
age ⇒ “4.5 Determining mean cell voltage”, page 132 .
• 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 bat‐
tery modules .
• The arms of the lifting platform must not hinder the lowering
of the high-voltage battery later.

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.

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

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– Remove front, side and rear underbody cladding ⇒ General

body repairs, exterior; Rep. gr. 66 ; Underbody cladding;
Assembly overview - underbody cladding .
– Perform classification of high-voltage battery 1 - AX2-
⇒ Rep. gr. 93 ; Inspecting and classifying high-voltage
battery 1 AX2 .
– Detach rear section of front wheel housing liner and press it
towards front ⇒ General body repairs, exterior; Rep. gr. 66 ;
Wheel housing liners; Removing and installing front wheel
housing liner .
– Unfasten front section of rear wheel housing liner and push it
towards rear ⇒ General body repairs, exterior; Rep. gr. 66 ;
Wheel housing liners; Removing and installing rear wheel
housing liner .
– Remove high-voltage central box ⇒ Rep. gr. 93 ; Removing
and installing high-voltage central box .

– Clamp off coolant hoses -1-, -2- with hose clamps up to

25mm - 3094- -A-.
– Place drip tray for workshop hoist - VAS 6208- underneath.
– Detach coolant hoses -1-, -2-.

– Immediately fit closure cap - VAS 691 005/20-2- on connec‐

tions -1- and -2- on coolant line for high-voltage battery.

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Vehicles without control unit 1 for automated driving J1274,

high:
– Remove bolt -2-.
– Open retaining clips -arrows- and move coolant hoses -1-
clear.

All vehicles (continued)

Vehicles with control unit 1 for automated driving J1274, high:
– Remove bolts -1-.
– Move coolant hoses -2- clear -arrows-.

All vehicles (continued)

– Remove floor mats.
– Remove covers -3- at front of floor covering -2-.
– Fold back front -2- and rear -1- of floor covering at perfora‐
tions -arrows-.
– Remove bolts underneath; to do so, move front seat as re‐
quired.

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– Unplug high-voltage connectors -1-, -2-, -4-, -6- ⇒ Rep.

gr. 93 ; Unplugging high-voltage connectors .
– Move high-voltage wire -5- clear.
– Remove bolt -arrow- and move bracket -3- clear.

– Unplug electrical connector -3- and move it clear.

– Remove bolt -2- and move bracket -1- clear.
– Remove bolts -5- for bracket -4-.

– Release catch -arrow B- and open retaining bracket -3-

-arrow C-.
– Release catches -arrows A- and move high-voltage wire -1-
clear at bracket -2- and high-voltage battery.

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Supporting high-voltage battery with scissor-type assembly plat‐

form if not subsequently removing any modules from high-volt‐
age battery
– Remove bolts -arrows- for skid plate for high-voltage battery
-1-.

– Position scissor-type assembly platform - VAS 6131A- -B-

horizontally.
Note
Take note of spirit level (bubble gauge).
– Extend scissor-type assembly platform and position under
high-voltage battery 1 - AX2- -1-.
Note
Shown without lifting platform for illustration purposes.
– Place two insulating mats - VAS 6762/44- -A- on scissor-
type assembly platform.

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– Carefully raise scissor-type assembly platform - VAS 6131A-

-A- so it makes contact with high-voltage battery 1 - AX2- -1-
from below.
Important
• There must not be any load on spirit level -arrow- of scissor-
type assembly platform from high-voltage battery -1-.

If removing one or more modules from high-voltage battery

– Remove skid plate for high-voltage battery ⇒ General body
repairs, exterior; Rep. gr. 66 ; Underbody cladding; Remov‐
ing and installing skid plate for high-voltage battery .

– Prepare scissor-type assembly platform - VAS 6131A- -B-:

A - Support - VAS 6131/19-
C - -VAS 6131/10-7-
D - -VAS 6131/10-5-
E - -VAS 6131/10-8- , adapter is higher than shown in illustra‐
tion
F - -VAS 6131/10-5-

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– Fit support - VAS 6131/19- -B- on extended scissor-type

assembly platform - VAS 6131A- -A- but do not tighten bolts
yet.
– Set supports -B- to dimensions -x- and -y-.
x - 1535 mm
y - 1264 mm
Important
• Supports - VAS 6131/19- must always be fitted off centre in
order to renew outer battery modules. The repair procedure
for the right battery modules is shown here.
• If renewing modules on both sides, first perform the following
work on one side.
– Fit cover for battery box and secure with 8 bolts.
– Either ⇒ Rep. gr. 93 ; lift high-voltage battery 1 AX2 and
turn scissor-type assembly platform, or install high-voltage
battery in vehicle, turn scissor-type assembly platform and
then remove high-voltage battery again. Then perform work
on other side.

– Set threaded spindles -C- and -D- to dimensions -x- and -y-.
Important
• Threaded spindles must not protrude by more than 50 mm.
x - 20 mm
y - 50 mm

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– Position scissor-type assembly platform - VAS 6131A- -A-

horizontally.
Note
Take note of spirit level (bubble gauge).
– Position scissor-type assembly platform under vehicle.
Note
Shown without lifting platform and supports for illustration pur‐
poses.
– Carefully position scissor-type assembly platform - VAS
6131A- against high-voltage battery 1 - AX2- -1- from un‐
derneath with 4x support - VAS 6131/19- -B- and support
elements from support set for Audi - VAS 6131/10- .
– Carefully guide -VAS 6131/10-7- -C- into openings on bat‐
tery housing.
– Turn spindles -D- with adapter - VAS 6131/10-8- so that they
move upwards until they make contact with battery housing.
Important
• Threaded spindles must not protrude by more than 50 mm.
– Tighten bolts of supports on scissor-type assembly platform
to 25 Nm.

All versions (continued)

– Open retaining clips -4- and move coolant hoses -1- clear.
– Remove bolts -arrows- on both sides and detach bracket -3-.
– Remove bolt -5- for retainer -2- on both sides.

– Unscrew nut -3- at potential equalisation line (rear right) be‐

tween body and high-voltage battery, and detach potential
equalisation line.
– Unscrew nuts -arrows- on both sides and move retainer -4-
clear.
– Remove bolts -1- on both sides.
– Remove two bolts -2- on both sides.

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NOTICE
Risk 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.

– Open retaining clips -arrows- and move high-voltage wires

-2- clear at left side of high-voltage battery 1 - AX2- -1-.
– Tie up high-voltage wires.

– Open retaining clips -arrows- and move electrical wire -3-

and coolant hoses -2- (right-side) clear at right side of high-
voltage battery 1 - AX2- -1-.
– Tie up electrical wire and coolant hoses.

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

pletely.

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

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– Position high-voltage battery on scissor-type assembly plat‐

form - VAS 6131A- underneath vehicle.
– Lift high-voltage battery with scissor-type assembly platform
until hoses and wiring on both sides can be secured.
– Lift battery into installation position.

– Screw in all bolts securing high-voltage battery to body at

front and rear until they make contact.
– Tighten bolts -2- on both sides ⇒ Rep. gr. 93 ; Assembly
overview - high-voltage battery (installed) .
– Lower scissor-type assembly platform.
– Fit remaining bolts.
– Tighten all bolts on high-voltage battery ⇒ Rep. gr. 93 ;
Assembly overview - high-voltage battery (installed) .
– Tighten nut -3- for potential equalisation line at body.

Important
• 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 .

– Plug in high-voltage connectors -1-, -2-, -4-, -6-.

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– Plug in electrical connector -3-.

– Fit other attachments.

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 .

Tightening torques
♦ ⇒ Rep. gr. 93 ; Assembly overview - high-voltage battery
(installed)
♦ ⇒ Running gear, axles, steering; Rep. gr. 40 ; Subframe;
Assembly overview - subframe
♦ ⇒ Running gear, axles, steering; Rep. gr. 44 ; Wheels,
tyres; Assembly overview - wheel
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody
cladding; Assembly overview - underbody cladding
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel hous‐
ing liners; Assembly overview - front wheel housing liner
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel hous‐
ing liners; Assembly overview - rear wheel housing liner

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4.11 Voltage and insulation measurement

4.11.1 Voltage and insulation measurement

for high-voltage battery with switching
unit
Special tools and workshop equipment required
♦ high-voltage test module - VAS 6558A-
♦ test probe - VAS 6558A/4-
♦ test probe - VAS 6558A/5-
Put on protective equipment:
♦ Fabric gloves
♦ Safety goggles
♦ Safety shoes with ESD protection
Protective equipment ⇒ Electronic parts catalogue (ETKA)

All tests should be performed with high-voltage test module -

VAS 6558A- .

Preparing measurements
– Select measurement method.
♦ High-voltage system - cross-section functions
♦ High-voltage test module VAS 6558/VAS 6558A
♦ Voltage measurement
♦ Selection of measurement type/function
♦ Low-impedance voltage measurement
♦ Perform a continuous measurement
– Check function of high-voltage test module - VAS 6558A- at
a valid power supply. ( Battery - A- )

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Checking voltage of high-voltage battery 1 - AX2-

– Detach covers -1-.
– Perform measurement at battery connectors underneath as
follows.

– Insert test probe - VAS 6558A/4- -A- and test probe - VAS
6558A/5- -B- in openings -1-, -2- next to insulated screw
connection.

– Measure voltage between high-voltage “positive” -1- and

high-voltage “negative” -2-.
– Note voltage.
– Repeat measurement on other side.

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Checking voltage from high-voltage “positive” to battery housing

– Check voltage between high-voltage “positive” -1- and earth
connection -3-.
Note
The voltage goes down during the measurement.
Important
• Specification: max. 5 V
– Repeat measurement on other side.

If the value is above the specification, there is an insulation fault

and only an HVE wearing personal protective equipment that
provides protection against electric shock and thermal risks due
to arc flashes is permitted to work on the high-voltage battery:

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)
♦ 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 (ETKA)

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Checking voltage from high-voltage “negative” to battery hous‐

ing
– Check voltage between high-voltage “negative” -2- and earth
connection -3-.
Note
The voltage goes down during the measurement.
Important
• Specification: max. 5 V
– Repeat measurement on other side.

If the value is above the specification, there is an insulation fault

and only an HVE wearing personal protective equipment that
provides protection against electric shock and thermal risks due
to arc flashes is permitted to work on the high-voltage battery:

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)
♦ 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 (ETKA)

4.11.2 Voltage and insulation measurement

on opened high-voltage battery
Special tools and workshop equipment required
♦ high-voltage test module - VAS 6558A-

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♦ terminal cover - T40480-

♦ test probe - VAS 6558A/24-
♦ test probe - VAS 6558A/25-
Put on protective equipment:
♦ 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 goggles
♦ Safety shoes with ESD protection
Protective equipment ⇒ Electronic parts catalogue (ETKA)

All tests should be performed with high-voltage test module -

VAS 6558A- .

Preparing measurements
– Select measurement method.
♦ High-voltage system - cross-section functions
♦ High-voltage test module VAS 6558/VAS 6558A
♦ Voltage measurement
♦ Selection of measurement type/function
♦ Low-impedance voltage measurement
♦ Perform a continuous measurement
– Check function of high-voltage test module - VAS 6558A- at
a valid power supply. ( Battery - A- )

– Perform measurement at battery connectors -1- as follows.

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Checking voltage from high-voltage “positive” to battery housing

– Attach terminal cover - T40480- -B- to high-voltage “nega‐
tive”.
– Measure voltage between high-voltage “positive” -1- and
earth connection -2- on both sides using test probe - VAS
6558A/24- -A-.
Note
The voltage goes down during the measurement.
Important
• Specification: max. 5 V

If the value is above the specification, there is an insulation fault

and only an HVE wearing personal protective equipment that
provides protection against electric shock and thermal risks due
to arc flashes is permitted to work on the high-voltage battery:

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)
♦ 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 (ETKA)

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Checking voltage from high-voltage “negative” to battery hous‐

ing
– Attach terminal cover - T40480- -B- to high-voltage “posi‐
tive”.
– Measure voltage between high-voltage “negative” -1- and
earth connection -2- on both sides using test probe - VAS
6558A/25- -A-.
Note
The voltage goes down during the measurement.
Important
• Specification: max. 5 V

If the value is above the specification, there is an insulation fault

and only an HVE wearing personal protective equipment that
provides protection against electric shock and thermal risks due
to arc flashes is permitted to work on the high-voltage battery:

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)
♦ Helmet with visor and protective hood approved for working
with electric arcs, combined min. protective effect of 630 kJ

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♦ 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 (ETKA)

4.12 Lifting high-voltage battery 1 AX2

Special tools and workshop equipment required
♦ forklift crossbeam - VAS 501 009-
♦ sling chains, single - VAS 501 011-
♦ swivel bolts - VAS 691 017-

Note
Proceed in the same manner to lift high-voltage battery out of its
packaging; to do so, remove side panels of packaging.

– Screw 4x swivel bolts - VAS 691 017- -A- into high-voltage

battery 1 - AX2- -1- and tighten to 45 Nm.

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

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

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– Shorten the two sling chains, single - VAS 501 011- -A- that
are to be attached to high-voltage battery at rear (as seen in
direction of travel) with mounting -arrow-.
Important
• -X- free chain links must be visible: X = 16.
– Shorten the two sling chains -A- that are to be attached to
high-voltage battery at rear (as seen in direction of travel)
with mounting -arrow-.
Important
• -X- free chain links must be visible: X = 15.

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

of forklift.
Important
• Dimension -a- = 1000 mm
– Attach 4x sling chains, single - VAS 501 011- -B- to swivel
bolts - VAS 691 017- -A-.
Important
• The open sides of the hooks must face outwards.
– Fix crossbeam to fork arms to prevent slipping; to do so,
tighten retaining bolts to 10 Nm and also secure with nut.

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 1 - AX2- -1- with forklift.

4.13 Opening high-voltage battery 1 AX2

Special tools and workshop equipment required
♦ removal wedge - VAS 895 015/2-
♦ scraper set - VAS 861 005-
♦ suction lifters - V.A.G 1344-
♦ wedge set - T90054-

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).

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Removing
– Remove coarse dirt from cover for battery housing with cloth
and vacuum cleaner.
– Clean work area with a lint-free cleaning cloth and isopropa‐
nol.
– Remove switching unit for high-voltage battery SX6 ⇒ Rep.
gr. 93 ; Removing and installing switching unit for high-volt‐
age battery SX6 .

The high-voltage battery is fitted with a contact protection de‐

vice that remains in place even when the battery connectors are
removed. If there is no damage that affects the safety of the
high-voltage battery, the following protective equipment must be
worn:
– Put on protective equipment:
♦ Fabric gloves
♦ Safety goggles
♦ Safety shoes with ESD protection
Protective equipment ⇒ Electronic parts catalogue (ETKA)

If there is damage that affects the safety of the high-voltage bat‐

tery, only an HVE wearing personal protective equipment that
provides protection against electric shock and thermal risks due
to arc flashes is permitted to work on the high-voltage battery:
Damage that affects the safety of the high-voltage battery in‐
cludes, for example:
♦ Insulation faults
♦ Visible damage
♦ Moisture ingress
♦ Safety issues identified during classification

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.

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– 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 (ETKA)

Continued
– Remove joint seal from bolt heads -1- and at corners be‐
tween cover and battery housing with scraper set - VAS 861
005- .
Important
• If, when removing the bolts -1-, one of them is identified as
a repair bolt, this bolt and its installation position must be
marked for reinstallation ⇒ Rep. gr. 93 ; Closing high-volt‐
age battery 1 AX2 .
– Remove all bolts -1-, -3-, -4-.
– Remove all spacer pins -2-.

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– Remove swarf from threaded holes at least twice using vac‐

uum cleaner with plastic nozzle -1-.

– Make a marking for penetration depth -a- = 50 mm on sever‐

al wedges from wedge set - T90054- .

– Drive wedge -A- in between cover -1- and battery housing

-2-.

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– Pull out outer butyl adhesive sealing cord -1-.

– Slide wedge -A- along behind.

– Drive wedges -A- (at least 3 on short side and at least 4

on long side) in max. 50 mm between cover and battery
housing.
– Turn wedges -A- evenly -arrows- to separate cover -1- from
battery housing.

– Pierce and tear open inner butyl adhesive sealing cord using
removal wedge - VAS 895 015/2- -B-. Slide wedge -A- along
behind.

Important
• Second and third person required.

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– Attach 6x suction lifters - V.A.G 1344- -A- to cover for battery

housing -1- and lift cover.
Important
• Do not bend cover.
• Do not turn cover over battery.

– Perform voltage and insulation measurement on opened

high-voltage battery ⇒ “4.11.2 Voltage and insulation meas‐
urement on opened high-voltage battery”, page 154 .

– Clean areas marked in red -1- with vacuum cleaner with

brush nozzle -2-.

– Remove sealant residue from battery housing; to do so,

press old butyl adhesive sealing cord together and use it
to dab off residue.

4.14 Closing high-voltage battery 1 AX2

Special tools and workshop equipment required
♦ compressed air gun, 18 bar - VAS 6648-

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♦ guide pins - T40446-

♦ suction lifters - V.A.G 1344-

Installing
– Perform voltage and insulation measurement on opened
high-voltage battery ⇒ “4.11.2 Voltage and insulation meas‐
urement on opened high-voltage battery”, page 154 .
– ⇒ “5.16 Provisional energisation of high-voltage battery 1
AX2”, page 216

If high-voltage battery 1 - AX2- has been opened, flow-drill

screws must be checked and renewed according to the follow‐
ing table:
– Check flow-drill screws.
Standard screw Repair screw 1 Repair screw 2
M5GF x 25 (T25) M5.4 x 20 (T30) M6 x 22 (T30)
Inner thread on Specified torque for Specified torque for
lower part of battery standard screw not repair screw 1 not
housing OK obtained obtained
New standard Use oversized Cut M6 thread
screws must be screw (new thread without pre-drilling;
used after high-volt‐ will be made) use repair screw 2
age battery 1 - ⇒ Electronic parts ⇒ Electronic parts
AX2- has been catalogue (ETKA) catalogue (ETKA)
opened ⇒ Elec‐
tronic parts cata‐
logue (ETKA)

Continued
– Clean sealing surfaces on battery housing and cover with
lint-free cleaning cloth and isopropanol and dry them off.
– Attach 6x suction lifters - V.A.G 1344- to top of cover for
battery housing.

– Turn cover for battery housing.

– Position butyl adhesive sealing cord -1- upright, making sure
only to press it on lightly.

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– Route butyl adhesive sealing cord along impression on bat‐

tery housing.
Important
• Only one joint for inner and outer butyl adhesive sealing
cord.

– Screw guide pins - T40446- -B- into battery housing.

– Fit cover for battery housing -1- with 6x suction lifters -A-.

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– Screw in bolts -3-, -4- by hand.

– Remove guide pins.
– Screw in screws -1- by hand.
– Use repair screws if threads are damaged ⇒ Electronic
parts catalogue (ETKA) .
– Screw in spacer pins -2- by hand.
– Tighten threaded connections -1-, -3-, -4-.
– Tighten spacer pins -2-.

– Install switching unit for high-voltage battery SX6 ⇒ Rep.

gr. 93 ; Removing and installing switching unit for high-volt‐
age battery SX6 .

Important
• Switching unit for high-voltage battery - SX6- must be instal‐
led.
• Leak test for high-voltage battery must have been per‐
formed.
– Apply joint sealant ⇒ Electronic parts catalogue (ETKA) with
compressed air gun, 18 bar - VAS 6648- to all outer screws
and in corners between cover and battery housing as shown
to seal.
– Spread joint sealant using a plastic scraper.
Important
• The screw heads and the areas around them must be com‐
pletely covered by joint sealant so that the seal is air tight.
• The screw heads must no longer stand out.
• Time for skin to form: approx. 10 minutes
– Spread joint sealant in corners and press it into bond be‐
tween cover and battery housing with a plastic scraper.
– Observe drying time for joint sealant on cover for high-volt‐
age battery (2 hours).

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Tightening torques
♦ ⇒ “4.1 Assembly overview - high-voltage battery (installed)”,
page 125
♦ ⇒ “5.7 Assembly overview - high-voltage battery (removed)”,
page 190

4.15 Removing and installing battery regula‐

tion control unit J840
Special tools and workshop equipment required
♦ compressed air gun, 18 bar - VAS 6648-

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 high-voltage central box ⇒ Rep. gr. 93 ; Removing
and installing high-voltage central box .

– Perform leak test for battery housing while it is installed

⇒ Rep. gr. 93 ; Leak test for high-voltage battery 1 AX2 .

Vehicles with cover on battery regulation control unit - J840-

– Unclip cover and detach.

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Continued
– Remove bolts -1- for battery regulation control unit - J840-
-2-.

– Detach control unit -2- and turn it over.

– Unplug electrical connector -1-.

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

– Clean sealing surface with a lint-free cleaning cloth and iso‐

propanol and dry it.

If cover for battery regulation control unit - J840- is available as

a replacement part:
– Engage cover on battery regulation control unit - J840- .

4. High-voltage battery unit 169

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If cover for battery regulation control unit - J840- is not available

as a replacement part:
– Apply joint sealant ⇒ Electronic parts catalogue (ETKA) to
bolts -1- using compressed air gun, 18 bar - VAS 6648- in
order to seal them.
– Spread joint sealant using a plastic scraper.
Important
• 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
– Observe drying time for joint sealant (2 hours).
– Use a paintbrush to apply special lubricant ⇒ Electronic
parts catalogue (ETKA) all the way around at gap between
control unit -2- and switching unit housing.

Continued
– Perform leak test ⇒ Rep. gr. 93 ; Leak test for high-voltage
battery 1 AX2 .

Tightening torques
♦ ⇒ Rep. gr. 93 ; Assembly overview - switching unit for
high-voltage battery

4.16 Removing and installing switching unit

for high-voltage battery SX6
Special tools and workshop equipment required
♦ Diagnostics box - VAS 5581A-
♦ diagnostic cable - VAS 5581A/18-
♦ guide pins - T40199-
♦ lifting strap - T10588-
♦ lifting tackle - 2024B-
♦ release tool - T90035-
♦ removal wedge - VAS 895 015/2-
♦ shackle - VAS 691 009A-
♦ sliding rail - T40275-
♦ terminal cover - T40480-
♦ wedge set - T90054-
♦ workshop hoist - VAS 6100-

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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).

Important
• Required qualification for the following work: HVE, second
mechanic EIP

Removing

Battery regulation control unit - J840- is integrated in switch‐

ing unit for high-voltage battery - SX6- . If switching unit for
high-voltage battery - SX6- is renewed, test plan for renewal of
battery regulation control unit J840 must be performed:
– Perform “Replace control module” function with ⇒ Vehicle
diagnostic tester ⇒ Rep. gr. 00 ; Starting diagnosis .

Important
• New switching unit for high-voltage battery - SX6- must be
connected to 12 V power supply for 60 min before it is instal‐
led.
– Connect diagnostic cable - VAS 5581A/18- to 12-volt con‐
nector -1- of switching unit for high-voltage battery - SX6- .
– Connect black earth clamp of diagnostic cable - VAS
5581A/18- to earth on housing of switching unit for high-volt‐
age battery - SX6-
– Connect diagnostic cable - VAS 5581A/18- to diagnostics
box - VAS 5581A- .
Important
• Gateway (GW) mode must be selected on diagnostics box -
VAS 5581A- .
• CAN bus terminal resistor of diagnostics box - VAS 5581A-
is pre-set to 120 Ω and must not be changed.
• Terminal 30 and terminal 15 must be switched on on diag‐
nostics box - VAS 5581A- .
• Diagnostics box - VAS 5581A- connected to mains connec‐
tor

4. High-voltage battery unit 171

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Continued
– Remove high-voltage battery 1 - AX2- ⇒ Rep. gr. 93 ;
Removing and installing 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 .
– Clean area around switching unit for high-voltage battery -
SX6- with cleaning cloth and isopropanol.
Important
• Make sure no dirt gets into opening in switching unit.

– Clean area around service covers -1-, -2- and -3- with clean‐
ing cloth and isopropanol.
Important
• Make sure no dirt gets into openings in switching unit.
– Remove bolts for service covers -1-, -3- for battery connec‐
tors.
– Remove bolts for service cover -2- for 12-V connector.
– Remove swarf from threaded holes using vacuum cleaner
with plastic nozzle.
– Detach service covers.

– Perform voltage and insulation measurement for high-volt‐

age battery with switching unit ⇒ “4.11.1 Voltage and insu‐
lation measurement for high-voltage battery with switching
unit”, page 151 .

The high-voltage battery is fitted with a contact protection de‐

vice that remains in place even when the battery connectors are
removed. If there is no damage that affects the safety of the
high-voltage battery, the following protective equipment must be
worn:
– Put on protective equipment:
♦ Fabric gloves
♦ Safety goggles
♦ Safety shoes with ESD protection
Protective equipment ⇒ Electronic parts catalogue (ETKA)

If there is damage that affects the safety of the high-voltage bat‐

tery, only an HVE wearing personal protective equipment that

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provides protection against electric shock and thermal risks due

to arc flashes is permitted to work on the high-voltage battery:
Damage that affects the safety of the high-voltage battery in‐
cludes, for example:
♦ Insulation faults
♦ Visible damage
♦ Moisture ingress
♦ Safety issues identified during classification

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)
♦ 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 (ETKA)

Continued
– Remove bolts -arrows- for battery connector on both sides.

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– Unplug high-voltage connector -1- on both sides and engage

at top -arrow-.

– Open cover -1-, unplug 12-V connector -2- using release tool
- T90035- and engage connector at top -arrow-.

– Remove special lubricant -arrows- from pressure-equalisa‐

tion element -1- and bolt -2- with isopropanol.
– Unscrew pressure-equalisation element -1- and cover open‐
ing with no-residue tape.

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– Remove all bolts -2- for switching unit -1-.

Important
• Make sure to include bolt -arrow- hidden behind high-voltage
connector.

– Remove swarf from threaded holes using vacuum cleaner

with plastic nozzle -1-.

– Fit old service covers -1-, -2-, -3- and secure in position by
screwing in bolt hand-tight.

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– To lift switching unit -1-, attach 3x lifting strap - T10588- -A-

to 5x shackle - VAS 691 009A- -D- and attach to lifting tackle
- 2024B- -B-, and engage on workshop hoist - VAS 6100-
-C-.

– Make a marking for penetration depth -a- = 50 mm on sever‐

al wedges from wedge set - T90054- .

– Slide several plastic wedges -A- under switching unit -1- at

grooves.

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– Cut open outer butyl adhesive sealing cord -2- with removal
wedge - VAS 895 015/2- -B- and pull it out outwards.

– Raise workshop hoist again and slide plastic wedges -A- in

up to max. depth of 50 mm. Tension lifting straps -C- and
shackles -B- evenly.
– Drive in at least 8 wedges to release switching unit -1- on
one side.
– Pierce and tear open inner butyl adhesive sealing cord using
removal wedge - VAS 895 015/2- .
– Lift switching unit -1-.

– Detach switching unit -1- from workshop hoist, turn it over

and place in on 2x sliding rail - T40275- -A-.

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– Immediately fit 4x terminal cover - T40480- -arrows- on con‐

nections on high-voltage battery.
– Remove sealant residue from switching unit and cover for
battery housing; to do so, press old butyl adhesive sealing
cord together and use it to dab off residue.

– Remove swarf from threaded holes using vacuum cleaner

with plastic nozzle -1-.

Installing
New switching unit is supplied with a butyl adhesive sealing
cord to protect sealing surfaces.
Important
• Butyl adhesive sealing cord must be removed from new
switching unit.
• Switching unit must be cleaned to remove sealant residue.
– Clean sealing surfaces with a lint-free cloth and isopropanol.

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– Press bolts -arrows- for battery connector back from under‐

side of switching unit on both sides.

– Route butyl adhesive sealing cord -1- upright along impres‐

sion, making sure only to press it on lightly.
Important
• Only one joint -arrows- for inner and outer butyl adhesive
sealing cord.

– Screw in 4x guide pins - T40199- -A-.

– Detach terminal covers from connections on high-voltage
battery.

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– Bring switching unit -1- into position with workshop hoist.

– Screw in bolts -2- on switching unit -1- by hand.
– Remove guide pins.
– Tighten bolts in specified sequence.

– Detach service covers -1-, -2-, -3-.

– Plug in 12-V connector -2- and close cover -1-.

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– Tighten bolts -arrows- for battery connector on both sides.

– Perform voltage and insulation measurement for high-volt‐

age battery with switching unit ⇒ “4.11.1 Voltage and insu‐
lation measurement for high-voltage battery with switching
unit”, page 151 .

– Clean sealing surfaces of service covers with a lint-free cloth

and isopropanol.

– Fit new service covers -1-, -2-, -3-, press them on and tight‐
en bolts in stages.

Important
• A potential equalisation measurement must be performed
on the high-voltage components affected after installation of
high-voltage components or potential equalisation lines.
– Perform “Starting up” function with ⇒ Vehicle diagnostic test‐
er ⇒ Rep. gr. 00 ; Starting diagnosis .
– Start selected program and follow instructions on display of
vehicle diagnostic tester.
– Perform potential equalisation measurement on switching
unit for high-voltage battery - SX6- .

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– Perform leak test ⇒ Rep. gr. 93 ; Leak test for high-voltage

battery 1 AX2 .

– Secure pressure-equalisation element -1-.

– Use a paintbrush to apply special lubricant ⇒ Electronic
parts catalogue (ETKA) to pressure-equalisation element -1-
and bolt -2- -arrows-.

Tightening torques
♦ ⇒ Rep. gr. 93 ; Assembly overview - switching unit for
high-voltage battery

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5 High-voltage battery components

5.1 Overview of fitting locations - battery

modules, 100 kWh

5.1.1 Overview of fitting locations - battery modules

5. High-voltage battery components 183

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1 - Battery module 1 - J991-

❑ ⇒ Rep. gr. 93 ; Re‐
moving battery module
❑ ⇒ Rep. gr. 93 ; Instal‐
ling battery module
2 - Battery module 2 - J992-
❑ ⇒ Rep. gr. 93 ; Re‐
moving battery module
❑ ⇒ Rep. gr. 93 ; Instal‐
ling battery module
3 - Battery module 3 - J993-
❑ ⇒ Rep. gr. 93 ; Re‐
moving battery module
❑ ⇒ Rep. gr. 93 ; Instal‐
ling battery module
4 - Battery module 4 - J994-
❑ ⇒ Rep. gr. 93 ; Re‐
moving battery module
❑ ⇒ Rep. gr. 93 ; Instal‐
ling battery module
5 - Battery module 5 - J995-
❑ ⇒ Rep. gr. 93 ; Re‐
moving battery module
❑ ⇒ Rep. gr. 93 ; Instal‐
ling battery module
6 - Battery module 6 - J996-
❑ ⇒ Rep. gr. 93 ; Re‐
moving battery module
❑ ⇒ Rep. gr. 93 ; Instal‐
ling battery module
7 - Battery module 7 - J997-
❑ ⇒ Rep. gr. 93 ; Re‐
moving battery module
❑ ⇒ Rep. gr. 93 ; Installing battery module
8 - Battery module 8 - J998-
❑ ⇒ Rep. gr. 93 ; Removing battery module
❑ ⇒ Rep. gr. 93 ; Installing battery module
9 - Battery module 9 - J999-
❑ ⇒ Rep. gr. 93 ; Removing battery module
❑ ⇒ Rep. gr. 93 ; Installing battery module
10 - Battery module 10 - J1000-
❑ ⇒ Rep. gr. 93 ; Removing battery module
❑ ⇒ Rep. gr. 93 ; Installing battery module
11 - Battery module 11 - J1001-
❑ ⇒ Rep. gr. 93 ; Removing battery module
❑ ⇒ Rep. gr. 93 ; Installing battery module
12 - Battery module 12 - J1002-
❑ ⇒ Rep. gr. 93 ; Removing battery module
❑ ⇒ Rep. gr. 93 ; Installing battery module

184 Rep. gr.93 - Electric drive systems

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5.2 Overview of fitting locations - battery

modules, 83 kWh

5.2.1 Overview of fitting locations - battery modules

1 - Battery module 1 - J991-

❑ ⇒ Rep. gr. 93 ; Re‐
moving battery module
❑ ⇒ Rep. gr. 93 ; Instal‐
ling battery module
2 - Battery module 2 - J992-
❑ ⇒ Rep. gr. 93 ; Re‐
moving battery module
❑ ⇒ Rep. gr. 93 ; Instal‐
ling battery module
3 - Battery module 3 - J993-
❑ ⇒ Rep. gr. 93 ; Re‐
moving battery module
❑ ⇒ Rep. gr. 93 ; Instal‐
ling battery module
4 - Battery module 4 - J994-
❑ ⇒ Rep. gr. 93 ; Re‐
moving battery module
❑ ⇒ Rep. gr. 93 ; Instal‐
ling battery module
5 - Not fitted
6 - Battery module 6 - J996-
❑ ⇒ Rep. gr. 93 ; Re‐
moving battery module
❑ ⇒ Rep. gr. 93 ; Instal‐
ling battery module
7 - Battery module 7 - J997-
❑ ⇒ Rep. gr. 93 ; Re‐
moving battery module
❑ ⇒ Rep. gr. 93 ; Instal‐
ling battery module
8 - Not fitted
9 - Battery module 9 - J999-
❑ ⇒ Rep. gr. 93 ; Removing battery module
❑ ⇒ Rep. gr. 93 ; Installing battery module
10 - Battery module 10 - J1000-
❑ ⇒ Rep. gr. 93 ; Removing battery module
❑ ⇒ Rep. gr. 93 ; Installing battery module
11 - Battery module 11 - J1001-
❑ ⇒ Rep. gr. 93 ; Removing battery module
❑ ⇒ Rep. gr. 93 ; Installing battery module
12 - Battery module 12 - J1002-
❑ ⇒ Rep. gr. 93 ; Removing battery module
❑ ⇒ Rep. gr. 93 ; Installing battery module

5. High-voltage battery components 185

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5.3 Overview of fitting locations - battery

modules control units, 100 kWh

5.3.1 Overview of fitting locations - battery modules control units

1 - Battery modules control

unit - J1208-
❑ ⇒ Rep. gr. 93 ; Re‐
moving and installing
battery modules control
units
2 - Battery modules control
unit 2 - J1209-
❑ ⇒ Rep. gr. 93 ; Re‐
moving and installing
battery modules control
units
3 - Battery modules control
unit 3 - J1210-
❑ ⇒ Rep. gr. 93 ; Re‐
moving and installing
battery modules control
units
4 - Battery modules control
unit 4 - J1211-
❑ ⇒ Rep. gr. 93 ; Re‐
moving and installing
battery modules control
units
5 - Battery modules control
unit 5 - J1212-
❑ ⇒ Rep. gr. 93 ; Re‐
moving and installing
battery modules control
units
6 - Battery modules control
unit 6 - J1213-
❑ ⇒ Rep. gr. 93 ; Re‐
moving and installing
battery modules control
units
7 - Battery modules control unit 7 - J1214-
❑ ⇒ Rep. gr. 93 ; Removing and installing battery modules control units
8 - Battery modules control unit 8 - J1215-
❑ ⇒ Rep. gr. 93 ; Removing and installing battery modules control units
9 - Battery modules control unit 9 - J1216-
❑ ⇒ Rep. gr. 93 ; Removing and installing battery modules control units
10 - Battery modules control unit 10 - J1217-
❑ ⇒ Rep. gr. 93 ; Removing and installing battery modules control units
11 - Battery modules control unit 11 - J1218-
❑ ⇒ Rep. gr. 93 ; Removing and installing battery modules control units
12 - Battery modules control unit 12 - J1219-
❑ ⇒ Rep. gr. 93 ; Removing and installing battery modules control units

186 Rep. gr.93 - Electric drive systems

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5.4 Overview of fitting locations - battery

modules control units, 83 kWh

5.4.1 Overview of fitting locations - battery modules control units

1 - Battery modules control

unit - J1208-
❑ ⇒ Rep. gr. 93 ; Re‐
moving and installing
battery modules control
units
2 - Battery modules control
unit 2 - J1209-
❑ ⇒ Rep. gr. 93 ; Re‐
moving and installing
battery modules control
units
3 - Battery modules control
unit 3 - J1210-
❑ ⇒ Rep. gr. 93 ; Re‐
moving and installing
battery modules control
units
4 - Battery modules control
unit 4 - J1211-
❑ ⇒ Rep. gr. 93 ; Re‐
moving and installing
battery modules control
units
5 - Not fitted
6 - Battery modules control
unit 6 - J1213-
❑ ⇒ Rep. gr. 93 ; Re‐
moving and installing
battery modules control
units
7 - Battery modules control
unit 7 - J1214-
❑ ⇒ Rep. gr. 93 ; Re‐
moving and installing
battery modules control units
8 - Not fitted
9 - Battery modules control unit 9 - J1216-
❑ ⇒ Rep. gr. 93 ; Removing and installing battery modules control units
10 - Battery modules control unit 10 - J1217-
❑ ⇒ Rep. gr. 93 ; Removing and installing battery modules control units
11 - Battery modules control unit 11 - J1218-
❑ ⇒ Rep. gr. 93 ; Removing and installing battery modules control units
12 - Battery modules control unit 12 - J1219-
❑ ⇒ Rep. gr. 93 ; Removing and installing battery modules control units

5. High-voltage battery components 187

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5.5 Overview of fitting locations - battery

connectors, 100 kWh

5.5.1 Overview of fitting locations - battery connectors

188 Rep. gr.93 - Electric drive systems

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1 - Battery connector 1 for

switching unit
❑ ⇒ Rep. gr. 93 ; As‐
sembly overview - bat‐
tery modules
2 - Battery connector 2 for
switching unit
❑ ⇒ Rep. gr. 93 ; As‐
sembly overview - bat‐
tery modules
3 - Battery connector for mod‐
ules 11-12
❑ ⇒ Rep. gr. 93 ; As‐
sembly overview - bat‐
tery modules
4 - Crash cover
5 - Battery connector for mod‐
ules 7-8
❑ ⇒ Rep. gr. 93 ; As‐
sembly overview - bat‐
tery modules
6 - Battery connector for mod‐
ules 8-9
❑ ⇒ Rep. gr. 93 ; As‐
sembly overview - bat‐
tery modules
7 - Crash cover
8 - Battery connector for mod‐
ules 10-11
❑ ⇒ Rep. gr. 93 ; As‐
sembly overview - bat‐
tery modules
9 - Battery connector for mod‐
ules 9-10
❑ ⇒ Rep. gr. 93 ; Assembly overview - battery modules
10 - Battery connector for modules 3-4
❑ ⇒ Rep. gr. 93 ; Assembly overview - battery modules
11 - Battery connector for modules 4-5
❑ ⇒ Rep. gr. 93 ; Assembly overview - battery modules
12 - Crash cover
13 - Battery connector for modules 2-3
❑ ⇒ Rep. gr. 93 ; Assembly overview - battery modules
14 - Battery connector for modules 5-6
❑ ⇒ Rep. gr. 93 ; Assembly overview - battery modules
15 - Crash cover
16 - Battery connector for modules 1-2
❑ ⇒ Rep. gr. 93 ; Assembly overview - battery modules

5. High-voltage battery components 189

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5.6 Overview of fitting locations - battery

connectors, 83 kWh

5.6.1 Overview of fitting locations - battery connectors

1 - Battery connector 1 for

switching unit
❑ ⇒ Rep. gr. 93 ; As‐
sembly overview - bat‐
tery modules
2 - Battery connector 2 for
switching unit
❑ ⇒ Rep. gr. 93 ; As‐
sembly overview - bat‐
tery modules
3 - Battery connector for mod‐
ules 11-12
❑ ⇒ Rep. gr. 93 ; As‐
sembly overview - bat‐
tery modules
4 - Crash cover
5 - Battery connector for mod‐
ules 7-9
❑ ⇒ Rep. gr. 93 ; As‐
sembly overview - bat‐
tery modules
6 - Crash cover
7 - Battery connector for mod‐
ules 10-11
❑ ⇒ Rep. gr. 93 ; As‐
sembly overview - bat‐
tery modules
8 - Battery connector for mod‐
ules 9-10
❑ ⇒ Rep. gr. 93 ; As‐
sembly overview - bat‐
tery modules
9 - Battery connector for mod‐
ules 3-4
❑ ⇒ Rep. gr. 93 ; Assembly overview - battery modules
10 - Battery connector for modules 2-3
❑ ⇒ Rep. gr. 93 ; Assembly overview - battery modules
11 - Crash cover
12 - Battery connector for modules 4-6
❑ ⇒ Rep. gr. 93 ; Assembly overview - battery modules
13 - Crash cover
14 - Battery connector for modules 1-2
❑ ⇒ Rep. gr. 93 ; Assembly overview - battery modules

5.7 Assembly overview - high-voltage battery (removed)

190 Rep. gr.93 - Electric drive systems

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1 - Spacer pin
❑ 10x
❑ Renew after removing
❑ 100 Nm
2 - Bolt
❑ M5x30
❑ 8x
❑ Renew after removing
❑ 5.5 Nm + 90°
3 - Cover for battery housing
❑ Renew after removing
4 - Bolt
❑ M5x18
❑ 8x
❑ Renew after removing
❑ 5.5 Nm + 90°
5 - Battery modules
❑ 12x on 100 kWh ver‐
sion
6 - Battery modules 5 and 8
❑ Not fitted on 83 kWh
version
7 - Battery housing
8 - Bolt
❑ 82x
❑ Renew after removing
❑ ⇒ Rep. gr. 93 ; Clos‐
ing high-voltage battery
1 AX2
❑ Standard bolt: 8 Nm
❑ Repair bolt, stage 1: 8 Nm
❑ Repair bolt, stage 2: 6 Nm

Gas vent valves in battery housing

5. High-voltage battery components 191

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1 - Gas vent valves

❑ 4x
❑ Renew after removing

5.8 Assembly overview - battery modules

192 Rep. gr.93 - Electric drive systems

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1 - Bolt
❑ 4x per battery module
❑ Renew after removing
❑ Tightening torque and
sequence ⇒ page 193
2 - Battery module
❑ ⇒ Rep. gr. 93 ; Re‐
moving battery module
❑ ⇒ Rep. gr. 93 ; Instal‐
ling battery module
3 - Battery connector with
insulated screw connection
(horizontal)
❑ ⇒ Rep. gr. 93 ; Over‐
view of fitting locations
- battery connectors,
100 kWh
❑ ⇒ Rep. gr. 93 ; Over‐
view of fitting locations
- battery connectors,
83 kWh
❑ 8.5 Nm
4 - Battery connector with
insulated screw connection
(vertical)
❑ ⇒ Rep. gr. 93 ; Over‐
view of fitting locations
- battery connectors,
100 kWh
❑ ⇒ Rep. gr. 93 ; Over‐
view of fitting locations
- battery connectors,
83 kWh
❑ 8.5 Nm
5 - Tolerance compensation element
❑ 4x per battery module
6 - Battery module control unit
❑ ⇒ Rep. gr. 93 ; Overview of fitting locations - battery modules control units, 100 kWh
❑ ⇒ Rep. gr. 93 ; Overview of fitting locations - battery modules control units, 83 kWh
❑ ⇒ Rep. gr. 93 ; Removing and installing battery modules control units

Bolts for battery modules - tightening torque and tightening se‐

quence
Bolts Tightening torque
-1- to -4- 16 Nm + 180°

5. High-voltage battery components 193

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Bolts for battery connector - tightening torque

Bolts Tightening torque
-Arrows- 8.5 Nm

Bolts for battery connector, 83 kWh

1 - Bolt
- 4x
- 4.5 Nm
2 - Battery connector, 83 kWh
- ⇒ Rep. gr. 93 ; Overview of fitting locations - battery connec‐
tors

1 - Bolt securing battery connector to frame

- 2x
- 4.5 Nm
2 - Battery connector for switching unit
- ⇒ Rep. gr. 93 ; Overview of fitting locations - battery connec‐
tors

5.9 Assembly overview - wiring harnesses

194 Rep. gr.93 - Electric drive systems

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1 - Wiring harness for high-

voltage battery AX2
❑ Renew after removing
❑ ⇒ Rep. gr. 93 ; Re‐
moving and installing
wiring harness for high-
voltage battery 1 AX2
2 - Bolt
❑ 4.5 Nm

5.10 Marking battery modules, battery con‐

nectors and control units
Important
• Mark battery modules, battery connectors and battery mod‐
ules control units before removing.
• Use a waterproof felt-tip pen for marking.
Label components according to relevant overview of fitting loca‐
tions.
♦ ⇒ Electric drive motor 0EL, 0EN; Rep. gr. 93 ; High-voltage
battery components; Overview of fitting locations - battery
modules
♦ ⇒ Electric drive motor 0EL, 0EN; Rep. gr. 93 ; High-voltage
battery components; Overview of fitting locations - battery
connectors
♦ ⇒ Electric drive motor 0EL, 0EN; Rep. gr. 93 ; High-voltage
battery components; Overview of fitting locations - battery
modules control units

5. High-voltage battery components 195

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5.11 Removing battery module

Special tools and workshop equipment required
♦ module grip tool - T40424/6-
♦ module release tool - T40424-
♦ scraper set - VAS 281 011-
♦ swivel bolt - VAS 691 013-
♦ terminal cover - T40480-
♦ workshop hoist - VAS 6100-

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).

Preparations
Important
• If a battery module needs to be renewed, determine the
mean cell voltage of the high-voltage battery first ⇒ “4.5 De‐
termining mean cell voltage”, page 132 .
• 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 .
• When renewing the outer modules, ensure that the high-volt‐
age battery is fitted off-centre in the mountings on the scis‐
sor-type assembly platform so that it is possible to position
the counterhold tool underneath the module that is to be
renewed.

– Remove high-voltage battery 1 - AX2- ⇒ Rep. gr. 93 ;

Removing and installing high-voltage battery 1 AX2 .
– ⇒ Rep. gr. 93 ; Open high-voltage battery 1 AX2 .

Removing
The high-voltage battery is fitted with a contact protection de‐
vice that remains in place even when the battery connectors are
removed. If there is no damage that affects the safety of the
high-voltage battery, the following protective equipment must be
worn:
– Put on protective equipment:

196 Rep. gr.93 - Electric drive systems

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♦ Fabric gloves
♦ Safety goggles
♦ Safety shoes with ESD protection
Protective equipment ⇒ Electronic parts catalogue (ETKA)

If there is damage that affects the safety of the high-voltage bat‐

tery, only an HVE wearing personal protective equipment that
provides protection against electric shock and thermal risks due
to arc flashes is permitted to work on the high-voltage battery:
Damage that affects the safety of the high-voltage battery in‐
cludes, for example:
♦ Insulation faults
♦ Visible damage
♦ Moisture ingress
♦ Safety issues identified during classification

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)
♦ 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 (ETKA)

Continued
– ⇒ “5.10 Marking battery modules, battery connectors and
control units”, page 195 .

5. High-voltage battery components 197

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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.

– Remove bolts from battery connectors on both sides of bat‐

tery module being removed -arrows- one after the other.
Note
Battery connectors for modules 3-4 and modules 9-10 are clip‐
ped into battery housing. Battery connectors for switching unit
are bolted onto battery housing.

– Remove swarf from threaded holes on battery connectors

using vacuum cleaner -1-.

198 Rep. gr.93 - Electric drive systems

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– Fit terminal cover - T40480- -A- on battery module -1- imme‐

diately after removing battery connectors.

– Remove wiring harness for high-voltage battery -3- ⇒ Rep.

gr. 93 ; Removing and installing wiring harness for high-volt‐
age battery 1 AX2 .
– Unclip crash cover -2- in affected area and detach.
Important
• Renew crash cover after removing.

– Unscrew bolts -arrows- for battery module.

5. High-voltage battery components 199

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– Screw in swivel bolt - VAS 691 013- -B- and tighten to

10 Nm.
– Secure module grip tool - T40424/6- to new battery module
-1-.
Important
• Hooks of clamping piece must engage in recesses on front
and rear of battery module.
– Tighten knurled screw -E- hand-tight.
– Insert fasteners -A- and -D-.

– Attach support bridge -A- from module release tool -

T40424- to module grip tool - T40424/6- -C-.
Important
• Do not place on threads of cover bolts.
– Slowly and carefully release battery module -1- from thermal
grease on one side using threaded spindle of support bridge
-A- with maximum of 7 Nm.
– Repeat procedure on other side of module.
Note
If the battery module cannot be released, wait for a minute,
release the threaded spindle and then repeat the procedure.
– Remove support bridge.
– Attach battery module to swivel bolt -B- and lift out with
workshop hoist - VAS 6100- ⇒ operating instructions for
module release tool - T40424/6- .

Important
• A second mechanic is required for the following work.
• Do not place battery module down on the battery cells.
– Set battery module -1- down on its smooth side on a clean,
lint-free surface.
Important
• Recesses -arrows- for high-voltage battery wiring harness
must be on top and must not be damaged.
• The battery module may be left in this position for a maxi‐
mum of 3 hours; use original packaging or battery housing to
store battery module for longer than 3 hours.
• If storing in battery housing, unscrew tolerance compensa‐
tion elements until battery cells do not make contact with
heat sink.

200 Rep. gr.93 - Electric drive systems

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– Remove remaining thermal grease with a lint-free cleaning

cloth and isopropanol.

– Scrape remaining thermal grease out of battery housing with

a wide plastic scraper from scraper set - VAS 281 011- .

– Clean contact area and threads with vacuum cleaner -1-.

– Clean battery module and battery housing with a lint-free

cleaning cloth and isopropanol.

– Classify battery module for shipping ⇒ Rep. gr. 93 ; Visually

inspecting and classifying battery module .

5.12 Installing battery module

Special tools and workshop equipment required
♦ adapter - T40474/2-
♦ adapter plate - T40474/3-
♦ assembly tool for high-voltage battery modules - T40451-

5. High-voltage battery components 201

 Q6 e-tron 2024 ➤
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♦ double cartridge gun - VAS 5237-

♦ module grip tool - T40424/6-
♦ one-handed clamp - VAS 6900/4-
♦ one-handed clamp, large - VAS 6900/11-
♦ plate - T40474/1-
♦ scissor-type assembly platform - VAS 6131A-
♦ setting gauge - 3371-
♦ swivel bolt - VAS 691 013-
♦ tapered mounting pin - VAS 6131/10-2-
♦ template - T40462-
♦ terminal cover - T40480-
♦ threaded spindle - VAS 6131/10-5-
♦ torque screwdriver - VAS 6494-
♦ workshop hoist - VAS 6100-

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).

Installing
– 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 .

The high-voltage battery is fitted with a contact protection de‐

vice that remains in place even when the battery connectors are
removed. If there is no damage that affects the safety of the
high-voltage battery, the following protective equipment must be
worn:
– Put on protective equipment:
♦ Fabric gloves
♦ Safety goggles
♦ Safety shoes with ESD protection
Protective equipment ⇒ Electronic parts catalogue

202 Rep. gr.93 - Electric drive systems

 Q6 e-tron 2024 ➤
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If there is damage that affects the safety of the high-voltage bat‐

tery, only an HVE wearing personal protective equipment that
provides protection against electric shock and thermal risks due
to arc flashes is permitted to work on the high-voltage battery:
Damage that affects the safety of the high-voltage battery in‐
cludes, for example:
♦ Insulation faults
♦ Visible damage
♦ Moisture ingress
♦ Safety issues identified during classification

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)
♦ 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

Continued
– Clean underside of module that is to be fitted with a clean,
lint-free cloth.

– Allow cartridges of 2-component thermal grease to reach

room temperature before using.

5. High-voltage battery components 203

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– Secure battery frame -1- to the 4 supports -B- on scissor-

type assembly platform - VAS 6131A- -C- with 4x one-hand‐
ed clamp, large - VAS 6900/11- -A-.

– Prepare 4x adapter - T40474/2- -B-, threaded spindle - VAS

6131/10-5- -C-, tapered mounting pin - VAS 6131/10-2- -D-
with 2x adapter plate - T40474/3- -E- and plate - T40474/1-
-A-.

– Secure extendable plate -C- to scissor-type assembly plat‐

form - VAS 6131A- with 4x one-handed clamp - VAS 6900/4-
-D-.
– Place prepared mountings -A- with plate - T40474/1- -B- in
position of module being replaced.

Important
• Module being replaced must be positioned above battery
mounting -D-.

204 Rep. gr.93 - Electric drive systems

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– Slide mountings -B- into battery mounting -D- by turning

adapter plate - T40474/3- -C-.
Note
For better clarity, only one side of mountings is shown.

– Ensure contours of high-voltage battery -1- are aligned with

plate - T40474/1- -B-.
– Carefully screw spindles of mountings -A- up until plate -
T40474/1- -B- makes contact with bottom of battery without
exerting pressure.
– Turn threaded spindles 90° further to exert light pressure.

– Remove 4 tolerance compensation elements -1-.

– Check threaded insert -2- can be removed freely, turn it back
and return it to its original position.
– Mark threaded insert with pen -3- so that you can check that
threaded insert turns when screwing in genuine bolts at a
later stage.

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– Mark centre of scale -1- on cartridges as shown and divide

into 3 fields -arrows- of 60 ml.
– Squeeze out 2-component thermal grease up to beginning of
scale -1- and dispose of it.

– Insert template - T40462- -A- in fitting location of module

being installed.
– Starting from outside, apply 2-component thermal grease in
even lines with double cartridge gun - VAS 5237- -B-.
Important
• Hold double cartridge gun - VAS 5237- so it is vertical.
• 5 lines correspond to one field on scale on cartridge = 60 ml.
– Remove template - T40462- .

– Attach terminal cover - T40480- -A- to both battery terminals

of new battery module -1-.

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– Screw in swivel bolt - VAS 691 013- -B- and tighten to

10 Nm.
– Secure module grip tool - T40424/6- to new battery module
-1-.
Important
• Hooks of clamping piece must engage in recesses on front
and rear of battery module.
– Tighten knurled screw -E- hand-tight.
– Insert fasteners -A- and -D-.
– Lift new battery module out of packaging with workshop
hoist - VAS 6100- ⇒ operating instructions for module grip
tool - T40424/6- .
– Insert battery module.
Important
• Ensure component is in correct installation position.

– Fit plates from setting gauge - 3371- -arrows- at sides of

module to position it so that holes are centred over threads.
Note
Release individual setting gauges from chain. To prevent indi‐
vidual setting gauges from falling in, secure each of them with a
cable tie.
– Insert bolts -1- to -4- from assembly tool for high-voltage
battery modules - T40451- and screw in until they make
contact.
– Set torque screwdriver - VAS 6494- to 1.5 Nm.
– Tighten bolts from assembly tool 90° in sequence -1- to -4-.
– Repeat until torque of 1.5 Nm is reached.
– Wait 3 minutes, then tighten bolts to 1.5 Nm again in diago‐
nal sequence.
– Wait 10 minutes, then tighten bolts to 1.5 Nm again in diago‐
nal sequence.
– Remove plates -arrows-.

– Wait another 10 minutes, then remove plate - T40474/1- -B-

and mountings -A- from underneath battery.

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– After waiting at least 2 hours, replace bolts from assembly

tool with genuine M8x85 bolts one at a time in sequence -1-
to -4- and tighten to specified torque immediately.
Important
• Threaded inserts of tolerance compensation elements must
turn along with bolts.

– Detach terminal cover - T40480- -A- from installed battery

module -1- and neighbouring battery modules.

– Fit battery connectors according to markings -arrows- ⇒

“5.10 Marking battery modules, battery connectors and con‐
trol units”, page 195 .

– Install new wiring harness for high-voltage battery ⇒ Rep.

gr. 93 ; Removing and installing wiring harness for high-volt‐
age battery 1 AX2 .

– ⇒ Rep. gr. 93 ; Close high-voltage battery 1 AX2 .

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Tightening torques
♦ ⇒ Rep. gr. 93 ; Assembly overview - battery modules

5.13 Removing and installing battery modules control unit

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).

Removing

If battery modules 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. 93 ; Open high-voltage battery 1 AX2 .
– If several battery modules control units are to be removed,
mark them for reinstallation ⇒ “5.10 Marking battery mod‐
ules, battery connectors and control units”, page 195 .

The high-voltage battery is fitted with a contact protection de‐

vice that remains in place even when the battery connectors are
removed. If there is no damage that affects the safety of the
high-voltage battery, the following protective equipment must be
worn:
– Put on protective equipment:
♦ Fabric gloves
♦ Safety goggles
♦ Safety shoes with ESD protection
Protective equipment ⇒ Electronic parts catalogue (ETKA)

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If there is damage that affects the safety of the high-voltage bat‐

tery, only an HVE wearing personal protective equipment that
provides protection against electric shock and thermal risks due
to arc flashes is permitted to work on the high-voltage battery:
Damage that affects the safety of the high-voltage battery in‐
cludes, for example:
♦ Insulation faults
♦ Visible damage
♦ Moisture ingress
♦ Safety issues identified during classification

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)
♦ 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 (ETKA)

Continued
100-kWh battery

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– Remove control units -3- and -9- (battery module remains

installed).
– ⇒ Rep. gr. 93 ; Removing and installing wiring harness for
high-voltage battery 1 AX2

83-kWh battery
– Remove control units -3-, -4-, -7-, -9- (battery module re‐
mains installed).
– ⇒ Rep. gr. 93 ; Removing and installing wiring harness for
high-voltage battery 1 AX2

All other control units

– Remove appropriate battery module with control unit ⇒ Rep.
gr. 93 ; Removing battery module .

Important
• Battery module is on other side (as described in removal
procedure).

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– Lift cover -2- using 3-mm flat-bladed screwdriver -A- and

release connector underneath.
– Release retaining catches -arrows-, and detach control unit
-1-.

Installing
Installation is carried out in reverse order; note the following:
Important
• If one or more battery modules control units are renewed,
they must be re-addressed before installing the cover for
battery housing as part of the provisional energisation.

– ⇒ “5.16 Provisional energisation of high-voltage battery 1

AX2”, page 216 .

5.14 Removing and installing wiring harness 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).

Removing
– ⇒ Rep. gr. 93 ; Open high-voltage battery 1 AX2 .
– Take photos and make sketches of routing of wiring har‐
ness.

The high-voltage battery is fitted with a contact protection de‐

vice that remains in place even when the battery connectors are
removed. If there is no damage that affects the safety of the
high-voltage battery, the following protective equipment must be
worn:

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– Put on protective equipment:

♦ Fabric gloves
♦ Safety goggles
♦ Safety shoes with ESD protection
Protective equipment ⇒ Electronic parts catalogue (ETKA)

If there is damage that affects the safety of the high-voltage bat‐

tery, only an HVE wearing personal protective equipment that
provides protection against electric shock and thermal risks due
to arc flashes is permitted to work on the high-voltage battery:
Damage that affects the safety of the high-voltage battery in‐
cludes, for example:
♦ Insulation faults
♦ Visible damage
♦ Moisture ingress
♦ Safety issues identified during classification

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)
♦ 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 (ETKA)

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Continued
Lug on connector will break when electrical connector -1- is
unplugged.
– Unplug all connectors -1- by pulling on wiring harness -3-.

– Unclip wiring harness along length of modules -arrow-.

– Remove bolt -3-.

– Detach bracket -1- with wiring harness -2-.

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– Clean all areas along which wiring is routed with vacuum

cleaner -1-.

Installing
Installation is carried out in reverse order; note the following:
Important
• Renew wiring harness after removing

– ⇒ “5.16 Provisional energisation of high-voltage battery 1

AX2”, page 216 .

5.15 Visually inspecting and classifying bat‐

tery module
Special tools and workshop equipment required
♦ module balancer - VAS 6910A-

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.

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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 6910A-
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 .

5.16 Provisional energisation of high-volt‐

age battery 1 AX2
Special tools and workshop equipment required
♦ diagnostic cable - VAS 6558A/48-
♦ high-voltage diagnostics box - VAS 5581A-
♦ sliding rail - T40275-
♦ vehicle diagnostic tester

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).

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Note
Provisional energisation of the high-voltage battery should be
performed in order to check the electrical function of control
units and battery modules before sealing.

– Put on protective equipment:

♦ Fabric gloves
♦ Safety goggles
♦ Safety shoes with ESD protection
Protective equipment ⇒ Electronic parts catalogue (ETKA)

– Set switching unit down on 2x sliding rail - T40275- -A-.

– Connect switching unit and wiring harness for high-volt‐
age battery in battery housing to diagnostic cable - VAS
6558A/48- -1-.
– Perform diagnosis of removed high-voltage battery ⇒ Rep.
gr. 93 ; Diagnosis of removed high-voltage battery 1 AX2 .

– Connect vehicle diagnostic tester to high-voltage diagnostics

box - VAS 5581A- .
– Select and start “Diagnosis” mode on ⇒ Vehicle diagnostic
tester.
– Perform provisional energisation with ⇒ Vehicle diagnostic
tester ⇒ Rep. gr. 00 ; Starting diagnosis .
If electrical function is OK, assemble high-voltage battery com‐
pletely:
♦ ⇒ Rep. gr. 93 ; Close high-voltage battery 1 AX2 .

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6 Power and control electronics for

electric drive

6.1 Assembly overview - power and control

electronics for electric drive (front)
– ⇒ Rep. gr. 93 ; Assembly overview - electric drive motor

6.2 Assembly overview - power and control

electronics for electric drive (rear)
– ⇒ Rep. gr. 93 ; Assembly overview - electric drive motor,
rear

6.3 Removing and installing power and

control electronics for electric drive
(front)
Special tools and workshop equipment required
♦ drip tray for workshop hoist - VAS 6208-
♦ hose clamps (up to 25 mm) - 3094-
♦ removal cylinder - T40468/1-
♦ removal pin - T40468/2-
Power and control electronics 2 for electric drive - JX4- are
referred to below as power electronics.
Three-phase current drive 2 - VX97- is referred to below as
three-phase current drive.

Removing
– Remove bracket for air conditioner compressor ⇒ Heating,
air conditioning; Rep. gr. 87 ; Air conditioner compressor;
Removing and installing bracket for air conditioner compres‐
sor

– Remove front underbody cladding ⇒ General body repairs,

exterior; Rep. gr. 66 ; Underbody cladding; Removing and
installing front underbody cladding .

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– Unplug electrical connector -1-.

– Unfasten clip -2-.
– Remove bolts -arrows-.
Note
Different bolt heads.

– Screw removal cylinder - T40468/1- -B- into thread -arrows-.

– Screw removal pin - T40468/2- -A- into removal cylinder -B-.
– Release cover -1- evenly from bonded joint by turning re‐
moval pins -A-.
– Detach cover -1-.

– Perform redundant de-energisation ⇒ Rep. gr. 93 ; De-en‐

ergising high-voltage system .

– Clamp off coolant hoses -1-, -3- and -4- with hose clamps
(up to 25 mm) - 3094- -A-.
– Place drip tray for workshop hoist - VAS 6208- underneath.
– Release hose clips -arrows- and detach coolant hoses -2-,
-1-.

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– Unplug electrical connector -2- for power electronics -1-.

– Remove bolts -arrows-.

– Unplug high-voltage connector -5- for three-phase current

drive -2- ⇒ Rep. gr. 93 ; Unplugging high-voltage connec‐
tors .
– Move electrical wire -3- clear.
– Unscrew bolts -1- and detach power electronics -2-.
– Loosen hose clip -4- and detach coolant hose.

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

– Clean sealing surfaces on motor and cover with chemical

cleaning agent so they are free of oil and grease.

– Apply sealant bead -1- onto clean sealing surface of cover.

Important
• Thickness of sealant bead: 2 to 3 mm
• Install cover within 10 minutes of applying sealant.

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If renewing power electronics:

– Perform necessary function(s) using ⇒ Vehicle diagnostic
tester ⇒ Rep. gr. 00 ; Starting diagnosis .

Continued
Tightening torques
♦ ⇒ Rep. gr. 93 ; Assembly overview - electric drive motor

6.4 Removing and installing power and

control electronics for electric drive
(rear)
Special tools and workshop equipment required
♦ removal cylinder - T40468/1-
♦ removal pin - T40468/2-
Power and control electronics for electric drive - JX1- are refer‐
red to below as power electronics.
Three-phase current drive - VX54- is referred to as three-phase
current drive below.

Removing
– ⇒ Rep. gr. 10 ; Remove rear motor .

– Remove bolts -arrows-.

Note
Different bolt heads.

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– Screw removal cylinder - T40468/1- -B- into thread -arrows-.

– Screw removal pin - T40468/2- -A- into removal cylinder -B-.
– Release cover -1- evenly from bonded joint by turning re‐
moval pins -A-.
– Detach cover -1-.

– Perform redundant de-energisation ⇒ Rep. gr. 93 ; De-en‐

ergising high-voltage system .

– Unfasten hose clips -3-, -6- and detach coolant hoses.

– Unplug electrical connector -2- and move it clear.
– Unscrew bolts -1-, -4- and detach power electronics -5-.

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

– Clean sealing surfaces on motor and cover with chemical

cleaning agent so they are free of oil and grease.

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– Apply sealant bead -1- onto clean sealing surface of cover.

Important
• Thickness of sealant bead: 2 to 3 mm
• Install cover within 10 minutes of applying sealant.

If renewing power electronics:

– Perform necessary function(s) using ⇒ Vehicle diagnostic
tester ⇒ Rep. gr. 00 ; Starting diagnosis .

Continued
Tightening torques
♦ ⇒ Rep. gr. 93 ; Assembly overview - electric drive motor,
rear
♦

6. Power and control electronics for electric drive 223

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7 Electric drive motor

7.1 Assembly overview - electric drive motor, front

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1 - Bolt
❑ For potential equalisa‐
tion line for three-phase
current drive 2 - VX97-
❑ 20 Nm
2 - Potential equalisation line
for three-phase current drive
2 - VX97-
3 - Bolt
❑ For drive motor tem‐
perature sender 2 -
G1146-
❑ Renew after removing
❑ 8 Nm +45°
4 - Drive motor temperature
sender 2 - G1146-
❑ ⇒ Rep. gr. 93 ; Re‐
moving and installing
front drive motor rotor
position sender
5 - Moulded gasket
❑ For power and control
electronics 2 for electric
drive - JX4-
❑ Renew after removing
6 - Bolt
❑ For power and control
electronics 2 for electric
drive - JX4-
❑ 4x
❑ Renew after removing
❑ ⇒ page 227
7 - Power and control elec‐
tronics 2 for electric drive - JX4-
❑ ⇒ Rep. gr. 93 ; Removing and installing power and control electronics for electric drive (front)
8 - Seal
❑ For coolant connection
❑ 2x
❑ Renew after removing
9 - Coolant connection
10 - Bolt
❑ For coolant connection
❑ 2x
❑ 8 Nm
11 - High-voltage wire
❑ ⇒ “9.2.1 Removing and installing high-voltage wiring harness for front drive motor”, page 241
12 - Bolt
❑ For high-voltage wire
❑ 2x
❑ 8 Nm
13 - Dowel sleeve

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❑ 2x
14 - Seal
❑ For oil temperature sender 2 - G664-
❑ Renew after removing
15 - Oil temperature sender 2 - G664-
❑ ⇒ Rep. gr. 93 ; Removing and installing front oil temperature sender
16 - Bolt
❑ For oil temperature sender 2 - G664-
❑ Renew after removing
❑ 8 Nm +45°
17 - Bolt
❑ For bus bar for power and control electronics 2 for electric drive - JX4-
❑ 3x
❑ 10 Nm
18 - Seal
❑ For coolant line
❑ 2x
❑ Renew after removing
19 - Coolant line
20 - Bolt
❑ For coolant line
❑ 2x
❑ 8 Nm
21 - Rotor position sender 1 for drive motor 2 - G1147-
❑ ⇒ Rep. gr. 93 ; Removing and installing front drive motor rotor position sender
22 - Shield
❑ For rotor position sender 1 for drive motor 2 - G1147-
23 - Bolt
❑ For rotor position sender 1 for drive motor 2 - G1147-
❑ 3x
❑ Renew after removing
❑ ⇒ page 227
24 - Cover
25 - Bolt
❑ For cover
❑ 7x
❑ Renew after removing
❑ ⇒ page 227

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Tightening torque and sequence: rotor position sender 1 for

drive motor 2 - G1147-
Stage Sequence Tightening torque
1 -1- to -3- 4 Nm
2 -1- to -3- 8 Nm
3 -1- to -3- Turn 60° further

Tightening torque and sequence: cover

Stage Sequence Tightening torque
1 -1- to -7- Screw in by hand
until contact is
made
2 -1- to -7- 8 Nm
3 -1- to -7- Turn 45° further

Tightening torque and sequence: power and control electronics

2 for electric drive - JX4-
Stage Sequence Tightening torque
1 -1- to -4- Screw in by hand
until contact is
made
2 -1- to -4- 16 Nm
3 -1- to -4- Turn 90° further

7.2 Assembly overview - electric drive motor, rear

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1 - Bolt
❑ For power and control
electronics for electric
drive - JX1-
❑ 4x
❑ Renew after removing
❑ ⇒ page 230
2 - Power and control elec‐
tronics for electric drive - JX1-
❑ ⇒ Rep. gr. 93 ; Re‐
moving and installing
power and control elec‐
tronics for electric drive
(rear)
3 - Seal
❑ For coolant connection
❑ 2x
❑ Renew after removing
4 - Coolant connection
5 - Bolt
❑ For coolant connection
❑ 2x
❑ 8 Nm
6 - High-voltage wire
❑ ⇒ “9.2.2 Removing and
installing high-voltage
wiring harness for rear
drive motor”, page 243
7 - Bolt
❑ For high-voltage wire
❑ 2x
❑ 8 Nm
8 - Seal
❑ For oil temperature sender - G8-
❑ Renew after removing
9 - Oil temperature sender - G8-
❑ ⇒ Rep. gr. 93 ; Removing and installing rear oil temperature sender
10 - Bolt
❑ For oil temperature sender - G8-
❑ Renew after removing
❑ 8 Nm +45°
11 - Dowel sleeve
❑ 2x
12 - Potential equalisation line for three-phase current drive - VX54-
13 - Bolt
❑ For potential equalisation line
❑ 20 Nm
14 - Seal
❑ For coolant line

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❑ 2x
❑ Renew after removing
15 - Bolt
❑ For coolant line
❑ 2x
❑ 8 Nm
16 - Coolant line
17 - Bolt
❑ For bus bar for power and control electronics for electric drive - JX1-
❑ 3x
❑ 10 Nm
18 - Drive motor rotor position sender 1 - G713-
❑ ⇒ Rep. gr. 93 ; Removing and installing rear drive motor rotor position sender
19 - Shield
❑ For drive motor rotor position sender 1 - G713-
20 - Bolt
❑ For drive motor rotor position sender 1 - G713-
❑ 3x
❑ Renew after removing
❑ ⇒ page 229
21 - Bolt
❑ For cover
❑ 9x
❑ Renew after removing
❑ ⇒ page 230
22 - Cover
23 - Bolt
❑ For drive motor temperature sender - G712-
❑ Renew after removing
❑ 8 Nm +45°
24 - Drive motor temperature sender - G712-
❑ ⇒ Rep. gr. 93 ; Removing and installing rear drive motor temperature sender
25 - Moulded gasket
❑ For power and control electronics for electric drive - JX1-
❑ Renew after removing

Tightening torque and sequence: drive motor rotor position

sender 1 - G713-
Stage Sequence Tightening torque
1 -1- to -3- 4 Nm
2 -1- to -3- 8 Nm
3 -1- to -3- Turn 60° further

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Tightening torque and sequence: cover

Stage Sequence Tightening torque
1 -1- to -9- Screw in by hand
until contact is
made
2 -1- to -9- 8 Nm
3 -1- to -9- Turn 45° further

Tightening torque and sequence: power and control electronics

for electric drive - JX1-
Stage Sequence Tightening torque
1 -1- to -4- Screw in by hand
until contact is
made
2 -1- to -4- 16 Nm
3 -1- to -4- Turn 90° further

7.3 Removing and installing front drive mo‐

tor rotor position sender
Removing
– Remove front underbody cladding ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody cladding; Removing and
installing front underbody cladding .

– Unplug electrical connector -1-.

– Remove bolts -arrows-.
– Detach cover -2-.

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– Carefully pry out rotor position sender 1 for drive motor 2 -

G1147- -1-.

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

If rotor position sender 1 for drive motor 2 - G1147- has been

renewed:
– Perform function “Renewing rotor position sender 1 for drive
motor 2 G1147” ⇒ Rep. gr. 00 ; Starting diagnosis .

Continued
Tightening torques
♦ ⇒ Rep. gr. 93 ; Assembly overview - electric drive motor

7.4 Removing and installing rear drive mo‐

tor rotor position sender
Removing
– Remove rear underbody cladding ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody cladding; Removing and
installing rear underbody cladding .

– Unplug electrical connector -1-.

– Release retaining clip -2-.
– Carefully push coolant line -3- to the side.
– Remove bolts -arrows-.
– Detach cover -4-.

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– Carefully pry out drive motor rotor position sender 1 - G713-

-1-.
– Carefully press coolant line -2- to side and detach sender
-1-.

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

If drive motor rotor position sender 1 - G713- has been re‐

newed:
– Perform function “Renewing drive motor rotor position send‐
er 1 G713” ⇒ Rep. gr. 00 ; Starting diagnosis .

Continued
Tightening torques
♦ ⇒ Rep. gr. 93 ; Assembly overview - electric drive motor,
rear

7.5 Removing and installing front drive mo‐

tor temperature sender
Special tools and workshop equipment required
♦ removal cylinder - T40468/1-
♦ removal pins - T40468/2-

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.

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

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– Remove front underbody cladding ⇒ General body repairs,

exterior; Rep. gr. 66 ; Underbody cladding; Removing and
installing front underbody cladding .

– Unplug electrical connector -1-.

– Open retaining clip -2-.
– Remove bolts -arrows-.
Note
Bolts have different heads.

– Screw removal cylinder - T40468/1- -B- into thread -arrows-.

– Screw removal pins - T40468/2- -A- into removal cylinder -
T40468/1- -B-.
– Release cover -1- evenly from bonded joint by turning re‐
moval pins - T40468/2- -A-.
– Detach cover -1-.

– Perform redundant de-energisation ⇒ Rep. gr. 93 ; De-en‐

ergising high-voltage system .

– Remove bolt -arrow-.

– Remove drive motor temperature sender 2 - G1146- -1-.

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

– Cover exposed parts of motor.

CAUTION
Risk of eye injury due to sealant residue
– Put on safety goggles.

– Remove remaining sealant from motor and cover -1- with a

rotating plastic brush or similar.
– Thoroughly clean sealing surfaces; they must be free of oil
and grease.

– Apply sealant bead -1- onto clean sealing surface of cover.

Important
• Width of sealant bead: 3 mm
• Install cover within 10 minutes of applying sealant.

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

Tightening torques
♦ ⇒ Rep. gr. 93 ; Assembly overview - electric drive motor

7.6 Removing and installing rear drive mo‐

tor temperature sender
Special tools and workshop equipment required
♦ removal cylinder - T40468/1-
♦ removal pins - T40468/2-

Removing
– ⇒ Rep. gr. 10 ; Remove rear motor .

– Remove bolts -arrows-.

Note
Bolts have different heads.

– Screw removal cylinder - T40468/1- -B- into thread -arrows-.

– Screw removal pins - T40468/2- -A- into removal cylinder -
T40468/1- -B-.
– Release cover -1- evenly from bonded joint by turning re‐
moval pins - T40468/2- -A-.
– Detach cover -1-.

– Perform redundant de-energisation ⇒ Rep. gr. 93 ; De-en‐

ergising high-voltage system .

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– Remove bolt -arrow-.

– Remove drive motor temperature sender - G712- -1-.

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

– Cover exposed parts of motor.

CAUTION
Risk of eye injury due to sealant residue
– Put on safety goggles.

– Remove remaining sealant from motor and cover -1- with a

rotating plastic brush or similar.
– Thoroughly clean sealing surfaces; they must be free of oil
and grease.

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– Apply sealant bead -1- onto clean sealing surface of cover.

Important
• Width of sealant bead: 3 mm
• Install cover within 10 minutes of applying sealant.

Tightening torques
♦ ⇒ Rep. gr. 93 ; Assembly overview - electric drive motor,
rear

7.7 Removing and installing front oil tem‐

perature sender
Removing
– Remove front underbody cladding ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody cladding; Removing and
installing front underbody cladding .

– Unplug electrical connector -2-.

– Remove bolt -arrow-.
– Remove oil temperature sender 2 - G664- -1-.

Installing
Installation is carried out in reverse order.

Tightening torques
♦ ⇒ Rep. gr. 93 ; Assembly overview - electric drive motor

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7.8 Removing and installing rear oil tem‐

perature sender
Removing
– Remove rear underbody cladding ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody cladding; Removing and
installing rear underbody cladding .

– Remove bolt -arrow-.

– Unplug electrical connector -2-.
– Remove oil temperature sender - G8- -1-.

Installing
Installation is carried out in reverse order.

Tightening torques
♦ ⇒ Rep. gr. 93 ; Assembly overview - electric drive motor,
rear

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8 Motor control unit

8.1 Removing and installing motor control

unit J623
Motor control unit - J623- is integrated in control unit for drive
system and running gear functions - J1312- ⇒ Running gear,
axles, steering; Rep. gr. 43 ; Electronic damping control; As‐
sembly overview - damping control .

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9 High-voltage wiring

9.1 Overview of fitting locations - high-voltage wiring

1 - High-voltage wire for

charging socket 2
❑ ⇒ Rep. gr. 93 ;
Removing and instal‐
ling high-voltage bat‐
tery charging socket 2
UX5
2 - High-voltage wiring har‐
ness for rear drive motor
❑ ⇒ “9.2.2 Removing and
installing high-voltage
wiring harness for rear
drive motor”, page 243
3 - High-voltage wire for
charging socket 1
❑ ⇒ Rep. gr. 93 ;
Removing and instal‐
ling high-voltage bat‐
tery charging socket 1
UX4
4 - High-voltage wire from
switching unit for high-volt‐
age battery to coupling point
(front)
❑ ⇒ “9.3 Removing and
installing high-voltage
wire from switching unit
for high-voltage bat‐
tery to coupling point
(front)”, page 244
5 - High-voltage wiring har‐
ness for front drive motor
❑ ⇒ “9.2.1 Removing and
installing high-voltage
wiring harness for front
drive motor”, page 241
6 - Coupling point (front)
7 - High-voltage wire for electrical air conditioner compressor
❑ ⇒ Rep. gr. 93 ; Removing and installing high-voltage wire for electrical air conditioner compressor
8 - Coupling point for high-voltage wire for high-voltage heater
9 - High-voltage wire for high-voltage heater
❑ ⇒ Rep. gr. 93 ; Removing and installing high-voltage wire for high-voltage heater
10 - High-voltage wiring harness from switching unit for high-voltage battery to high-voltage central box
❑ ⇒ “9.4 Removing and installing high-voltage wiring harness from switching unit for high-voltage battery
to high-voltage central box”, page 244

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9.2 Removing and installing high-voltage

wiring harness for drive motor

9.2.1 Removing and installing high-voltage

wiring harness for front drive motor
Removing
– Remove high-voltage battery 1 AX2 ⇒ Rep. gr. 93 ; Remov‐
ing and installing high-voltage battery 1 AX2 .
– Remove bracket for air conditioner compressor ⇒ Heating,
air conditioning; Rep. gr. 87 ; Air conditioner compressor;
Removing and installing bracket for air conditioner compres‐
sor .

Left-hand drive vehicles

– Detach intermediate steering shaft from steering rack and
move clear by telescoping together ⇒ Running gear, axles,
steering; Rep. gr. 48 ; Steering column; Removing and in‐
stalling intermediate steering shaft .

All vehicles (continued)

– Move coolant hose -2- and transmission unit breather -4-
clear at bracket -3-.
– Remove bolts -arrows-.
– Unplug high-voltage connector -1- ⇒ Rep. gr. 93 ; Unplug‐
ging high-voltage connectors .

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– Release catch -arrow B- and open retaining bracket -3-

-arrow C-.
– Release catches -arrows A-, move high-voltage wire -1-
clear at bracket -2- and unplug connector ⇒ Rep. gr. 93 ;
Unplugging high-voltage connector .

– Unscrew bolt -5- on bracket -4-.

– Guide high-voltage wire -3- out downwards.

Installing
Installation is carried out in the 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
Component Tightening torque
Bracket to motor 8 Nm
Bracket to body 8 Nm

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9.2.2 Removing and installing high-voltage

wiring harness for rear drive motor
Removing
– Remove subframe ⇒ Running gear, axles, steering; Rep.
gr. 42 ; Subframe; Removing and installing subframe .

– Remove bench seat ⇒ General body repairs, interior; Rep.

gr. 72 ; Rear seats; Removing and installing bench seat/
individual seats .
– Remove lower C-pillar trim on both sides ⇒ General body
repairs, interior; Rep. gr. 70 ; Passenger compartment trim
panels; Removing and installing lower C-pillar trim .

– Fold up insulating mat back towards rear.

– Remove nuts -arrows-.
– Detach seat recess cover -1-.

– Unplug high-voltage connector -5- ⇒ Motor; Rep. gr. 93 ;

High-voltage wiring; Unplugging high-voltage connectors .
– Remove bolts -1-, -4- for brackets -2-, -3-.
– Release fastener -arrow- and move bracket -3- clear.

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– Unclip high-voltage wiring -arrow- and guide out towards

rear.
– Detach brackets and guides from high-voltage wiring har‐
ness.

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 ; Assembly overview - high-voltage central
box
Component Tightening torque
Bracket to high-voltage central 8 Nm
box
Bracket to body 8 Nm

9.3 Removing and installing high-voltage

wire from switching unit for high-volt‐
age battery to coupling point (front)
Removing
– Remove high-voltage wiring harness for front drive motor ⇒
“9.2.1 Removing and installing high-voltage wiring harness
for front drive motor”, page 241 .

Installing
Install in reverse order of removal:

9.4 Removing and installing high-voltage

wiring harness from switching unit for

244 Rep. gr.93 - Electric drive systems

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high-voltage battery to high-voltage

central box
Removing
– Remove high-voltage central box ⇒ Rep. gr. 93 ; Removing
and installing high-voltage central box .

– Unclip high-voltage wire -arrow-.

– Unplug high-voltage connector -1- ⇒ Rep. gr. 93 ; Unplug‐
ging high-voltage connectors .
– Remove high-voltage wire.

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 .

9.5 Removing and installing high-voltage

wire for electrical air conditioner com‐
pressor
Removing
– Remove front left wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liners; Remov‐
ing and installing front wheel housing liner .

– Release receiver and place to side with lines attached

⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
Removing and installing receiver .

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– Unclip high-voltage wiring harness for air conditioner com‐

pressor - VX81- -arrows-.
– Unplug high-voltage connector -1- ⇒ Rep. gr. 93 ; Unplug‐
ging high-voltage connectors .

– Open retainer -2- -arrow-.

– Unclip high-voltage wiring -1- from retainers -5- and bracket
-4-.
– Unplug high-voltage connector -3- ⇒ Rep. gr. 93 ; Unplug‐
ging high-voltage connectors .

Left-hand drive vehicles:

– Remove lower side bulkhead ⇒ General body repairs, exte‐
rior; Rep. gr. 50 ; Bulkhead; Removing and installing bulk‐
head .

– Remove brake pressure unit ⇒ Brake system; Rep. gr. 47 ;

Brake pressure unit; Removing and installing brake pressure
unit .

– Move electrical wiring harness -3- clear and pull it to one

side.
– Unclip high-voltage wiring harness from bracket -1- and
move clear -arrows-.
– Unplug high-voltage connector -2- ⇒ Rep. gr. 93 ; Unplug‐
ging high-voltage connectors .

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– Move high-voltage wiring harness -1- clear along bulkhead

-arrows-.

All vehicles (continued)

Right-hand drive vehicles:
– Remove heat exchanger for high-voltage battery ⇒ Heating,
air conditioning; Rep. gr. 87 ; Refrigerant circuit; Removing
and installing heat exchanger for high-voltage battery .

– Remove bolt -1-.

– Lift off bracket -2- with rubber bushes -3- and detach.

– Move retaining clip -arrow- with high-voltage wiring harness

clear at bulkhead (bottom side) -1-.

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– Unclip high-voltage wiring harness from bracket -2- and

move clear.
– Unplug high-voltage connector -1- ⇒ Rep. gr. 93 ; Unplug‐
ging high-voltage connectors .

All vehicles (continued)

– Unscrew nut -3- and detach bracket -1- towards outside.
– Detach high-voltage wiring -2- from bracket -1-.
– Guide out high-voltage wiring.

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
⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit;
Assembly overview - heat exchanger for high-voltage battery
Component Tightening torque
Nut securing bracket to front 8 Nm
left wheel housing (outside)
Nut securing bracket to front 8 Nm
left wheel housing (inside)

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9.6 Removing and installing high-voltage

wire for high-voltage heater
Removing
– Remove heater and air conditioning unit ⇒ Heating, air con‐
ditioning; Rep. gr. 87 ; Front heater and air conditioning unit;
Removing and installing heater and air conditioning unit .

– Unplug high-voltage connector -3- from high-voltage heater

(PTC) - ZX17- -4- ⇒ Rep. gr. 93 ; Unplugging high-voltage
connectors .
– Unfasten clips -2-.
– Detach grommet -5- and remove high-voltage wire -1-.

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 .

9.7 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 lock -1- -arrow A-.
– Press connector lock in direction of -arrow B- and, at the
same time, unplug high-voltage connector -2-.

All vehicles (continued)

8-pin high-voltage connector with one-stage release mechanism
– Release connector lock -1- to side -arrow A-.
– Press catch -2- in direction of -arrow B- and, at the same
time, unplug high-voltage connector.

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All vehicles (continued)

4-pin high-voltage connector with one-stage release mechanism
– Release connector lock -1- to side -arrow A-.
– Press catch -2- in direction of -arrow B- and, at the same
time, unplug high-voltage connector.

All vehicles (continued)

2-pin high-voltage connector with two-stage release mechanism
– Pull out connector lock -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-.

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All vehicles (continued)

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 lock -1- out as far as stop -arrow B-.
– Press fastener in direction of -arrow C- and unplug high-volt‐
age connector.

All vehicles (continued)

3-pin high-voltage connector (large version) with two-stage re‐
lease mechanism
– Press down fastener -arrow A- and pull connector lock -1-
out as far as stop -arrow B-.
– Press fastener in direction of -arrow C- and unplug high-volt‐
age connector.

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All vehicles (continued)

4-pin high-voltage connector with bracket
– Remove bolts -arrows-.
– Unplug high-voltage connector -1-.

All vehicles (continued)

4-pin high-voltage connector without bracket
– Remove bolts -1-.
– Unplug high-voltage connector -2-.

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All vehicles (continued)

2-pin high-voltage connector with three-stage release mecha‐
nism
– Release catch with screwdriver -A- -arrow B- and detach
end piece -1- towards rear -arrow E-.
– Pull sleeve -2- back slightly -arrow D-.
– Press catch on both sides -arrow C- and unplug high-voltage
connector at the same time.

All vehicles (continued)

3-pin high-voltage connector with two-stage release mechanism
– Press down catch -arrow B- and pull connector lock -1- out
as far as stop -arrow A-.
– Press catch in direction of -arrow C- and unplug high-voltage
connector.

All vehicles (continued)

4-pin high-voltage connector with two-stage release mechanism
– Pull out connector lock -2- -arrow A-.
– Press catch -1- in direction of -arrow B- and, at the same
time, unplug high-voltage connector.

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All vehicles (continued)

2-pin high-voltage connector with two-stage release mechanism
– Pull out connector lock -1- -arrow A-.
– Press catch -2- in direction of -arrow B- and, at the same
time, unplug high-voltage connector.

All vehicles (continued)

2-pin high-voltage connector with two-stage release mechanism
– Pull out connector lock -1- -arrow A-.
– Press catch -2- in direction of -arrow B- and, at the same
time, unplug high-voltage connector.

All vehicles (continued)

Tightening torques
♦ ⇒ Motor; Rep. gr. 93 ; High-voltage wiring; Overview of
fitting locations - high-voltage wiring

9. High-voltage wiring 255

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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 program.
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
repairs, exterior; Rep. gr. 50 ; Bulkhead; Removing and
installing plenum chamber cover .

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– Pull securing clip -2- out of connector housing.

– 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-.

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– Release retainer -3- with a narrow-bladed screwdriver

-arrow A-.
– 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 sys‐
tem; Rep. gr. 97 ; Cleaning contact surfaces .

12.2 Overview of fitting locations - potential equalisation lines

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1 - Potential equalisation for

high-voltage battery 1 - AX2-
❑ ⇒ Rep. gr. 93 ; As‐
sembly overview - high-
voltage battery (instal‐
led)
2 - Potential equalisation line
for high-voltage central box -
JX6-
❑ ⇒ Rep. gr. 93 ; As‐
sembly overview - high-
voltage central box
3 - High-voltage battery
charging socket 2 - UX5-
❑ ⇒ Rep. gr. 93 ;
Assembly overview -
charging socket 2
4 - High-voltage battery
charging socket 1 - UX4-
❑ ⇒ Rep. gr. 93 ;
Assembly overview -
charging socket
5 - Potential equalisation line
for three-phase current drive -
VX54-
❑ ⇒ Rep. gr. 93 ; As‐
sembly overview - rear
electric drive motor
6 - Potential equalisation line
for three-phase current drive
2 - VX97-
❑ ⇒ Rep. gr. 93 ; As‐
sembly overview - front
electric drive motor
7 - Potential equalisation line
for air conditioner compressor - VX81-
❑ ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Assembly overview - air
conditioner compressor
8 - Potential equalisation line for high-voltage heater (PTC) - ZX17-
❑ ⇒ Heating, air conditioning; Rep. gr. 87 ; Front heater and air conditioning unit; Assembly overview -
attachments for front heater and air conditioning unit (air distribution housing, heat condenser etc.)

12.3 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.

12. Potential equalisation lines 261

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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

262 Rep. gr.93 - Electric drive systems

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13 Charging socket

13.1 Assembly overview - charging socket,

EU, NAR

13.1.1 Assembly overview - charging socket

13. Charging socket 263

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1 - Cable guide
❑ Renew cable guide if
damaged or deformed
2 - Nut
❑ 8 Nm
3 - Earth wire
4 - Bolt
❑ 2x
❑ ⇒ page 265
5 - Upper part of mounting for
high-voltage battery charging
socket
6 - High-voltage battery
charging socket 1 - UX4-
❑ ⇒ Rep. gr. 93 ;
Removing and instal‐
ling high-voltage bat‐
tery charging socket 1
UX4
7 - Actuator for high-voltage
charging socket lock 1 - F498-
❑ ⇒ “13.8.1 Removing
and installing actuator
for high-voltage charg‐
ing socket lock F498”,
page 282
8 - Bolt
❑ 2x
❑ 1.5 Nm
9 - Grommet
10 - Wire retainer
11 - Manual release cable
❑ Removing and installing ⇒ “13.8.1 Removing and installing actuator for high-voltage charging socket
lock F498”, page 282
12 - Bolt
❑ 4x
❑ 6 Nm
13 - Bolt
❑ 2x
❑ ⇒ page 265
14 - Lower part of mounting for high-voltage battery charging socket
15 - Control unit 1 for activation of charging flap and charging socket - J1245-
❑ ⇒ Rep. gr. 93 ; Removing and installing control unit 1 for activation of charging flap and charging
socket J1245
16 - Nut
❑ 2x
❑ 8 Nm
17 - Cable guide
18 - Earth wire

264 Rep. gr.93 - Electric drive systems

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❑ Tightening torques ⇒ Rep. gr. 93 ; Removing and installing high-voltage central box

Charging socket 1 to mounting - tightening torques and se‐

quence
Bolts Tightening torque
-1- to -4- 7 Nm

13.2 Assembly overview - charging socket,

China, Japan

13.2.1 Assembly overview - charging socket

13. Charging socket 265

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1 - Cable guide
❑ Renew cable guide if
damaged or deformed
2 - Nut
❑ 8 Nm
3 - Earth wire
4 - Bolt
❑ 2x
❑ ⇒ page 266
5 - Upper part of mounting for
high-voltage battery charging
socket
6 - High-voltage battery
charging socket 1 - UX4-
❑ ⇒ Rep. gr. 93 ;
Removing and instal‐
ling high-voltage bat‐
tery charging socket 1
UX4
7 - Wire retainer
8 - Bolt
❑ 4x
❑ 6 Nm
9 - Bolt
❑ 2x
❑ ⇒ page 266
10 - Lower part of mounting
for high-voltage battery charg‐
ing socket
11 - Nut
❑ 2x
❑ 8 Nm
12 - Cable guide
13 - Earth wire
❑ Tightening torques ⇒ Rep. gr. 93 ; Removing and installing high-voltage central box

Charging socket 1 to mounting - tightening torques and se‐

quence
Bolts Tightening torque
-1- to -4- 7 Nm

266 Rep. gr.93 - Electric drive systems

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13.3 Assembly overview - charging socket

2, EU, NAR

13.3.1 Assembly overview - charging socket 2

13. Charging socket 267

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1 - Bolt
❑ 2x
❑ 1.5 Nm
2 - Actuator for high-voltage
charging socket lock 2 - F499-
❑ ⇒ “13.8.2 Removing
and installing actuator
for high-voltage charg‐
ing socket lock F499”,
page 286
3 - High-voltage battery
charging socket 2 - UX5-
❑ ⇒ Rep. gr. 93 ;
Removing and instal‐
ling high-voltage bat‐
tery charging socket 2
UX5
4 - Upper part of mounting for
high-voltage battery charging
socket
5 - Bolt
❑ 2x
❑ ⇒ page 269
6 - Earth wire
7 - Nut
❑ 8 Nm
8 - Lower part of mounting for
high-voltage battery charging
socket
9 - Cable guide
❑ Renew cable guide if
damaged or deformed
10 - Earth wire
❑ Tightening torques ⇒ Rep. gr. 93 ; Removing and installing high-voltage central box
11 - Cable guide
12 - Nut
❑ 2x
❑ 8 Nm
13 - Control unit 2 for activation of charging flap and charging socket - J1246-
❑ ⇒ Rep. gr. 93 ; Removing and installing control unit 2 for activation of charging flap and charging
socket J1246 - EU, NAR
14 - Bolt
❑ 2x
❑ ⇒ page 269
15 - Bolt
❑ 4x
❑ 6 Nm
16 - Manual release cable
❑ Removing and installing ⇒ “13.8.2 Removing and installing actuator for high-voltage charging socket
lock F499”, page 286

268 Rep. gr.93 - Electric drive systems

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17 - Grommet

Charging socket 2 to mounting - tightening torques and se‐

quence
Bolts Tightening torque
-1- to -4- 7 Nm

13.4 Assembly overview - charging socket

2, China, Japan

13.4.1 Assembly overview - charging socket 2

13. Charging socket 269

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1 - Bolt
❑ 2x
❑ 1.5 Nm
2 - Actuator for high-voltage
charging socket lock 2 - F499-
❑ ⇒ “13.8.2 Removing
and installing actuator
for high-voltage charg‐
ing socket lock F499”,
page 286
3 - High-voltage battery
charging socket 2 - UX5-
❑ ⇒ Rep. gr. 93 ;
Removing and instal‐
ling high-voltage bat‐
tery charging socket 2
UX5
4 - Upper part of mounting for
high-voltage battery charging
socket
5 - Bolt
❑ 2x
❑ ⇒ page 271
6 - Earth wire
7 - Nut
❑ 8 Nm
8 - Lower part of mounting for
high-voltage battery charging
socket
9 - Cable guide
❑ Renew cable guide if
damaged or deformed
10 - Earth wire
❑ Tightening torques ⇒ Rep. gr. 93 ; Removing and installing high-voltage central box
11 - Cable guide
12 - Nut
❑ 2x
❑ 8 Nm
13 - Control unit 1 for activation of charging flap and charging socket - J1245-
❑ ⇒ Rep. gr. 93 ; Removing and installing control unit 1 for activation of charging flap and charging
socket J1245
14 - Bolt
❑ 2x
❑ ⇒ page 271
15 - Bolt
❑ 4x
❑ 6 Nm
16 - Manual release cable
❑ Removing and installing ⇒ “13.8.2 Removing and installing actuator for high-voltage charging socket
lock F499”, page 286

270 Rep. gr.93 - Electric drive systems

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17 - Grommet

Charging socket 2 to mounting - tightening torques and se‐

quence
Bolts Tightening torque
-1- to -4- 7 Nm

13.5 Removing and installing high-voltage

battery charging socket 1 UX4 - EU,
NAR

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.

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

– Switch off ignition. Deposit vehicle key and other drive au‐
thorisation systems (e.g. smartphone) outside vehicle.
– Remove high-voltage central box - JX6- ⇒ Rep. gr. 93 ;
Removing and installing high-voltage central box .

– Unplug high-voltage connector -arrow- ⇒ Rep. gr. 93 ; Un‐

plugging high-voltage connectors .

13. Charging socket 271

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– Remove rear left wheel housing liner ⇒ General body re‐

pairs, exterior; Rep. gr. 66 ; Wheel housing liners; Remov‐
ing and installing rear wheel housing liner .
– Remove charging flap unit (left-side) ⇒ General body re‐
pairs, exterior; Rep. gr. 55 ; Charging flap unit; Removing
and installing charging flap unit .
– Remove luggage compartment side trim (left-side) ⇒ Gener‐
al body repairs, interior; Rep. gr. 70 ; Luggage compartment
trim panels; Removing and installing luggage compartment
side trim .

– Pry manual release cable -2- off support bracket -1- on fuse
carrier and move it clear.
– Move manual release cable clear -arrow- and press grom‐
met -3- through towards outside.

– Unplug electrical connectors -3-, -4-.

– Move clear and unplug electrical connector -5-.
– Remove nut -1-.
– Move earth wires and wiring harness -2- clear.
– Move manual release cable -6- clear -arrow- and guide it out
of body.

272 Rep. gr.93 - Electric drive systems

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– Release catch -1- and slide control unit 1 for activation of

charging flap and charging socket - J1245- -2- off bracket in
direction of -arrow-.

– Unscrew nuts -1- and move wire retainer -2- clear.

– Move high-voltage wiring -3- clear -arrows-.
– Guide high-voltage wires out by hand.

13. Charging socket 273

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– Remove bolts -2-.

– Release catches -arrows- and guide high-voltage battery
charging socket 1 - UX4- -1- out of body downwards.
– Set charging socket down on a clean surface.

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.

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

Tightening torques
♦ ⇒ Rep. gr. 93 ; Assembly overview - charging socket

274 Rep. gr.93 - Electric drive systems

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13.6 Removing and installing high-voltage

battery charging socket 1 UX4 - China,
Japan

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.

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

– Remove bench seat/individual seats ⇒ General body re‐
pairs, interior; Rep. gr. 72 ; Rear seats; Removing and in‐
stalling bench seat/individual seats .
– Remove lower C-pillar trim ⇒ General body repairs, interior;
Rep. gr. 70 ; Passenger compartment trim panels; Remov‐
ing and installing lower C-pillar trim .
– Switch off ignition. Deposit vehicle key and other drive au‐
thorisation systems (e.g. smartphone) outside vehicle.

– Fold up insulating mat back towards rear.

– Remove bolts -arrows-.
– Detach cover -1-.

13. Charging socket 275

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– Unplug high-voltage connector -2- ⇒ Rep. gr. 93 ; Unplug‐

ging high-voltage connectors .
– Remove bolt and move earth wire -1- clear.

– Remove rear left wheel housing liner ⇒ General body re‐

pairs, exterior; Rep. gr. 66 ; Wheel housing liners; Remov‐
ing and installing rear wheel housing liner .
– Remove charging flap unit (left-side) ⇒ General body re‐
pairs, exterior; Rep. gr. 55 ; Charging flap unit; Removing
and installing charging flap unit .

– Remove nut -1-.

– Move earth wires and wiring harness -2- clear.

276 Rep. gr.93 - Electric drive systems

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– Unscrew nuts -1- and move wire retainer -2- clear.

– Move high-voltage wiring -3- clear -arrows-.
– Guide high-voltage wires out by hand.

– Remove bolts -2-.

– Release catches -arrows- and guide charging socket -1- out
of body downwards.
– Set charging socket down on a clean surface.

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 .

13. Charging socket 277

 Q6 e-tron 2024 ➤
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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.

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

Tightening torques
♦ ⇒ Rep. gr. 93 ; Assembly overview - charging socket
♦ ⇒ Rep. gr. 93 ; Assembly overview - high-voltage central
box

13.7 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.

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

– Switch off ignition. Deposit vehicle key and other drive au‐
thorisation systems (e.g. smartphone) outside vehicle.
– Remove high-voltage central box - JX6- ⇒ Rep. gr. 93 ;
Removing and installing high-voltage central box .
– Remove rear right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liners; Remov‐
ing and installing rear wheel housing liner .
– Install charging flap unit (right-side) ⇒ General body repairs,
exterior; Rep. gr. 55 ; Charging flap unit; Removing and
installing charging flap unit .
– Remove luggage compartment side trim (right-side) ⇒ Gen‐
eral body repairs, interior; Rep. gr. 70 ; Luggage compart‐
ment trim panels; Removing and installing luggage compart‐
ment side trim .

278 Rep. gr.93 - Electric drive systems

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– Move manual release cable -2- clear -arrows- and press

grommet -1- through towards outside.

– Unplug electrical connectors -2-, -3-.

– Move manual release cable -1- clear -arrow- and guide it out
of body.

– Remove nuts -arrows-.

– Move earth wires -1-, -2- clear.

13. Charging socket 279

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– Release catch -1- and slide control unit 2 for activation of

charging flap and charging socket - J1246- -2- off bracket in
direction of -arrow-.

– Move electrical wiring -4- clear.

– Unscrew nuts -2- and move wire retainer -3- clear.
– Move wiring harness -1- clear -arrows-.
– Guide wiring harness out by hand.

280 Rep. gr.93 - Electric drive systems

 Q6 e-tron 2024 ➤
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– Remove bolts -1-.

– Release catches -arrows- and guide high-voltage battery
charging socket 2 - UX5- -2- out of body downwards.
– Set charging socket down on a clean surface.

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.

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

Tightening torques
♦ ⇒ Rep. gr. 93 ; Assembly overview - charging socket 2

13. Charging socket 281

 Q6 e-tron 2024 ➤
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13.8 Removing and installing actuator for

high-voltage charging socket lock - EU,
NAR

13.8.1 Removing and installing actuator for

high-voltage charging socket lock F498
Special tools and workshop equipment required
♦ hot air blower - VAS 1978/14A-
♦ wiring harness repair set - VAS 1978B-

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.

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

– Switch off ignition. Deposit vehicle key and other drive au‐
thorisation systems (e.g. smartphone) outside vehicle.
– Remove rear left wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liners; Remov‐
ing and installing rear wheel housing liner .
– Remove charging flap unit (left-side) ⇒ General body re‐
pairs, exterior; Rep. gr. 55 ; Charging flap unit; Removing
and installing charging flap unit .
– Remove luggage compartment side trim (left-side) ⇒ Gener‐
al body repairs, interior; Rep. gr. 70 ; Luggage compartment
trim panels; Removing and installing luggage compartment
side trim .

282 Rep. gr.93 - Electric drive systems

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– Pry manual release cable -2- off support bracket -1- on fuse
carrier and move it clear.
– Move manual release cable clear -arrow- and press grom‐
met -3- through towards outside.

– Unplug electrical connectors -3-, -4-.

– Move clear and unplug electrical connector -5-.
– Remove nut -1-.
– Move earth wires and wiring harness -2- clear.
– Move manual release cable -6- clear -arrow- and guide it out
of body.

– Release catch -1- and slide control unit 1 for activation of

charging flap and charging socket - J1245- -2- off bracket in
direction of -arrow-.

13. Charging socket 283

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– Remove bolts -2-.

– Release catches -arrows- and guide high-voltage battery
charging socket 1 - UX4- -1- out of body downwards.
– Set charging socket down on a clean surface.

– Move electrical wiring -1-, -4- clear.

– Remove bolts -2-.
– Release catches -arrows- and detach mounting -3- from
charging socket.

– Move high-voltage wires -3- clear.

– Pry manual release cable -2- off support bracket and move it
clear.
– Remove bolts -arrows-.
– Detach mounting -1- from charging socket -4-.

284 Rep. gr.93 - Electric drive systems

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– Detach manual release cable -1- from actuator -3-.

– Remove bolts -2-.
– Detach actuator.
– 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 connectors from wiring harness re‐
pair set - VAS 1978B- to ends of wires so that they are offset
from each other ⇒ Electrical system; General information;
Rep. gr. 97 ; Wiring; Repairing 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.

13. Charging socket 285

 Q6 e-tron 2024 ➤
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– ⇒ Rep. gr. 93 ; Re-energise high-voltage system .

Tightening torques
♦ ⇒ Rep. gr. 93 ; Assembly overview - charging socket

13.8.2 Removing and installing actuator for

high-voltage charging socket lock F499
Special tools and workshop equipment required
♦ hot air blower - VAS 1978/14A-
♦ wiring harness repair set - VAS 1978B-

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.

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

– Switch off ignition. Deposit vehicle key and other drive au‐
thorisation systems (e.g. smartphone) outside vehicle.
– Remove rear right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liners; Remov‐
ing and installing rear wheel housing liner .
– Install charging flap unit (right-side) ⇒ General body repairs,
exterior; Rep. gr. 55 ; Charging flap unit; Removing and
installing charging flap unit .
– Remove luggage compartment side trim (right-side) ⇒ Gen‐
eral body repairs, interior; Rep. gr. 70 ; Luggage compart‐
ment trim panels; Removing and installing luggage compart‐
ment side trim .

286 Rep. gr.93 - Electric drive systems

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– Move manual release cable -2- clear -arrows- and press

grommet -1- through towards outside.

– Unplug electrical connectors -2-, -3-.

– Move manual release cable -1- clear -arrow- and guide it out
of body.

– Remove nuts -arrows-.

– Move earth wires -1-, -2- clear.

13. Charging socket 287

 Q6 e-tron 2024 ➤
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– Release catch -1- and slide control unit 1 for activation of

charging flap and charging socket - J1245- -2- off bracket in
direction of -arrow-.

– Remove bolts -1-.

– Release catches -arrows- and guide high-voltage battery
charging socket 2 - UX5- -2- out of body downwards.
– Set charging socket down on a clean surface.

288 Rep. gr.93 - Electric drive systems

 Q6 e-tron 2024 ➤
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– Move electrical wiring -1- clear.

– Pry manual release cable -4- off support bracket and move it
clear.
– Remove bolts -2-.
– Release catches -arrows- and detach mounting -3- from
charging socket.

– Move electrical wiring -3- clear.

– Remove bolts -arrows-.
– Detach mounting -1- from charging socket -2-.

13. Charging socket 289

 Q6 e-tron 2024 ➤
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– Detach manual release cable -1- from actuator -3-.

– Remove bolts -2-.
– Detach actuator.
– 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 approx. 90 mm.
– Strip ends of wires on vehicle wiring harness and actuator.
– Connect suitable crimp connectors from wiring harness re‐
pair set - VAS 1978B- to ends of wires so that they are offset
from each other ⇒ Electrical system; General information;
Rep. gr. 97 ; Wiring; Repairing 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.

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

290 Rep. gr.93 - Electric drive systems

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Tightening torques
♦ ⇒ Rep. gr. 93 ; Assembly overview - charging socket 2

13.9 Removing and installing actuator for

high-voltage charging socket lock -
China, Japan

13.9.1 Removing and installing actuator for

high-voltage charging socket lock F499
Special tools and workshop equipment required
♦ hot air blower - VAS 1978/14A-
♦ wiring harness repair set - VAS 1978B-

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.

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

– Switch off ignition. Deposit vehicle key and other drive au‐
thorisation systems (e.g. smartphone) outside vehicle.
– Remove rear right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liners; Remov‐
ing and installing rear wheel housing liner .
– Install charging flap unit (right-side) ⇒ General body repairs,
exterior; Rep. gr. 55 ; Charging flap unit; Removing and
installing charging flap unit .
– Remove luggage compartment side trim (right-side) ⇒ Gen‐
eral body repairs, interior; Rep. gr. 70 ; Luggage compart‐
ment trim panels; Removing and installing luggage compart‐
ment side trim .

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– Move manual release cable -2- clear -arrows- and press

grommet -1- through towards outside.

– Unplug electrical connectors -2-, -3-.

– Move manual release cable -1- clear -arrow- and guide it out
of body.

– Remove nuts -arrows-.

– Move earth wires -1-, -2- clear.

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– Release catch -1- and slide control unit 1 for activation of

charging flap and charging socket - J1245- -2- off bracket in
direction of -arrow-.

– Remove bolts -1-.

– Release catches -arrows- and guide high-voltage battery
charging socket 2 - UX5- -2- out of body downwards.
– Set charging socket down on a clean surface.

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– Move electrical wiring -1- clear.

– Pry manual release cable -4- off support bracket and move it
clear.
– Remove bolts -2-.
– Release catches -arrows- and detach mounting -3- from
charging socket.

– Move electrical wiring -3- clear.

– Remove bolts -arrows-.
– Detach mounting -1- from charging socket -2-.

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– Detach manual release cable -1- from actuator -3-.

– Remove bolts -2-.
– Detach actuator.
– 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 approx. 90 mm.
– Strip ends of wires on vehicle wiring harness and actuator.
– Connect suitable crimp connectors from wiring harness re‐
pair set - VAS 1978B- to ends of wires so that they are offset
from each other ⇒ Electrical system; General information;
Rep. gr. 97 ; Wiring; Repairing 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.

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

13. Charging socket 295

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Tightening torques
♦ ⇒ Rep. gr. 93 ; Assembly overview - charging socket 2

13.10 Removing and installing control unit

1 for activation of charging flap and
charging socket J1245 - EU, NAR

13.10.1 Removing and installing control unit

1 for activation of charging flap and
charging socket J1245
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 rear left wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liners; Remov‐
ing and installing rear wheel housing liner .

– Unplug electrical connectors -3-.

– Release catch -1- and slide control unit 1 for activation of
charging flap and charging socket - J1245- -2- off bracket in
direction of -arrow-.

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Installing
Installation is carried out in reverse sequence.

13.11 Removing and installing control unit

1 for activation of charging flap and
charging socket J1245 - China, Japan

13.11.1 Removing and installing control unit

1 for activation of charging flap and
charging socket J1245
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 rear right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liners; Remov‐
ing and installing rear wheel housing liner .

– Unplug electrical connectors -2-.

– Release catch -1- and slide control unit 1 for activation of
charging flap and charging socket - J1245- -3- off bracket in
direction of -arrow-.

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Installing
Installation is carried out in reverse sequence.

13.12 Removing and installing control unit

2 for activation of charging flap and
charging socket J1246 - EU, NAR
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 rear right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liners; Remov‐
ing and installing rear wheel housing liner .

– Unplug electrical connectors -2-.

– Release catch -1- and slide control unit 2 for activation of
charging flap and charging socket - J1246- -3- off bracket in
direction of -arrow-.

Installing
Installation is carried out in reverse sequence.

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14 High-voltage central box

14.1 Assembly overview - high-voltage central box

1 - Nut
❑ 20 Nm
2 - High-voltage central box -
JX6-
❑ ⇒ page 299
3 - Bolt
❑ 5x
❑ 20 Nm
4 - Bolt
❑ 20 Nm
5 - PE conductor to charging
socket (left-side)
6 - PE conductor to charging
socket (right-side)
7 - Bolt
❑ 8 Nm
8 - Potential equalisation line
❑ ⇒ Rep. gr. 93 ; Over‐
view of fitting locations
- potential equalisation
lines
9 - Bolt
❑ 20 Nm
10 - Terminal 30 wire

Seat recess cover - tightening torque

Component Tightening torque
Nut 24 Nm

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14.2 Removing and installing high-voltage

central box
Special tools and workshop equipment required
♦ closure caps - VAS 691 005/3-
♦ drip tray for workshop hoist - VAS 6208-
♦ end caps - VAS 6762/48-
♦ hose clamps up to 25mm - 3094-
♦ plugs - VAS 691 005/2-

Removing

If high-voltage central box - JX6- is renewed, test plan for re‐

newal 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.

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

– ⇒ Electrical system; Rep. gr. 27 ; Battery; Disconnecting
and connecting battery

– Remove bench seat/individual seats ⇒ General body re‐

pairs, interior; Rep. gr. 72 ; Rear seats; Removing and in‐
stalling bench seat/individual seats .
– Remove lower C-pillar trim on both sides ⇒ General body
repairs, interior; Rep. gr. 70 ; Passenger compartment trim
panels; Removing and installing lower C-pillar trim .

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– Fold up insulating mat back towards rear.

– Remove nuts -arrows-.
– Detach cover -1-.

– Unscrew potential equalisation line -2- and PE conductor -3-.

– Unscrew terminal 30 wire -1- and immediately attach end
caps - VAS 6762/48- or wrap wire with insulating tape to
prevent short circuit.
– Unplug electrical connector -4-.

– Detach rear section of front right wheel housing liner and

press it towards front ⇒ General body repairs, exterior; Rep.
gr. 66 ; Wheel housing liners; Removing and installing front
wheel housing liner .
– Remove rear underbody cladding ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody cladding; Assembly over‐
view - underbody cladding .

– Clamp off coolant hose -1- with hose clamps up to 25mm -

3094- -A-.

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Vehicles without control unit 1 for automated driving J1274,

high:
– Clamp off coolant hose -1- with hose clamps up to 25mm -
3094- -A-.
– Place drip tray for workshop hoist - VAS 6208- underneath.
– Release hose clip -arrow- and detach coolant hose -2-.
– Drain off coolant.

All vehicles (continued)

Vehicles with control unit 1 for automated driving J1274, high:
– Clamp off coolant hoses -1-, -2- with hose clamps up to
25mm - 3094- -A-.
– Place drip tray for workshop hoist - VAS 6208- underneath.
– Detach coolant hose -1-.
– Drain off coolant.

All vehicles (continued)

– Place absorbent material underneath.
– Detach coolant lines -1-, -2-.
– Seal off coolant lines immediately with plugs - VAS 691
005/2- .
– Cover connections on high-voltage central box immediately
with 2x closure caps - VAS 691 005/3- .

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– Unscrew PE conductor -3-.

– Remove bolts -2- and unclip wire retainer.
– Remove bolts -1-.

– Lift high-voltage central box - JX6- -4- slightly and pull to‐
wards rear -arrow-.
– Unplug high-voltage connectors -1-, -2-, -3- ⇒ Rep. gr. 93 ;
Unplugging high-voltage connectors .
Important
• Second mechanic required
– Remove high-voltage central box.

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.

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

– ⇒ Rep. gr. 19 ; Fill cooling system .

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Tightening torques
♦ ⇒ Rep. gr. 93 ; Assembly overview - high-voltage central
box

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15 Charging unit for high-voltage bat‐

tery

15.1 Charging unit for high-voltage battery

Control unit for high-voltage battery charging unit - J1050- is
integrated in high-voltage central box - JX6- ⇒ Rep. gr. 93 ;
Assembly overview - high-voltage central box

15. Charging unit for high-voltage battery 305

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16 Voltage converter

16.1 Voltage converter

Voltage converter - A19- is integrated in high-voltage central
box - JX6- ⇒ Electric drive motor; Rep. gr. 93 ; High-voltage
central box; Assembly overview - high-voltage central box .

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17 Engine sound generation

17.1 Overview of fitting locations - engine sound generation

1 - Actuator 2 for engine

sound generator - R258-
❑ ⇒ Rep. gr. 93 ; As‐
sembly overview - en‐
gine sound generation
2 - Engine sound generator
control unit - J943-
❑ Right-hand drive vehi‐
cles: layout is symmet‐
rically reversed
❑ ⇒ Rep. gr. 93 ; As‐
sembly overview - en‐
gine sound generation
3 - Actuator 1 for engine
sound generator - R257-
❑ ⇒ Rep. gr. 93 ; As‐
sembly overview - en‐
gine sound generation

17.2 Assembly overview - engine sound generation

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1 - Actuator 2 for engine

sound generator - R258-
❑ ⇒ “17.4.2 Removing
and installing actuator
2 for engine sound gen‐
erator R258”, page 310
2 - Nut
❑ 3x
❑ 4 Nm
3 - Bolt
❑ 2x
❑ 3 Nm
4 - Engine sound generator
control unit - J943-
❑ Right-hand drive vehi‐
cles: layout is symmet‐
rically reversed
❑ ⇒ Rep. gr. 93 ; Re‐
moving and installing
engine sound generator
control unit J943
5 - Bracket
❑ Right-hand drive vehi‐
cles: layout is symmet‐
rically reversed
6 - Nut
❑ 2x
❑ 3.5 Nm
7 - Bracket
8 - Bolt
❑ 3x
❑ 6 Nm
9 - Actuator 1 for engine sound generator - R257-
❑ ⇒ “17.4.1 Removing and installing actuator 1 for engine sound generator R257”, page 309
10 - Bolt
❑ 2x
❑ 6 Nm

17.3 Removing and installing engine sound

generator control unit J943
Removing
– Switch off ignition. Deposit vehicle key and other drive au‐
thorisation systems (e.g. smartphone) outside vehicle.
– Remove footwell cover (driver side) ⇒ General body repairs,
interior; Rep. gr. 68 ; Storage compartments/covers/trim
panels; Removing and installing footwell cover (driver side) .

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– Unplug electrical connector -3-.

– Remove bolts -4-.
– Swivel engine sound generator control unit - J943- -1- in
direction of -arrow- and detach it downwards from bracket
-2-.

Installing
Installation is carried out in reverse sequence.

Tightening torques
♦ ⇒ Rep. gr. 93 ; Assembly overview - engine sound genera‐
tion

17.4 Removing and installing actuator for

engine sound generator

17.4.1 Removing and installing actuator 1 for

engine sound generator R257
Removing
– Switch off ignition. Deposit vehicle key and other drive au‐
thorisation systems (e.g. smartphone) outside vehicle.
– Remove front aerial for entry and start authorisation - R376-
⇒ Electrical system; Rep. gr. 94 ; Entry and start authorisa‐
tion; Overview of fitting locations - keyless entry system .

– Unplug electrical connector -3-.

– Remove bolts -1- and release actuator 1 for engine sound
generator - R257- -2-.

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– Remove bolts -arrows- and detach actuator -1- from bracket

-2-.

Installing
Installation is carried out in reverse sequence.

Tightening torques
♦ ⇒ Rep. gr. 93 ; Assembly overview - engine sound genera‐
tion

17.4.2 Removing and installing actuator 2 for

engine sound generator R258
Removing
– Switch off ignition. Deposit vehicle key and other drive au‐
thorisation systems (e.g. smartphone) outside vehicle.
– Remove rear underbody cladding ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody cladding; Removing and
installing rear underbody cladding .

– Unplug electrical connector -2- and move it clear.

– Remove nuts -arrows-.
– Detach actuator 2 for engine sound generator - R258- -1-
towards rear.

Installing
Installation is carried out in reverse sequence.

310 Rep. gr.93 - Electric drive systems

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Tightening torques
♦ ⇒ Rep. gr. 93 ; Assembly overview - engine sound genera‐
tion

17. Engine sound generation 311

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18 Accelerator mechanism

18.1 Assembly overview - accelerator pedal module

1 - Accelerator pedal module -

GX2-
❑ With accelerator pedal
position sender - G79-
and accelerator pedal
position sender 2 -
G185-
❑ ⇒ Rep. gr. 93 ; Re‐
moving and installing
accelerator pedal mod‐
ule GX2
2 - Pedal bracket
3 - Electrical connector
4 - Bolt
❑ 10 Nm

18.2 Assembly overview - accelerator pedal module

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1 - Bearing bracket
2 - Bolt
❑ 10 Nm
3 - Accelerator pedal module -
GX2-
❑ With accelerator pedal
position sender - G79-
and accelerator pedal
position sender 2 -
G185-
❑ ⇒ Rep. gr. 93 ; Re‐
moving and installing
accelerator pedal mod‐
ule GX2
4 - Nut
❑ 3x
❑ 10 Nm

18. Accelerator mechanism 313

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18.3 Removing and installing accelerator

pedal module GX2
Removing
– Remove bolt -1-.
– Disengage accelerator pedal module - GX2- -3- from bottom
of pedal bracket and detach.
– Unplug electrical connector -2-.

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

– Attach accelerator pedal module to bottom of pedal bracket,

insert centring pin and tighten bolt.

Tightening torques
♦ ⇒ Rep. gr. 93 ; Assembly overview - accelerator pedal
module

314 Rep. gr.93 - Electric drive systems