D3E8049EE06 Electrical System E Golf

Service
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Golf 2009 ➤
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Electrical System E-Golf
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Edition 10.2014
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
93 - Electric Drive
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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 © 2015 Volkswagen AG, Wolfsburg D3E8049EE06

Golf 2009 ➤
Electrical System E-Golf - Edition 10.2014
Contents
93 - Electric Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 High Voltage System Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Clean Working Conditions When Working on High Voltage System . . . . . . . . . . . . . . . . . . 7
3 High Voltage System, De-Energizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 High Voltage System, Turning Back On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5 Component Location Overview - High Voltage Components . . . . . . . . . . . . . . . . . . . . . . . . 10
6 High Voltage Technology Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.1 High Voltage Vehicle Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
7 High Volt Battery . . . . . . . . . . . . . . . . . . . . . a.g.en. A. G. ..V.o.lk.sw. a.g.en. A. G. .do. . . . . . . . . . . . . . . . . . . 14
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7.1 General Information . . . . . . . . . . . . . . y.V.ol.ks. . . . . . . . . . . . . . . . . . . . n. o.t .gu. . . . . . . . . . . . . . 14
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7.2 Overview - High Voltage Battery .or.ise. d. . . . . . . . . . . . . . . . . . . . . . . . . . . . .ra.nt.e . . . . . . . . . . 14
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7.3 High Voltage Battery, Removingauand Installing . . . . . . . . . . . . . . . . . . . . . . . . .o.r a.c . . . . . . . 15
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7.4 High Voltage Battery 1 AX2 / High s
Voltage Battery 2 AX3 , Checking . . . . . . . . . . . . . . . . 22
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8 Electric Drive Power and Control Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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8.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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8.2 Electric Drive Power and Control Electronics, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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8.3 Electric Drive Output and Control Electronics, Removing and Installing . . . . . . . . . . . . . . 24
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9 Electro-Drive Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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9.2 Electric Drive Motor, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
9.3 Electro-Drive Drive Motor, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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9.4 Electro-Drive Drive Motor, Calibrating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9.5 Transmission, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
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10 High Voltage Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

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10.2 Component Location Overview - High Voltage Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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10.3 Drive Motor High Voltage Wiring Harness, Removing and Installing . . . . . . . . . . . . . . . . . . 40
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11 High Voltage Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
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11.1 Component Location Overview - High Voltage System Cooling . . . . . . . . . . . . . . . . . . . . 41

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12 Battery Chargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
for
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12.1 High Voltage Battery Charger 3, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 42

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13 High Voltage Battery Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
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14 High voltage heater (PTC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
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15 Immediate upload button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
16 Driving Program Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
17 Electric A/C Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
18 Potential Equalization Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
18.1 Potential Equalization Cable on High Voltage Battery 1 AX2 in Luggage Compartment,
Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
18.2 Potential Equalization Cable on Electric Drive Power and Control Electronics JX1 , Removing
and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
18.3 Electro-Drive Drive Motor V141 Potential Equalization Cable, Removing and Installing . . 50
18.4 High Voltage Battery 2 AX3 Potential Equalization Cable under Floor Panel, Removing and
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
18.5 Electrical A/C Compressor V470 Potential Equalization Cable, Removing and Installing . . 51
18.6 High Voltage Battery Charger 2 AX5 Potential Equalization Cable, Removing and
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
18.7 High Voltage Battery Charger 1 AX4 Potential Equalization Cable, Removing and
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
18.8 Potential Equalization Cable Engine Support, Removing and Installing . . . . . . . . . . . . . . 52
Contents i
Golf 2009 ➤
18.9 Connection and Junction Box 1 SX1 Potential Equalization Cable Bracket, Removing and
Installing, High Voltage Network Junction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
18.10 Connection and Junction Box 1 SX1 Potential Equalization Cable, Removing and Installing,
High Voltage Network Junction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
18.11 High Voltage Heater (PTC) Z115 Potential Equalization agenCable . . . . .A.G.d.oe
AG. Volkswagen .............. 54
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18.12 High Voltage Battery Charger 3 AX6 PotentialbyEqualization V o Cable, Removing oand t gu
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Installing . . . . . . . . . . . . . . . . . . . . . . . . .ris. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . r.an.te. . . . . .
ed
54
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18.13 High Voltage Charge Network Distributor au SX4 Potential Equalization Cable, Removing rand
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Installing . . . . . . . . . . . . . . . . . . . . .s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c. . .
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18.14 Electric Drive Power and Control Electronics JX1 Potential Equalization Cable Bracket
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Engine Support, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
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18.15 Overview - Potential Equalization Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
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19 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
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20 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
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ii Contents
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93 – Electric Drive
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1 High Voltage System Safety Precau‐
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Check with the importer is there are any questions regarding the
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designations “high voltage technician”, “high voltage expert” or

high voltage system.
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Before beginning work on the high voltage system, a high voltage
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technician. Refer to ⇒ page 6 must disable the high voltage
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⇒ “3 High Voltage System, De-Energizing”, page 8 .
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For a list of work requiring the high voltage system to be disabled,
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Pay close attention to the following when working on the high
voltage system, otherwise fatal injuries could occur:
♦ Only a qualified technician (or at least a high voltage tech‐
nician) should disable the high voltage electrical system.
♦ The high voltage technician makes sure the system is dis‐
abled and cannot turn on again.
♦ The high voltage technician makes sure the system can‐
not turn on again by safekeeping the key and the high
voltage system maintenance connector.
♦ The high voltage technician puts a sign on the vehicle
saying the voltage is disabled.
♦ The minimum requirement for working on the E-Golf (for
example, performing Maintenance work, changing a tire,
checking the Convenience System) is that the technician
be a high voltage technician.
♦ Only a technicians specializing in electrical systems with
additional training in working with high voltage may re‐
move the high voltage battery.
♦ The high voltage technician must disable the system be‐
fore any work may be performed on the high voltage
system.
♦ Only a high voltage expert (HVE) may perform repairs to
the vehicle if it is not possible to disable the high voltage
electrical system.
♦ Individuals with electrical medical equipment must not
work on vehicles with a high voltage electrical system. Ex‐
amples of electrical medical equipment include pain med‐
ication pumps, implanted heart defibrillators, pacemakers,
insulin pumps and hearing aids.
Follow all guidelines for clean working conditions when working

on the high voltage system. Refer to
1. High Voltage System Safety Precautions 1

Golf 2009 ➤
⇒ “2 Clean Working Conditions When Working on High Voltage

System”, page 7 .
Follow all Safety Precautions when handling high voltage cables.
Refer to ⇒ “10.1 General Information”, page 37 .
Note
♦ Check the contact surfaces on the potential equalization ca‐

bles before installation.
♦ The contact surfaces must be clean. There must be no rust or
grease on them.
♦ Otherwise, clean the contact surfaces using the Contact Sur‐
face Cleaning Set - VAS6410- . Refer to ⇒ Electrical Equip‐
ment General Information; Rep. Gr. 97 ; Contact Surface
Cleaning Set -VAS6410- .
Observe the following precautions when working on the high volt‐

age system:
♦ Only the high voltage technician may disable the high voltage
system using the specific procedures or methods.
♦ Only technicians, who have the minimum requirements as a
high voltage technician, may work on the E-Golf.
♦ Always visually inspect the area around high voltage compo‐
nents when working on an electric vehicle.
♦ Do not excessively bend or flex high voltage cables.
♦ Always contact a high voltage technician if anything unusual
occurs or if something is unclear. swa
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♦ When working near high voltageedcomponents
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Working on the High Voltage System

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When working on the fol‐ Minimum qualifications. Refer to

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Disabling the high volt‐ High voltage technician

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When working on the following compo‐ The High Voltage System Must Be Minimum qualification.
nents: Disabled By A High Voltage Techni‐ Refer to ⇒ page 6 :
cian Prior To Beginning the Work?
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Yes No
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Electro-Drive Drive Motor - V141- including X High voltage technician

the transmission
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Electric Drive Power and Control Electron‐ X High voltage technician

m
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TW High Voltage System Maintenance X High voltage technician

in t
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Connector
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Electrical A/C Compressor High Voltage X High voltage technician

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Cable - P3- (high voltage distributor/air con‐

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Drive Motor High Voltage Cable 1 - P4-
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Drive Motor High Voltage Cable 2 - P5- X High voltage technician
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Drive Motor High Voltage Cable 3 - P6- X High voltage technician
High Voltage Battery High Voltage Cable - X High voltage technician
P7-
2 Rep. Gr.93 - Electric Drive

Golf 2009 ➤
Yes No
Wire Junction/High Voltage Battery Cable - X High voltage technician
P8-
High Voltage Cable for the Power and Con‐ X High voltage technician
trol Electronics, Positive - P9-
High Voltage Cable for the Power and Con‐ X High voltage technician
trol Electronics, Negative - P10-
High Voltage Heating High Voltage Cable X High voltage technician
(PTC) - P11-
Charger 1/Wire Junction High Voltage Ca‐ X High voltage technician
ble - P12-
ble - P13-
ble - P14-
Charger 1/High Voltage Charge Network wage
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High voltage technician
Distributor High Voltage Cable - P15- y Volks ot g
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Charger 2/High Voltage Charge Network ed X
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Distributor High Voltage Cable -auP16-
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Charger 3/High Voltage Charge Network X High voltage technician
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Distributor High Voltage Cable - P17-
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High Voltage Charge Network Distributor/ X High voltage technician
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High Voltage Charging Socket High Volt‐
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High Voltage Charge Network Distributor/ X High voltage technician
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High Voltage Charging Socket High Volt‐
urposes, in part or in wh
age Cable 2 - P19-
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High Voltage Battery 1 - AX2- (luggage X Technicians specializ‐
compartment) ing in electrical systems
with high voltage rrectne
High Voltage Battery 2 - AX3- (floor panel X Technicians specializ‐
battery) ing in electrical systems
ss
with high voltage

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Charging the high voltage battery in the X High voltage technician

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Electrical A/C Compressor - V470- X High voltage technician

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Potential equalization cables with connec‐ X High voltage technician

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Potential equalization cables with connec‐ X High voltage technician

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High voltage component cooling system X High voltage technician
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Temperature Sensor in Front Of High Volt‐ X High voltage technician
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Temperature Sensor after High Voltage X High voltage technician

Battery Heat Exchanger - G786-
Temperature Sensor after Heat Exchanger X High voltage technician
- G787-
Temperature Sensor after Electro-Drive X High voltage technician
Drive Motor - G788-
Temperature Sensor after Electric Drive X High voltage technician
Power and Control Electronics - G789-
Heater Coolant Shut-Off Valve - N279- X High voltage technician
High Voltage Battery Coolant Shut-Off X High voltage technician
Valve - N540-

Golf 2009 ➤
Yes No
Heater and A/C Unit Refrigerant Cut-Off X High voltage technician
Valve - N541-
High Voltage Battery Heater Core Refrig‐ X High voltage technician
erant Cut-Off Valve - N542- AG. Volkswagen AG d
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Coolant Pump in front of Electric Drive yV X ua High voltage technician
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Power and Control Electronics - V508- thoris tee
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Coolant Pump In Front Of High Voltagess
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X High voltage
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Heater (PTC) - V509-
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High Voltage Heater (PTC) - Z115- X High voltage technician

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Measuring insulation resistance X High voltage technician
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High Voltage Battery Charger 1 - AX4- X High voltage technician
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High Voltage Battery Charge Connection 1 X High voltage technician
- U34-
High Voltage Battery Charge Connection 2 X High voltage technician
rrectne
- U35-
Connection and Junction Box 1 - SX1- X High voltage technician
ss o
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High Voltage Charge Network Distributor - X High voltage technician
inform
SX4-
mer
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Exterior Speaker - R68- (left) X High voltage technician
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Exterior Speaker 2 - R69- (right) X High voltage technician
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Structure Borne Sound Control Module - X High voltage technician
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High Voltage Battery Heat Exchanger - X High voltage technician

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Immediate Upload Button - E766- X High voltage technician
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Fuse in high voltage network distributor X High voltage technician
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High Voltage Battery Fan - V510- X High voltage technician

High Voltage Charge Flap Lock 1 Adjuster X High voltage technician
- F496-
High Voltage Charge Flap Lock 2 Adjuster X High voltage technician
- F497-
High Voltage Connector Lock 1 Adjuster - X High voltage technician
F498-
High Voltage Connector Lock 2 Adjuster - X High voltage technician
F499-
Conventional work near high voltage components

Yes No
Reservoir X High voltage technician
Front subframe X High voltage technician
Front brakes X
Rear axle X High voltage technician
Underbody Panel X High voltage technician

Golf 2009 ➤
nents: agen ADisabled
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Welding (cover all high voltage
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ss
nents and check afterwards). Remove the
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Vehicle Body Work (Using an Alignment X High voltage technician
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Vehicle body work (assembly and glass re‐ X High voltage technician
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Paint work. Refer to ⇒ Paint General Infor‐ X High voltage technician
es, in part or in w
mation; Rep. Gr. 00 ; Safety Precautions
t to the co
when Painting a Vehicle with Electric Drive .
When working near high voltage compo‐ X High voltage technician
rrectness of i
nents and high voltage cables, do not use
tools that generate heat, that have sharp
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edges or that are used for cutting or shap‐

ing, such as welding, soldering, hot air or
thermal adhesive equipment.
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Left and Right Headlamps, Removing and X High voltage technician

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Installing
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Headlamp Bulbs, Removing and Installing X High voltage technician

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Yes No
12V Battery, Removing and Installing X High voltage technician
General Controls Modules and Electric X High voltage technician
Components, 12V, Removing and Instal‐
ling
Fluids, Coolant and Fluids, Draining and X High voltage technician
Filling
Drain coolant/evacuate/fill X High voltage technician
Refrigerant pipes directly to the A/C com‐ X High voltage technician
pressor
A/C electric drive power test (to check the X High voltage technician
refrigerant circuit pressure for A/C Service
Station)
Peripheral refrigerant line (work that does X High voltage technician
not involve the A/C compressor directly
without opening the opening the refrigerant
circuit, for example, loosening and tighten‐
ing the refrigerant line)
Do the work while the drive engine is lifted X High voltage technician
i.e. with an engine mount
Power Steering Control Module - J500- X High voltage technician
Electric vacuum pump (12 V) X High voltage technician
Painting and drying through 55 °C (other‐ X High voltage technician
wise remove the battery)

Golf 2009 ➤
Qualification explanation
Qualification Area of application
High voltage technician The qualified high voltage tech‐
nician has the following author‐
izations:
1. General Work and Mainte‐
nance
2. Disabling
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HVE (high voltage expert) A high voltage expert is actually
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voltage system in the case that
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a high voltage technician is not

able to perform measurements
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with the standard tools and
equipment. The high voltage
expert must continue the work
rrectne
if the high voltage technician
does not have the authority to
ss
work on the high voltage sys‐
o
cial p
f
tem. The high voltage expert is
inform
responsible exclusively to disa‐
mer
ble the high voltage system if it atio

m
cannot be disabled by the high

o
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voltage technician using the

i
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usual means or methods.

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Technicians specializing in Electro specialists with addi‐

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electrical systems with high tional training in working with

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Golf 2009 ➤
2 Clean Working Conditions When

Working on High Voltage System
Carefully follow the guidelines for clean working conditions when
working on the high voltage system:
♦ Thoroughly clean the connection locations/maintenance
openings and the area around them prior to loosening/open‐
ing.
♦ Place the removed parts on a clean surface and cover them.
Use only lint-free cloths!
♦ Cover or seal any open components carefully if the repair is
not going to be performed immediately.
♦ Install only clean components.
♦ Remove the replacement parts from their packaging just prior
to installing them.
♦ Do not use any parts that have been removed from their pack‐
aging and left out (for example, in a tool boxes). en AG. V
olkswagen AG
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♦ When the system is open: do not use compressed
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2. Clean Working Conditions When Working on High Voltage System 7

Golf 2009 ➤
3 High Voltage System, De-Energizing

Special tools and workshop equipment required
♦ Vehicle Diagnostic Tester
♦ Hybrid Test Module - VAS6558-
♦ “Danger High Voltage” Sticker
♦ “Do Not Switch On High Voltage System” Sticker
WARNING
Individuals performing this task could receive an electrical

shock.
An electrical shock can result in death.
Read and follow the High Voltage Electrical System General
Warnings. Refer to
⇒ “1 High Voltage System Safety Precautions”, page 1 .
♦ A high voltage technician must disable the system before
any work can be performed on the high voltage electrical
system or the vehicle body. To find out which procedures
require this step, refer to the table “Procedures that require
the high voltage system to be disabled:”. Refer to
⇒ page 2
♦ The minimum requirement for working on the E-Golf is that
the technician be a high voltage technician.
– De-energize the high voltage system using the Vehicle Diag‐

nostic Tester .
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Rep. Gr.93 - Electric Drive
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Golf 2009 ➤
4 High Voltage System, Turning Back

On
♦ Vehicle Diagnostic Tester
WARNING
Individuals performing this task could receive an electrical

shock.
An electrical shock can result in death.
Warnings. Refer to
♦ A high voltage technician must disable the system before
any work can be performed on the high voltage electrical
system or thewvehicleagen
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⇒uthpage 2
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or
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♦ s Only technicians trained in electrical systems may work
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– Turn back on the high voltage system using the Vehicle Diag‐
, is n
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4. High Voltage System, Turning Back On 9

Golf 2009 ➤
5 Component Location Overview - High Voltage Components
1 - Electric Drive Power and

Control Electronics - JX1-
❑ Electrical Drive Control
Module - J841-
❑ Voltage Converter -
A19-
❑ Drive Motor Inverter -
A37-
❑ Intermediate Circuit Ca‐
pacitor 1 - C25-
❑ Removing and instal‐
ling. Refer to
⇒ “8 Electric Drive Pow‐
er and Control Electron‐
ics”, page 23 .
2 - High Voltage Battery
Charger 3 - AX6-
ling. Refer to
⇒ “12.1 High Voltage
Battery Charger 3, Re‐wagen AG. Volkswagen AG doe
moving and Installing”,
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3 - Connection and
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ac
Box 1 - SX1- s
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4 - Charger 3/Wire Junction

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High Voltage Cable - P14-

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5 - Charger 3/High Voltage

spec
Charge Network Distributor

es, in part or in w
t to the co

6 - High Voltage Charge Net‐
work Distributor/High Voltage
rrectness of i
Charging Socket High Voltage

Cable 1 - P20-
l purpos
7 - Exterior Speaker - R68- Left and Exterior Speaker 2 - R69- Right

nform
ercia
8 - High Voltage Battery Charger 1 - AX4-

m
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9 - High Voltage Battery Charger 2 - AX5-

ion in
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10 - Front High Voltage Battery Charge Connection 2 - U35-

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11 - High Voltage Cable for the Power and Control Electronics, Positive - P9-
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12 - High Voltage Cable for the Power and Control Electronics, Negative - P10-
n
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13 - Electro-Drive Drive Motor - V141-
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❑ Removing and installing. Refer to ⇒ “9.2 Electric Drive Motor, Removing and Installing”, page 28 .
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14 - Drive Motor High Voltage Wiring Harness - PX2-
❑ Drive Motor High Voltage Cable 1 - P4-

Golf 2009 ➤
15 - Electrical A/C Compressor - V470-

16 - High Voltage Charge Network Distributor - SX4-
17 - Charger 1/High Voltage Charge Network Distributor High Voltage Cable - P15-
18 - Charger 1/Wire Junction High Voltage Cable - P12-
19 - Charger 2/High Voltage Charge Network Distributor High Voltage Cable - P16-
20 - Charger 2/Wire Junction High Voltage Cable - P13-
21 - Rear High Voltage Battery Charge Connection 1 - U34-
22 - High Voltage Heating High Voltage Cable (PTC) - P11-
23 - High Voltage Heater (PTC) - Z115-
24 - Transmission
25 - Electric A/C Compressor High Voltage Cable - P3-
26 - High Voltage Charge Network Distributor/High Voltage Charging Socket High Voltage Cable 2 - P21-
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27 - Floor Battery/High Voltage Network Wire Junctiony VHigh
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5. Component Location Overview - High Voltage Components 11

Golf 2009 ➤
6 High Voltage Technology Description

⇒ “6.1 High Voltage Vehicle Drives”, page 12
6.1 High Voltage Vehicle Drives n AG. Volkswagen AG

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⇒ “6.1.1 General Information”, page 12 db ara
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⇒ “6.1.2 Driving Modes”, page 12 ss
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6.1.1 General Information
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The selector lever in the center console has the standard gears:
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reverse (R), forward (D) and neutral (N) There is also a B (braking)
h re
hole
setting, in which the Golf uses the maximum amount of kinetic
spec
energy when decelerating and braking. This "recuperation" is
es, in part or in w
t to the co
similar to heavy engine braking. In D, the Golf likewise recuper‐
ates and then the shift paddles on the steering wheel dispense
the intensity.
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Note
Additional information:
nf
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Refer to the Owner's Manual.

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6.1.2 Driving Modes
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Use the “Range” button in the center console to select a driving
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mode:
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Normal Vmax = 135 km/h. Climatronic in normal mode. All the
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power of the electric drive is available.
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Eco Vmax = 120 km/h. The Climatronic is in optimal consump‐
Prote AG.
tion Eco mode. The power of the electric drive is reduced when
compared to the Normal driving mode. Energy consumption is
reduced when compared to Normal drive mode.
Range Vmax = 95 km/h. The Climatronic is off. The power of the
electric drive is reduced once again when compared to the Eco
driving mode. The energy consumption is reduced compared to
Eco drive mode once again.
Note
♦ The power of the electric drive is limited in the Range and Eco
drive modes. This limiting effect can be temporarily cancelled
out by heavy acceleration ("Kickdown").
♦ It is not possible to heat or cool the vehicle when the Clima‐
tronic is deactivated in the Range mode. The defroster how‐
ever still works.
Drive Mode Button, Removing and Installing. Refer to ⇒ Electrical

Equipment; Rep. Gr. 96 ; Button in Center Console Storage
Compartment, Removing and Installing .
6.1.3 Regenerating
Regenerating:
Regenerating means the energy from the moving wheels is re‐
covered and regenerated into electrical energy. The recovered
energy is used to brake the vehicle. Electric current is produced

Golf 2009 ➤
by the Electro-Drive Drive Motor - V141- working as a generator

and this electricity is stored in the high voltage battery or it is used
to supply auxiliary components.
If the high voltage battery cannot store any more energy after a
long recovery, then the vehicle cannot regenerate any more. It is
possible again only when the battery is no longer fully charged.
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6. High Voltage Technology Description 13

Golf 2009 ➤
7 High Volt Battery

⇒ “7.1 General Information”, page 14
⇒ “7.2 Overview - High Voltage Battery”, page 14
⇒ “7.3 High Voltage Battery, Removing and Installing”,
page 15
⇒ “7.4 High Voltage Battery 1 AX2 / High Voltage Battery 2 AX3 ,
Checking”, page 22
7.1 General Information
WARNING agen
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Only a technicians specializing in electrical systems with ad‐rised
nte
ditional training in working with high voltage may remove atheut
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high voltage battery. ss c
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The high voltage batteries provide the Three-Phrase Current
erm
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Drive - VX54- with the necessary high voltage in order to be able
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to drive the vehicle. It is composed of 2 units. One battery is inside
wit
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the luggage compartment and the second one is under the vehi‐
h re
hole
cle. Both batteries should always be considered as a single unit.
spec
es, in part or in w
It is not permitted to drive through deep water (splash water) or
t to the co
us direct streams of water (high pressure cleaning of the battery
system).
rrectness of i
It is necessary to inspect the battery system if the plastic gets
deformed (for example, placing something on it). Check the in‐
l purpos
structions under the chapters High Voltage Battery 1 - AX2- and

High Voltage Battery 2 - AX3- . Refer to
⇒ “7.4 High Voltage Battery 1 AX2 / High Voltage Battery 2 AX3 ,
nform
ercia
Checking”, page 22 .
m
at
om
i
An increased cell voltage delta in the battery system can occur
on
c
in t
caused by different self-discharging rates in the battery cells and
or
his
e
this limits the useable energy. The battery system has functions
at
do
riv
that compensate for this self-discharging (balancing) and this as‐

p
cum
or
sures maximum useable energy. It is there necessary that the

f
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battery system is regularly charging and discharging.

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– Severe discharge must be avoided. The battery system must yri
gh by
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be charged if the state of charge is less than 20%.
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7.2 Overview - High Voltage Battery

Golf 2009 ➤
1 - High Voltage Battery 2 -

AX3-
WARNING
Only a technicians spe‐
cializing in electrical sys‐
tems with additional
training in working with
high voltage may re‐ AG. Volkswagen AG d
move the high voltage agen oes
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❑ Removing and instal‐ss a c
ling. Refer to
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⇒ “7.3 High Voltage Bat‐
du
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tery, Removing and In‐
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stalling”, page 15 .
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⇒ “7.3 High Voltage Bat‐
tery, Removing and In‐
rrectness of i
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AX2- High Voltage Connector

nform
ercia
AX2- Radiator Connection

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AX2- 12 V Connection
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AX2- Potential Equalization

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7 - High Voltage Battery 1 - t. C rig
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8 - High Voltage Battery 2 - AX3- 12 V Connection
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9 - High Voltage System Maintenance Connector - TW-

10 - Pilot Line Connector 1 - TV44-
7.3 High Voltage Battery, Removing and In‐

stalling
♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Shop Crane - VAS6100-
♦ Scissor Lift Table - VAS6131A-
♦ Lifting tool, high voltage battery AX5, inside the luggage com‐
partment
♦ High voltage battery holder AX6, on the floor panel
♦ Tool for unlocking the high voltage cable from the high voltage
batteries
7. High Volt Battery 15

Golf 2009 ➤
AG. Volkswagen AG d
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WARNING ss a ra
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Read and follow the High Voltage Electrical System General du
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Warnings. Refer to
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Note
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Pay attention to the instructions for handling high voltage cables.
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WARNING
nform
ercia
High voltage on the electric vehicle high voltage system.

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Danger of electrocution!
on
c
in t
or
The following procedure requires working on the high voltage
his
ate
system. Disable the high voltage system now. Refer to
do
priv
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WARNING
co Vo
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Only a technicians specializing in electrical systems with ad‐

ditional training in working with high voltage may remove the
high voltage battery.
Perform the following:

– De-energize the high voltage system. Refer to
– Disconnect the 12 V battery.
– Remove the luggage compartment floor. Refer to ⇒ Body In‐
terior; Rep. Gr. 70 ; Trim Panels, Luggage Compartment;
Cargo Floor, Removing and Installing .
– Remove the tire mobility kit and vehicle tools from the luggage
compartment.
– Remove the nuts -arrows A- from the high voltage battery and
then remove the potential equalization cable (ground cable)
from the battery.

Golf 2009 ➤
– Remove the bolts -arrows- and the cover -1-.
– Unclip the connector -1- from the holder in direction of

-arrow- and then disconnect the connector.
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– Unlock the high voltage connector -1- using the unlock tool
h re
-A- and then disconnect it from the battery.
hole
spec
es, in part or in w
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WARNING
High voltage on the high volt battery system in spite of the volt‐
age being disabled. rrectness of i
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Only an technicians specializing in electrical systems and in
nform
ercia
working with high voltage may perform the work.

m
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tion in
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– Remove the bolts -1-, the nuts -2- and the cover -A-.
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Golf 2009 ➤
– Remove the 4 bolts from the fan and then move the fan to the
side.
Caution
Danger of a battery short circuit.

Make sure nothing can fall into the air guide leading to the bat‐
tery.
Cover the air guides with tape.
– Remove the nuts -arrows- and the air guide -1-.
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– Cover the air guide with tape.

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– Remove the 12 nuts -1 and 2-.

nform
mer
atio
om
n
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Golf 2009 ➤
– Remove the seals -1 and 2- from the stud bolts and lay them
down.
– Remove the 4 bolts -1- from the battery.
AG. Volkswagen AG d
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– Lift the battery out of the vehicle using the craneVand
olks lifting
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– Set up the Scissor Lift Table - VAS6131A- .
rrectness of i
-1- VAS6131/1-6
l purpos
-2- VAS6131/1-4
nform
-3- VAS6131/1-4
mercia
-4- VAS6131/1-6
a
com
tion in
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Golf 2009 ➤
– Secure the high voltage battery charger 3 AX6 on the Scissor

Lift Table - VAS6131A- .
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– Remove the bolts -arrows- and the underbody panel -1-.
t to the co
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cial p
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mer
atio
om
n
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– Unlock and disconnect the connector -1- using the unlock tool
en
ng
t.
-2-.
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– Unlock and disconnect the connector -2- using the unlock tool
-A-.
– Remove the cap nut -arrow- and remove the potential equali‐
zation cable -1- from the stud bolt.

Golf 2009 ➤
– Remove the coolant hoses -1- from the High Voltage Battery
1 - AX2- .
– Disconnect the connector -2-.
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– Bolt the battery support frame to High Voltage Battery 1 -
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pt
AX2- .
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spec
es, in part or in w
t to the co
rrectness of i
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nf
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orm
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– Remove the bolts -arrows- from High Voltage Battery 1 - AX2-
f
en
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t.
on the vehicle underbody.
yi Co
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– Lower the High Voltage Battery 1 - AX2- using the scissor lift rig ht
py by
table.
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Installing:
Install in reverse order of removal. Note the following:
Note
♦ Check the contact surfaces on the potential equalization cable

before installation.
grease on them.
– Restart the high voltage system and complete the required

documentation. Refer to
⇒ “4 High Voltage System, Turning Back On”, page 9 .

Golf 2009 ➤
7.4 High Voltage Battery 1 - AX2- / High

Voltage Battery 2 - AX3- , Checking
Perform a visual inspection as well as an electrical check. Visually
inspect the battery housing, the high voltage connections and the
coolant hose connections. Use the Vehicle Diagnostic Tester for n AG. Volkswagen A
the electric test. Document the following results from the electric
olks
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test: db
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ris tee
Electrical test: tho or
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ss
♦ Faults stored in the DTC memory
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♦ Umin/ Umax
itte
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♦ Riso
ility
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♦ kWh
h re
hole
spec
♦ Ah
es, in part or in w
t to the co
Visual inspection:
♦ The insulation on the high voltage connections must not be
damage.
rrectness of i
♦ The coolant connections must be intact and without any leaks.
l purpos
♦ The battery housing must be bolted securely to the vehicle.

The outer contour of the plastic battery housing may not be
nf
ercia
o
deformed more than 10 mm.
rm
m
atio
m
♦ The battery housing and its mounts must not be corroded

o
n in
c
which could impair the vehicle safety in traffic or the function

or
thi
e
of the battery.
t
sd
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cu
♦ There must be no corrosion on the ground cable (potential
o
m
f
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equalization cable) between the vehicle and the battery hous‐

t.
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Note
agen
Prote AG.
It is recommended to check the battery system once a month or

after every 3,000 km of driving.

Golf 2009 ➤
8 Electric Drive Power and Control

Electronics
⇒ “8.1 General Information”,. page
Volksw23
age n AG n AG d
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⇒ “8.2 Electric Drive
yV
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s no
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page 23 ise d b ara
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⇒ “8.3 sElectric
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t
Drive Output and Control Electronics, Removing
or
ac
and Installing”,
s page 24
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The Electro-Drive Drive Motor - V141- forms the connection be‐
ility
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tween the Electric Drive Power and Control Electronics - JX1- and
wit
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the high voltage battery. It contains the Voltage Converter - A19- ,
h re
hole
the Drive Motor Inverter - A37- and the Electrical Drive Control
spec
Module - J841- .
es, in part or in w
t to the co
The Drive Motor Inverter - A37- converts the DC current from the
High Voltage Battery into AC for driving using the Electro-Drive
Drive Motor - V141- . The Voltage Converter - A19- changes the
rrectness of i
high voltage to low voltage to supply the 12V vehicle electrical
l purpos
system. The Electric Drive Power and Control Electronics - JX1-

is water cooled and is installed in the engine compartment on the
right front side.
nform
ercia
The following high voltage cables are part of the Electric Drive
m
at
Power and Control Electronics - JX1- :
om
ion
c
in t
r
♦ High Voltage Cable for the Power and Control Electronics,

o
his
e
Positive - P9- from the Electric Drive Power and Control Elec‐
at
do
riv
tronics - JX1- to the High Voltage Network Wire Junction -

p
cum
or
TV31-
f
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ng
t.
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C py
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Negative - P10- from the Electric Drive Power and Control
gh ht
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Electronics - JX1- to the High Voltage Network Wire Junction
cop Vo
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- TV31-
agen
Prote AG.
♦ Drive Motor High Voltage Cable 1 - P4- from the Electric Drive
Power and Control Electronics - JX1- to the Three-Phrase
Current Drive - VX54-
8.2 Electric Drive Power and Control Elec‐

tronics, Checking
WARNING
Inspect the Electric Drive Power and Control Electronics - JX1-

for:
♦ Traces of fluid on the water connections
♦ Damage on the housing and the connector
♦ Coolant level in the coolant reservoir
♦ Applicable potential equalization cable. Refer to
⇒ “18 Potential Equalization Cables”, page 49 .
8. Electric Drive Power and Control Electronics 23

Golf 2009 ➤
8.3 Electric Drive Output and Control Elec‐

tronics, Removing and Installing
♦ Hose Clamps - Up To 25mm - 3094-
WARNING

Warnings. Refer to
Note

Removing:
WARNING
AG. Volkswagen AG d
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Hybrid vehicle high d voltage in the high voltage system. uDanger
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of electrocution!
thor The
is
following procedure requires working on
eo
the high voltage
s au system. Disable the high voltage system now.r ac
Refer to ⇒ “3 High Voltage System, De-Energizing”, page 8 .
s
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pe
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– Disconnect the 12 V battery. Refer to ⇒ Electrical Equipment;

hole
Rep. Gr. 27 ; Battery, Disconnecting and Connecting .

spec
es, in part or in w
t to the co
– Remove charger 3. Refer to

⇒ “12.1 High Voltage Battery Charger 3, Removing and In‐
rrectness of i
– Open the high voltage cable holder -1- and disengage the high
voltage cables.
l purpos
– Remove the bolt -3- (3 Nm), bolts -4-, -5- (9 Nm), -6- and -7-
(20 Nm) and the holder.
nform
ercia
– Remove the nut -2- and then remove the potential equalization
m
a
com
ti
cable from the Electric Drive Power and Control Electronics -

on in
JX1- .
r
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fo
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t.
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Cop py
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rig ht
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Prote AG.

Golf 2009 ➤
– Remove the bolts -arrows- (2.5 Nm) and the cover -3 -.

– Remove the nuts -arrows-.
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– Remove the high voltage cables -1- and -2- from the Electric
, is n
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Drive Power and Control Electronics - JX1- .
hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
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– Cut the shields -arrows- to prevent damaging the high voltage
thi
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sd
a
cables.
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f
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t.
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Cop py
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Vo
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Prote AG.
– Remove the bolts -arrows- (5 Nm) and then remove the cover
-1- from the Electric Drive Power and Control Electronics -
JX1- .

Golf 2009 ➤
– Remove the nuts -arrows- (15 Nm). Remove the threaded

connections -1- (18 Nm) and then remove the high voltage
cables with the shield from the Electric Drive Power and Con‐
trol Electronics - JX1- .
– Cut the shields -arrows- to prevent damaging the high voltage

cables.
– Remove the bolts -arrows- (10 Nm).
lkswage es n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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cted agen
Prote AG.

Golf 2009 ➤
– Remove the bolts -arrows- (10 Nm).

– Disconnect the coolant hose from the Electric DriveenPower
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Control Electronics - JX1- . olks
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Catch the escaping coolant in a suitable container.
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– Remove the Electric Drive Power and Control Electronics - pe
ility
JX1- upward and out of the vehicle.
ot
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Installing:
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
l purpos
nform
ercia
grease on them.
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on in
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– Tighten all threaded connections to the tightening specifica‐
Co
Cop py
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documentation. Refer to Prote AG.

Golf 2009 ➤
AG. Volkswagen AG d
9 Electro-Drive Drive Motor Volksw
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not
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⇒ “9.1 General Information”, page 28 orise nte
eo
th
u ra
⇒ “9.2 Electric Drive Motor, Removing and Installing”,
ss a
page 28 c
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⇒ “9.3 Electro-Drive Drive Motor, Replacing”, page 35
pt
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⇒ “9.4 Electro-Drive Drive Motor, Calibrating”, page 36
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⇒ “9.5 Transmission, Removing and Installing”, page 36
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9.1 General Information hole
spec
es, in part or in w
The Electro-Drive Drive Motor - V141- is where the internal com‐
t to the co
bustion engine is located. It works directly with the transmission
input shaft and performs the following:
rrectness of i
♦ It functions like an engine to drive the vehicle with electricity
only.
l purpos
♦ It functions like a generator to supply and charge the vehicle

electrical system and the Hybrid Battery - A38- with current.
nform
ercia
9.2 Electric Drive Motor, Removing and In‐

m
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ate
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f
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♦ Tray - VAG1306- C py
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Prote AG.
♦ Mount for the Electro-Drive Drive Motor - V141-

♦ Ladder - VAS5085-
WARNING

Warnings. Refer to
Note

Removing:
WARNING
High voltage on the electric vehicle high voltage system.



Golf 2009 ➤

– Disconnect the upper coolant hose from the Electro-Drive
Drive Motor - V141- using Hose Clamps - Up To 25mm -
3094- .
– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.
Gr. 50 ; Noise Insulation .
– Remove the front section of the wheel housing liner. Refer to
⇒ Body Exterior; Rep. Gr. 66 ; Wheel Housing Liner .
– Unlock and disconnect the connector from the Electro-Drive

Drive Motor - V141- .
– Remove the A/C compressor and tie it up with a suitable wire.
Refer to ⇒ Heating, Ventilation and Air Conditioning; Rep. Gr.
87 .
– Remove the bolt -1- (8 Nm). Open the hose holder -3-. Re‐
move the bracket -2-.
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– Disconnect the lower coolant hose from the Electro-Drive

, is n
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Drive Motor - V141- using Hose Clamps - Up To 25mm -

hole
spec
3094- .
es, in part or in w
t to the co
– Open the clamp -3- and remove the lower coolant hose -2-
from the Electro-Drive Drive Motor - V141- and drain the
coolant.
rrectness of i
– Remove the input shafts (50 Nm +45°).

l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
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fo
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t.
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rig ht
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Prote AG.
9. Electro-Drive Drive Motor 29

Golf 2009 ➤
– Remove the nut -1- (40 Nm +90°). Remove the bolt -2-.
– Remove the bolt -3- (100 Nm +90°). Remove the pendulum
support -4-.
AG. Volkswagen AG d
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pt
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– Loosen the clamp -1- and remove the upper coolant hose -2-
an
itte
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from the Electro-Drive Drive Motor - V141- .
erm
ab
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Remove the bolt -B- (6 Nm).

m
at
– Remove the High Voltage Battery Charger 3 - AX6- and move
om
ion
it to the side with the coolant hoses still connected.
c
in t
or
his
te
– Open the high voltage cable holder -1- and disengage the high
a
do
riv
voltage cables.
p
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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cted agen
Prote AG.
– Remove the bolt -3- (3 Nm), bolts -4-, -5- (9 Nm), -6- and -7-
(20 Nm) and the holder.

Golf 2009 ➤
– Remove the nut -arrows- (23 Nm). Remove the potential

equalization cables -1- and -2- from the stud bolt.
– Disconnect the high voltage cable -arrow- from the Connection

and Junction Box 1 - SX1- -1-.
– Loosen the bolts -arrows- and open Connection and Junction

Box 1 - SX1- .
lkswage es n
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– Loosen the bolts -arrows-.

an
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ab
pe
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Note
ot
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hole
The wiring harness -1- and transmission temperature sensor are

spec
not installed in all vehicles.

es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
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thi
s
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t.
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Cop py
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by
31
cted agen
Prote AG.
9. Electro-Drive Drive Motor
Golf 2009 ➤
– Disconnect the connector -arrow-. Free up the wiring harness

-1- and guide it toward the transmission.
– Open the high voltage cable switch -1-. Remove the bolts
-arrows- and remove the bracket -2-.
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ab
ility
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hole
spec
es, in part or in w
t to the co
– Open the retainers -arrows- and disengage the selector lever
cable.
rrectness of i
l purpos
nform
mercia
at
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ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
. rig
– Remove the bolts -2- and -4- and the bracket -1-. Let the cool‐
t
gh ht
yri by
ant pump -3- hang with the lines still connected. Make sure the cop Vo
by lksw
running direction is correct when installing. cted agen
Prote AG.

Golf 2009 ➤
– Remove the bolts -arrows- (5 Nm) and then remove the cover
-1- from the Electric Drive Power and Control Electronics -
JX1- .
– Remove the nuts -arrows- (15 Nm). Remove the threaded

connections -1- (18 Nm) and then remove the high voltage
cables with the shield from the Electric Drive Power and Con‐
trol Electronics - JX1- .
AG. Volkswagen AG d
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– Cut the 3 shieldsss-arrows-
a
to prevent damaging the high volt‐ c
age cables.
ce
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un
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an
d
itte
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ab
ility
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wit
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h re
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spec
t to the co
rrectnes
– Remove the bolts -arrows- (15 Nm) and the connections.

s o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
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cted agen
Prote AG.

Golf 2009 ➤
– Remove the bolts -arrows- (6 Nm) and the insulation plate.
AG. Volkswagen AG d
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ab
ility
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– Loosen the bolt -1- (60 Nm +90°).
h re
ole,
spec
t to the co
rrectness o
cial p
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mer
atio
om
n
c
i
or
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– Loosen the bolt -1- (60 Nm +90°).
thi
te
sd
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pr
cum
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fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
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cted agen
Prote AG.

Golf 2009 ➤
– Position the bracket for the Electro-Drive Drive Motor - V141-

on the Scissor Lift Table - VAS6131A- . Secure the bracket
under the Electro-Drive Drive Motor - V141- .
– Remove the bolts from the engine- and transmission mount
using ladder VAS5085. agen
AG. Volkswagen AG d
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– Lower the Scissor Lift Table - VAS6131A- slowly withethe byV gu
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Electro-Drive Drive Motor - V141- . Make sure therehois enough
ris nte
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clearance. s aut ra
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Installing:
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Note
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spec
es, in part or in w
t to the co
grease on them.
rrectness of i
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nf
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atio
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– Pay attention to the installed position of the coolant pump.

o
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or c
thi
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– The arrow -3- on the clamp -1- must point up.

t
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– Tighten all threaded connections to the tightening specification
o
m
f
en
ng
and then seal them with sealing paint.

t.
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Cop py
– Replace all bolts and nut that were loosened. ht. rig
rig ht
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Prote AG.
9.3 Electro-Drive Drive Motor, Replacing

– Remove the bolts -arrows- from the transmission mount -1-
(40 Nm+180°) and secure the new Electro-Drive Drive Motor
- V141- with new bolts.

AG. Volkswagen AG d
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Golf a2009
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➤ ra
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– Remove the bolts -arrows- from the engine mount -1- (40 Nm
itte
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+90°) and secure the new Electro-Drive Drive Motor - V141-
ab
pe
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with new bolts.
ot
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h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Remove the bolt -arrow- (20 Nm) from the potential equaliza‐
m
a
tion cable -1- and attach it to the new Electro-Drive Drive Motor
com
tio
- V141- .
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Prote AG.
9.4 Electro-Drive Drive Motor, Calibrating

– Calibrate the electro-drive drive motor using the Vehicle Di‐
agnostic Tester .
9.5 Transmission, Removing and Installing

Currently is it not possible to replace the transmission separately.

Golf 2009 ➤
10 High Voltage Cables

⇒ “10.1 General Information”, page 37
⇒ “10.2 Component Location Overview - High Voltage Cables”,
page 38
⇒ “10.3 Drive Motor High Voltage Wiring Harness, Removing and
Installing”, page 40

Safety precautions for working with high voltagencables
AG. Volkswagen A G do
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WARNING ris
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Working with high voltage cables:
ss
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♦ Do not support yourself or lay tools on the high voltage
an
d
itte
cable or on any of its components.
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ab
pe
ility
♦ When working near high voltage components and high
ot
wit
voltage cables, do not use tools that generate heat, that
, is n
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have sharp edges or that are used for cutting or shaping,
hole
such as welding, soldering, hot air or thermal adhesive
spec
es, in part or in w
equipment.
t to the co
♦ When working near high voltage components and high
voltage cables, do not use tools that generate heat such
as welding, soldering, hot air or thermal adhesive equip‐
rrectness of i
ment.
l purpos
♦ Do not excessively bend or flex high voltage cables.

♦ Always contact a high voltage technician if there are ques‐
nform
ercia
tions or if something is not clearly understood.

m
a
com
tion in
r
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thi
The following high voltage cables connect the high voltage com‐
s
iva
ponents with each other:

do
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cum
fo
♦ Electrical A/C Compressor High Voltage Cable - P3- from

en
ng
t.
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Connection and Junction Box 1 - SX1- to the Electrical A/C
Co
op py
Compressor - V470- . t. C rig
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Power and Control Electronics - JX1- to the Electro-Drive Prote AG.
Drive Motor - V141-
Power and Control Electronics - JX1- to the Electro-Drive
Drive Motor - V141-
Power and Control Electronics - JX1- to the Electro-Drive
Drive Motor - V141-
♦ High Voltage Battery High Voltage Cable - P7- between the
high voltage batteries.
♦ Wire Junction/High Voltage Battery Cable - P8- from High
Voltage Battery 2 - AX3- (battery under the floor panel) to
Connection and Junction Box 1 - SX1- .
Positive - P9- from Connection and Junction Box 1 - SX1- to
the Electric Drive Power and Control Electronics - JX1- .
Negative - P10- from Connection and Junction Box 1 - SX1-
to the Electric Drive Power and Control Electronics - JX1- .
10. High Voltage Cables 37

Golf 2009 ➤
♦ High Voltage Heating High Voltage Cable (PTC) - P11- from

the Connection and Junction Box 1 - SX1- to the High Voltage
Heater (PTC) - Z115- .
♦ Charger 1/Wire Junction High Voltage Cable - P12- from High
Voltage Battery Charger 1 - AX4- to Connection and Junction
Box 1 - SX1- .
♦ Charger 2/Wire Junction High Voltage Cable - P13- from High
Voltage Battery Charger 2 - AX5- to Connection and
AG. VolkswagenJunction
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♦ Charger 3/Wire Junction oHigh
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e Voltage Cable - P14- from High nte
Voltage Battery Charger
au 3 - AX6- to Connection and Junction
th eo
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Box 1 - SX1- . ss c
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♦ Charger 1/High Voltage Charge Network Distributor High Volt‐
du
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age Cable - P15- from the High Voltage Battery Charger 1 -
y li
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AX4- to the High Voltage Charge Network Distributor - SX4- .
ility
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age Cable - P16- from High Voltage Battery Charger 2 - AX5-
hole
to the High Voltage Charge Network Distributor - SX4- .
spec
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t to the co
age Cable - P17- from High Voltage Battery Charger 3 - AX6-
to the High Voltage Charge Network Distributor - SX4- .
rrectness of i
♦ High Voltage Charge Network Distributor/High Voltage Charg‐
ing Socket High Voltage Cable 1 - P18- from the High Voltage
l purpos
Battery Charge Connection 1 - U34- (in the rear under the fuel
filler door) to the High Voltage Charge Network Distributor -
nf
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SX4- .
orm
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♦ High Voltage Charge Network Distributor/High Voltage Charg‐
om
ing Socket High Voltage Cable 2 - P19- from High Voltage

n in
or c
Battery Charge Connection 2 - U35- (in the front under the VW

thi
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emblem) to the High Voltage Charge Network Distributor -

iva
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SX4- .
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10.2 Component Location Overview - High
yi Co
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Component Location Overview - High Voltage Charge Network
cted agen
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Distributor/High Voltage Charging Socket High Voltage Cable 2 -
P19- , High Voltage Charge Network Distributor/High Voltage
Charging Socket High Voltage Cable 1 - P18- and High Voltage
Battery High Voltage Cable - P7-

Golf 2009 ➤
AG. Volkswagen AG d
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1 - High Voltage Battery olksw not
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Charge Connection 1 - U34- ed b ara
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2 - High Voltage Battery High aut ra
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Voltage Cable - P7- ss
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Cable 1 - P18-
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Charging Socket High Voltage es, in part or in w
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Cable 2 - P19-
rrectness of i
Charge Connection 2 - U35-
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Component Location Overview - Engine Compartment High Volt‐

age Cable
10. High Voltage Cables 39

Golf 2009 ➤

Cable 1 - P18-
2 - Wire Junction/High Voltage
Battery Cable - P8-
Cable 2 - P19- AG. Volkswagen AG d
agen oes
olksw not
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5 - Charger 1/High Voltage d b ara
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Charge Network Distributor tho r eo
High Voltage Cable - P15- ss au ra
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Charge Connection 2 - U35-
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11 - High Voltage Cable for the

Power and Control Electron‐
m
ics, Positive - P9-

com
tion in
r
12 - High Voltage Cable for the

te o
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Power and Control Electron‐

s
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ics, Negative - P10-

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13 - Drive Motor High Voltage Wiring Harness - PX2-

n
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14 - Electric A/C Compressor High Voltage Cable - P3-
rig
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co
15 - High Voltage Heating High Voltage Cable (PTC) - P11-
by lksw
cted agen
Prote AG.
10.3 Drive Motor High Voltage Wiring Har‐

ness, Removing and Installing
Currently the drive motor high voltage wiring harness cannot be
replaced separately, but rather only with the entire Electro-Drive
Drive Motor - V141- . The following describes removing and in‐
stalling the high volt connections on the Electric Drive Power and
Control Electronics - JX1- of the three-phase cable.

Golf 2009 ➤
11 High Voltage Cooling System

⇒ “11.1 Component Location Overview - High Voltage System
Cooling”, page 41
11.1 Component Location Overview - High

Voltage System Cooling
WARNING
The coolant system is under pressure when the engine is

warm.
Danger of scalding by steam and hot coolant.
AG. Volkswagen AG d
agen
Reduce the pressure in the cooling system Vol by covering the cap
oes
ksw not
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on the coolant reservoir with a cloth edand
by opening it slowly and ara
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carefully. tho
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au ra
c
ss
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un
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d
itte
y li
1 - Coolant Pump in front of
erm
ab
Electric Drive Power and Con‐
ility
ot p
trol Electronics - V508-
wit
is n
h re
2 - Coolant Pump In Front Of
ole,
spec
High Voltage Heater (PTC) -
V509-
t to the co
3 - Manual Bleed Valve for
Coolant System
rrectne
4 - High Voltage Battery Cool‐
ant Shut-Off Valve - N540-
ss o
5 - Temperature Sensor in
cial p
f in
Front Of High Voltage Heater
form
mer
(PTC) - G785- atio

m
6 - High Voltage Heater (PTC)

o
n
c
i
or
- Z115-
thi
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sd
va
7 - Temperature Sensor after

i
o
pr
cum
r
Heat Exchanger - G787-

fo
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ng
t.
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8 - Temperature Sensor after t. Cop py
High Voltage Battery Heat Ex‐
rig
gh ht
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changer - G786- op Vo
by c lksw
cted agen
Prote
9 - High Voltage Battery Heat
AG.
Exchanger - VX63-
10 - Heater Coolant Shut-Off
Valve - N279-
Electro-Drive Drive Motor -
G788-
Electric Drive Power and Con‐
trol Electronics - G789-
11. High Voltage Cooling System 41

Golf 2009 ➤
12 Battery Chargers
⇒ “12.1 High Voltage Battery Charger 3, Removing and Instal‐
ling”, page 42
12.1 High Voltage Battery Charger 3, Re‐

moving and Installing
WARNING

Warnings. Refer to
Note

AG. Volkswagen AG d
agen oes
olksw not
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by
WARNINGrise d ara
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High voltage ons the electric vehicle high voltage system.
s c
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hole
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es, in part or in w
Perform the following:

t to the co

rrectness of i

l purpos
– Unlock the connector -2- and disconnect it from the battery

charger.
nform
ercia
– Remove the bolt -5- and the locking plate -4-. Unlock the high
m
voltage cable connector -3- and disconnect it from the battery

com
tio
charger.
n in
r
te o
thi
– Remove the bolts -1- (9 Nm) and pull the battery charger for‐
s
iva
do
ward out of the bracket.

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Golf 2009 ➤
– Loosen the clamps -2- and remove the

AG. Vcoolant
olkswagehoses
n AG d from the
battery charger. agen oes
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Installing: ed nte
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Install in reverse order of removal. Note the following: au ra
c
ss
ce
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nl
– Tighten all threaded connections to the tightening specifica‐
pt
du
an
tions.
itte
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ility
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documentation. Refer to
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
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orm
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t.
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Cop py
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rig ht
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co Vo
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Prote AG.
12. Battery Chargers 43

Golf 2009 ➤
13 High Voltage Battery Heat Exchang‐

er
PTC Heating Element, Removing and Installing, refer to ⇒ Heat‐
ing, Ventilation and Air Conditioning; Rep. Gr. 87 .
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
tho eo
au ra
ss c
ce
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2009 ➤
14 High voltage heater (PTC)

PTC Heating Element, Removing and Installing, refer to ⇒ Heat‐
ing, Ventilation and Air Conditioning; Rep. Gr. 80 .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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orm
m
atio
om
n in
or c
thi
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sd
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t.
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Cop py
t. rig
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pyri by
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co lksw
by
cted agen
Prote AG.
14. High voltage heater (PTC) 45

Golf 2009 ➤
15 Immediate upload button

The immediate upload button is located inside the center console.
Refer to ⇒ Electrical Equipment; Rep. Gr. 96 ; Lamps and Con‐
trols in Center Console .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
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nl
pt
du
an
itte
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ab
ility
ot p
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2009 ➤
16 Driving Program Button

The driving program button is located inside the center console.
Refer to ⇒ Electrical Equipment; Rep. Gr. 96 ; Lamps and Con‐
trols in Center Console .
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
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ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
16. Driving Program Button 47

Golf 2009 ➤
17 Electric A/C Compressor

The Electrical A/C Compressor - V470- is installed inside the en‐
gine compartment in the front on the right side.
For removing and installing the Electrical A/C Compressor -
V470- , refer to ⇒ Heating, Ventilation and Air Conditioning; Rep.
Gr. 87 .
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Golf 2009 ➤
AG. Volkswagen AG d
agen oes
ksw
18 d by Vol
Potential Equalization Cables
not
gu
ara
rise nte
⇒ “18.1 Potential Equalization
autho
Cable on High Voltage Battery 1 eo
ra
AX2 in Luggage Compartment,
ss Removing and Installing”, c
page 49
ce
le
un
pt
an
d
itte
⇒ “18.2 Potential Equalization Cable on Electric Drive Power and
y li
rm
ab
Control Electronics JX1 , Removing and Installing”, page 50
pe
ility
ot
⇒ “18.3 Electro-Drive Drive Motor V141 Potential Equalization
wit
, is n
h re
Cable, Removing and Installing”, page 50
hole
spec
⇒ “18.4 High Voltage Battery 2 AX3 Potential Equalization Cable
es, in part or in w
under Floor Panel, Removing and Installing”, page 50
t to the co
⇒ “18.5 Electrical A/C Compressor V470 Potential Equalization
Cable, Removing and Installing”, page 51
rrectness of i
⇒ “18.6 High Voltage Battery Charger 2 AX5 Potential Equaliza‐
l purpos
tion Cable, Removing and Installing”, page 51

⇒ “18.7 High Voltage Battery Charger 1 AX4 Potential Equaliza‐
nform
ercia
tion Cable, Removing and Installing”, page 52

m
a
⇒ “18.8 Potential Equalization Cable Engine Support, Removing
com
tion in
and Installing”, page 52
r
te o
thi
s
⇒ “18.9 Connection and Junction Box 1 SX1 Potential Equaliza‐
iva
do
r
tion Cable Bracket, Removing and Installing, High Voltage Net‐

rp
cum
fo
work Junction”, page 53
en
ng
t.
yi Co
op
⇒ “18.10 Connection and Junction Box 1 SX1 Potential Equali‐
C py
t. rig
gh
zation Cable, Removing and Installing, High Voltage Network
ht
pyri by
Vo
Junction”, page 53
co lksw
by
cted agen
Prote AG.
⇒ “18.11 High Voltage Heater (PTC) Z115 Potential Equalization
Cable”, page 54
⇒ “18.12 High Voltage Battery Charger 3 AX6 Potential Equali‐
zation Cable, Removing and Installing”, page 54
⇒ “18.13 High Voltage Charge Network Distributor SX4 Potential
Equalization Cable, Removing and Installing”, page 54
⇒ “18.14 Electric Drive Power and Control Electronics JX1 Po‐
tential Equalization Cable Bracket Engine Support, Removing
and Installing”, page 55
⇒ “18.15 Overview - Potential Equalization Cable”, page 55
18.1 Potential Equalization Cable on High

Voltage Battery 1 - AX2- in Luggage
Compartment, Removing and Installing
Note

grease on them.
♦ If necessary, clean the contact surfaces using the Contact
Surface Cleaning Set - VAS6410- . Refer to ⇒ Electrical
Equipment General Information; Rep. Gr. 97 ; Contact Sur‐
face Cleaning Set -VAS6410- .
– Tightening specification for the nuts -A-: 20 Nm.

– Tightening specification, nut to body -B-: 9 Nm.
18. Potential Equalization Cables 49

Golf 2009 ➤
18.2 Potential Equalization Cable on Electric

Drive Power and Control Electronics -
JX1- , Removing and Installing
Note

grease on them.
– Tighten the nut -1- to 20 Nm.

– Tightening specification for the nut to the body: 20 Nm.
18.3 Electro-Drive Drive Motor - V141- Po‐ lkswagen AG. Volkswagen AG does n
tential Equalization Cable, Removing
o ot g
yV ua
db ran
ir se
and Installing au
tho tee
or
a
ss c
ce
e
nl
pt
du
Note
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
grease on them.
es, in part or in w
t to the co
rrectness of i
l purpos
– Tightening specification for the bolt -A-: 23 Nm.

nf
ercia
– Tightening specification for the bolt -B-: 23 Nm. orm

m
atio
m
18.4 High Voltage Battery 2 - AX3- Potential

o
n in
or c
thi
Equalization Cable under Floor Panel,

te
sd
iva
Removing and Installing

r
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Note
t
gh ht
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Vo
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agen
Prote AG.
grease on them.
– Tightening specification for the nuts: 20 Nm.

Golf 2009 ➤
olkswagen AG
lkswagElectrical
en AG. V System E-Golf
does
not
- Edition 10.2014
o
byV gu
ara
ed
18.5 Electrical A/C Compressor - V470- Po‐ tho
ris nte
eo
tential Equalization Cable, Removing au ra
ss c
ce
and Installing
le
un
pt
an
d
itte
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erm
ab
ility
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Note
wit
is n
h re
ole,
spec
t to the co
grease on them.
rrectne
ss
o
cial p
f inform
mer
– Bolt -A- tightening specification: 6 Nm.
atio
m
– Tightening specification for the bolt -B-: 23 Nm.

o
n
c
i
or
n thi
te
sd
a
18.6 High Voltage Battery Charger 2 - AX5-

iv
o
pr
cum
r
fo
Potential Equalization Cable, Removing
en
ng
t.
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and Installing Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
Note
AG.

grease on them.

– Bolt -B- tightening specification: 6 Nm.

Golf 2009 ➤

and Installing
Note

grease on them.

18.8 Potential Equalization Cable Engine

Support, Removing and Installing
Note
♦ Check the contact surfaces onAGthe

. Vopotential
lkswagen equalization cable
before installation. ksw
agen AG do
es n
y Vol ot g
u
♦ The contact surfaces
ris
ed
b
must be clean. There must be noararust
nte or
grease on them.
tho eo
au ra
c
ss
ce
e

nl
pt
du
an

itte
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erm
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ility
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hole
spec

es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Golf 2009 ➤
18.9 Connection and Junction Box 1 - SX1-

Potential Equalization Cable Bracket,
Removing and Installing, High Voltage
Network Junction
Note

grease on them.

18.10 Connection and Junction Box 1 - SX1-

and Installing, High Voltage Network
Junction
Note

Volkswa
before installation. ksw
agen
AG. gen AG
does
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V gu
♦ The contact surfacesismust
ed b be clean. There must be no rust
y
or
ara
nte
grease on them. tho r eo
au ra
c
♦ If necessary, clean
ss
the contact surfaces using the Contact
ce
le

un
pt

an
d
itte
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ility
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hole

spec
es, in part or in w
t to the co
rrectness of i
l purpos
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mercia
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com
tion in
r
te o
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t.
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Cop py
t. rig
gh ht
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co lksw
by
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Prote AG.

Golf 2009 ➤
18.11 High Voltage Heater (PTC) - Z115- Po‐

tential Equalization Cable
Note

grease on them.


and Installing
Note
♦ Check the contact surfaces

wage
on
n AGthe
. Vopotential equalization
lkswagen AG
doe cable
before installation.y Volks s no
t gu
db ara
ise
The contactthsurfaces must be clean. There must be no rust
♦ e o or
nte
or
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u ra
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s
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pt

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ab

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ility
ot
wit
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hole
spec

es, in part or in w
t to the co
18.13 High Voltage Charge Network Distribu‐

tor - SX4- Potential Equalization Cable,
rrectness of i
Removing and Installing

l purpos
nform
ercia
Note
m
a
com
tio

n in
r
te o
thi
s
iva
do

r
rp
cum
grease on them.
fo
en
ng
t.
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♦ If necessary, clean the contact surfaces using the Contact Cop py
t. rig
gh ht
yri by
cop Vo
by lksw
face Cleaning Set -VAS6410- . cted agen
Prote AG.

Golf 2009 ➤
18.14 Electric Drive Power and Control Elec‐

tronics - JX1- Potential Equalization Ca‐
ble Bracket Engine Support, Removing
and Installing agen
AG. Volkswagen AG d
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olks not
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ara
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Note ris
tho eo
au ra
c
ss
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an
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ility
grease on them.
ot
wit
, is n
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hole
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es, in part or in w
t to the co
rrectness of i
l purpos
18.15 Overview - Potential Equalization Cable
nform
mercia
a
com
tio
Note
n in
r
te o
thi
s
iva

do
r
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cum
fo
en
ng
t.
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op
grease on them.
C py
t. rig
gh ht
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cop Vo
by lksw
cted agen
Prote AG.

Golf 2009 ➤
19 Special Tools
♦ “Danger High Voltage” Sticker AG. Volkswagen AG d
agen oes
olksw not
y V gu
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au ra
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ole,
spec
t to the co
♦ “Do Not Switch On High Voltage System” Sticker
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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t.
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Cop py
t. rig
♦ High Voltage Battery Holder AX6, on Floor Panel gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Lifting Tool, High Voltage Battery AX5, Inside Luggage Com‐

partment

Golf 2009 ➤
♦ Mount for Electro-Drive Drive Motor - V141-
AG. Volkswagen AG d
agen oes
olksw not
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aut ra
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♦ Tool For Unlocking High Voltage Cable from High Voltage
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♦ Tray - VAG1306-
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♦ Ladder - VAS5085-
19. Special Tools 57

Golf 2009 ➤
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♦ Hose Clamps - Up To 25mm - 3094-

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Golf 2009 ➤
20 Revision History
DRUCK NUMBER: K0059051421
Fac‐ Edit Job Fe Notes Quality
tory Edi‐ Type ed‐ Checke
Edi‐ tion ba d By
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10.2 09/0 Lo‐ Changed 5K1 to 5K1 while Tom

014 4/20 cal awaiting factory update in Perry
15 Up‐ reference to feedback
date 1121655
10.2 12/1 Fac‐ N/ Tom
014 5/20 tory A Perry
14 Up‐
date
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20. Revision History 59

Cautions & Warnings
Please read these WARNINGS and CAUTIONS before proceeding with maintenance
and repair work. You must answer that you have read and you understand these
WARNINGS and CAUTIONS before you will be allowed to view this information.
•= If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this manual, we
suggest you leave such repairs to an authorized Volkswagen retailer or other qualified shop. We especially urge
you to consult an authorized Volkswagen retailer before beginning repairs on any vehicle that may still be covered
wholly or in part by any of the extensive warranties issued by Volkswagen.
•= Disconnect the battery negative terminal (ground strap) whenever you work on the fuel system or the electrical
system. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.
•= Volkswagen is constantly improving its vehicles and sometimes these changes, both in parts and specifications,
are made applicable to earlier models. Therefore, part numbers listed in this manual are for reference only. Always
check with your authorized Volkswagen retailer parts department for the latest information.
•= Any time the battery has been disconnected on an automatic transmission vehicle, it will be necessary to
reestablish Transmission Control Module (TCM) basic settings using the VAG 1551 Scan Tool (ST).
•= Never work under a lifted vehicle unless it is solidly supported on stands designed for the purpose. Do not support
a vehicle on cinder blocks, hollow tiles or other props that may crumble under continuous load. Never work under a
vehicle that is supported solely by a jack. Never work under AG. Volkswagen AG d the engine is running.
agen the vehicle while
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•= For vehicles equipped with an anti-theft radio, d ran
ris be sure of the correct radio activation code tee before disconnecting the
e
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battery or removing the radio. If the wrong
aut code is entered when the power is restored, the
or radio may lock up and
ac
become inoperable, even if the correctsscode is used in a later attempt.
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If you are going to work under a vehicle on the ground, make sure that the ground is level. Block the wheels to
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keep the vehicle from rolling. Disconnect the battery negative terminal (ground strap) to prevent others from
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starting the vehicle while you are under it.

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•= Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to yourself and spec
others if you are tired, upset or have taken medicine or any other substances that may impair you or keep you from
es, in part or in w
t to the co
being fully alert.
•= Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.
rrectness of i
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•= Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid. Wear
goggles, gloves and other protective clothing whenever the job requires working with harmful substances.
nf
ercia
•= Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near
rm
m
atio
machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery, severe
om
n in
injury could result.

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•= Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used
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cu
only once and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts,
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washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners with
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Page 1 of 3
© 2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0
AG. Volkswagen AG d
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Cautions & Warnings
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•= Illuminate the work area adequately but safely. Use a portable safety light for working inside or under the vehicle.
s
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Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled
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fuel or oil.
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•= Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not create dust by
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grinding, sanding, or by cleaning with compressed air. Avoid breathing asbestos fibers and asbestos dust.
h re
ole,
Breathing asbestos can cause serious diseases such as asbestosis or cancer, and may result in death.
spec
t to the co
•= Finger rings should be removed so that they cannot cause electrical shorts, get caught in running machinery, or be
crushed by heavy parts.
rrectne
•= Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the
instructions thoroughly; do not attempt shortcuts. Use tools that are appropriate to the work and use only
ss
replacement parts meeting Volkswagen specifications. Makeshift tools, parts and procedures will not make good
o
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f
repairs.
inform
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atio
•= Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or beverage containers that
om
n
might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills at
c
i
or
n thi
once, but do not store the oily rags, which can ignite and burn spontaneously.
te
sd
iva
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•= Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten
fo
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fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque
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•= Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping hydrogen gas is
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ignited, it will ignite gas trapped in the cells and cause the battery to explode.
•= Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of
the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local ordinances that
govern the disposal of wastes.
•= The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C system should be
serviced only by trained automotive service technicians using approved refrigerant recovery/recycling equipment,
trained in related safety precautions, and familiar with regulations governing the discharging and disposal of
automotive chemical refrigerants.
•= Before doing any electrical welding on vehicles equipped with anti-lock brakes (ABS), disconnect the battery
negative terminal (ground strap) and the ABS control module connector.
•= Do not expose any part of the A/C system to high temperatures such as open flame. Excessive heat will increase
system pressure and may cause the system to burst.
•= When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the Transmission
Control Module (TCM), the ABS control module, and the trip computer. In cases where one or more of these
components is not separately fused, disconnect the control module connector(s).
•= Some of the vehicles covered by this manual are equipped with a supplemental restraint system (SRS), that
automatically deploys an airbag in the event of a frontal impact. The airbag is operated by an explosive device.
Handled improperly or without adequate safeguards, it can be accidentally activated and cause serious personal
injury. To guard against personal injury or airbag system failure, only trained Volkswagen Service technicians
should test, disassemble or service the airbag system.
Page 2 of 3
Version 1.0
Cautions & Warnings
•= Do not quick-charge the battery (for boost starting) for longer than one minute, and do not exceed 16.5 volts at the
battery with the boosting cables attached. Wait at least one minute before boosting the battery a second time.
•= Never use a test light to conduct electrical tests of the airbag system. The system must only be tested by trained
Volkswagen Service technicians using the VAG 1551 Scan Tool (ST) or an approved equivalent. The airbag unit
must never be electrically tested while it is not installed in the vehicle.
•= Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that may have been
inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of ignition away from the tire repair
area. Inflate and deflate the tire at least four times before breaking the bead from the rim. Completely remove the
tire from the rim before attempting any repair.
•= When driving or riding in an airbag-equipped vehicle, never hold test equipment in your hands or lap while the
vehicle is in motion. Objects between you and the airbag can increase the risk of injury in an accident.
I have read and I understand these Cautions and Warnings.

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Page 3 of 3
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8 Electric Drive Power and Control Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

9 Electro-Drive Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

9.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

10 High Voltage Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

10.2 Component Location Overview - High Voltage Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

11.1 Component Location Overview - High Voltage System Cooling . . . . . . . . . . . . . . . . . . . . 41

12.1 High Voltage Battery Charger 3, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 42

designations “high voltage technician”, “high voltage expert” or

technician. Refer to ⇒ page 6 must disable the high voltage

⇒ “3 High Voltage System, De-Energizing”, page 8 .

For a list of work requiring the high voltage system to be disabled,

Follow all guidelines for clean working conditions when working

1. High Voltage System Safety Precautions 1

⇒ “2 Clean Working Conditions When Working on High Voltage

♦ Check the contact surfaces on the potential equalization ca‐

Observe the following precautions when working on the high volt‐

Working on the High Voltage System

When working on the fol‐ Minimum qualifications. Refer to

lowing components: ⇒ page 6

Disabling the high volt‐ High voltage technician

Electro-Drive Drive Motor - V141- including X High voltage technician

Electric Drive Power and Control Electron‐ X High voltage technician

TW High Voltage System Maintenance X High voltage technician

Electrical A/C Compressor High Voltage X High voltage technician

Cable - P3- (high voltage distributor/air con‐

2 Rep. Gr.93 - Electric Drive

Distributor High Voltage Cable - P17-

age Cable 1 - P18-

age Cable 2 - P19-

with high voltage

Charging the high voltage battery in the X High voltage technician

Electrical A/C Compressor - V470- X High voltage technician

Potential equalization cables with connec‐ X High voltage technician

tion to high voltage components

Potential equalization cables with connec‐ X High voltage technician

Temperature Sensor after High Voltage X High voltage technician

1. High Voltage System Safety Precautions 3

High Voltage Heater (PTC) - Z115- X High voltage technician

High Voltage Battery Charger 1 - AX4- X High voltage technician

High Voltage Battery Charger 3 - AX6- X High voltage technician

Exterior Speaker 2 - R69- (right) X High voltage technician

High Voltage Battery Heat Exchanger - X High voltage technician

High Voltage Battery Fan - V510- X High voltage technician

Conventional work near high voltage components

4 Rep. Gr.93 - Electric Drive

mation; Rep. Gr. 00 ; Safety Precautions

edges or that are used for cutting or shap‐

Left and Right Headlamps, Removing and X High voltage technician

Headlamp Bulbs, Removing and Installing X High voltage technician

1. High Voltage System Safety Precautions 5

5. Starting the vehicle again

with an extra qualification that

allows them to disable the high

voltage system in the case that

a high voltage technician is not

ble the high voltage system if it atio

cannot be disabled by the high

voltage technician using the

usual means or methods.

Technicians specializing in Electro specialists with addi‐