VW Toureg 2003-2017 - Hybrid Electrical System

Service
Workshop Manual
Touareg 2010 ➤
Touareg 2015 ➤
Hybrid electrical system
Edition 03.2016
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
93 - Electric drive systems
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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 © 2016 Volkswagen AG, Wolfsburg D3E8028E634

Touareg 2010 ➤ , Touareg 2015 ➤
Hybrid electrical system - Edition 03.2016
Contents
AG. Volkswagen A
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93 - Electric drive systems . . . h.ori.s . . . . . . . . . . . . . . . . . . . . . . . . . ra.n.tee. . . . .......... 1
ed
t o
1 au
General warning instructions for work on the high-voltage system . . . .r a.c . . ........... 1
ss
ce
le
2 De-energising the high-voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
un
pt
an
d
itte
3 Re-energising the high-voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
y li
rm
ab
3.1 Potential equalisation lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
pe
ility
ot
4 General description of hybrid technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
wit
, is n
h re
4.1 Overview of hybrid components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
hole
spec
4.2 Hybrid vehicle operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
es, in part or in w
t to the co
5 Hybrid-specific components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.1 Electric drive motor V141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.2 Hybrid battery unit AX1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
rrectness of i
5.3 Power and control electronics for electric drive JX1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
l purpos
5.4 B+ line with fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

5.5 High-voltage cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
nform
ercia
5.6 Electrical air conditioner compressor V470 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

5.7 Auxiliary hydraulic pump for gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
m
a
com
tio
5.8 Vacuum pump for brakes V192 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
n in
r
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5.9 Electrical power steering pump V466 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
thi
s
iva
5.10 Pressure regulator for disengagement clutch N511 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
do
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rp
cum
5.11 Hybrid vehicle cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
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Contents i
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ii Contents
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93 – Electric drive systems
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1 General warning instructions for work
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on the high-voltage system
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(VRL008934; Edition 03.2016)
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Note
t to the co
♦ In the event of queries or uncertainties regarding the terms
rrectness of i
“electrically informed person”, “high-voltage technician”, “high-
voltage expert” or the hybrid system, contact the responsible
l purpos
importer prior to starting any work.

♦ Additional information:
nform
mercia
⇒ Self-study programme No. 450 ; The high-voltage system in
at
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the Touareg
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Before work on the high-voltage system is started, a high-voltage

at
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technician must de-energise ⇒ page 5 the high-voltage system

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⇒ page 6 .
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The types of work for which the high-voltage system has to be de- Cop py
energised are indicated in the list entitled “Work on the high-
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voltage system” ⇒ page 2 .
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WARNING
The following must be observed when the high-voltage system

is de-energised, otherwise there is a danger of fatal injury.
♦ The high-voltage system must only be de-energised by a
correspondingly qualified person (high-voltage techni‐
cian).
♦ The high-voltage technician ascertains that the system is
de-energised and secures it to prevent reactivation.
♦ The system is secured to prevent reactivation by the high-
voltage technician's securely storing the ignition key, the
maintenance connector and the pilot line connector.
♦ The high-voltage technician identifies the vehicle as de-
energised by attaching a corresponding sign.
♦ All work (e.g. maintenance, tyre replacement, conven‐
ience electronics) on vehicles with a high-voltage system
must only be carried out by persons with electrical training.
If you are uncertain about anything, consult your respon‐
sible high-voltage technician.
♦ The system must first be de-energised by a high-voltage
technician before any work is done on the high-voltage
system and before any repair work is done on the body.
♦ If the high-voltage system cannot be de-energised, further
repairs must only be carried out by a high-voltage expert
(HVE).
♦ Persons wearing medical devices must not carry out any
work on vehicles with high-voltage system. Medical devi‐
ces include internal analgesic pumps, implanted defibril‐
lators, pacemakers, insulin pumps and hearing aids.
1. General warning instructions for work on the high-voltage system 1

WARNING
Handling high-voltage cables:

♦ Do not support yourself or your tools on high-voltage ca‐
bles and their components.
♦ Work involving metal-removing, deforming and sharp-
edged tools in the vicinity of high-voltage components and
cables is prohibited. . Volkswage AG n AG d
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♦ Work involving heat sourcesy Vsuch
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hot air and thermal bondinged in the vicinity of high-voltage
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components and cablesth is prohibited.
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♦ High-voltage cables
s must not be extensively bent or
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kinked.
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♦ In the event of queries or uncertainties, contact your re‐
erm
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sponsible high-voltage technician.
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♦ The contact surfaces of potential equalisation lines must be
checked prior to removal.
rrectne
♦ The contact surfaces must be clean, rust- and grease-free.
ss
♦ Otherwise, repair the contact surfaces using the contact sur‐
o
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face cleaning set - VAS 6410- ⇒ Electrical system; General
inform
information; Rep. gr. 97 ; Contact surface cleaning set VAS
mer
6410 .
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Work for which the high-voltage system has to be de-energised:

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♦ All work on a hybrid vehicles must only be carried out by per‐

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sons who are at least qualified as persons who have been
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♦ During each activity on a hybrid vehicle, the hybrid-specific
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components in the activity/work area must be visually inspec‐
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ted.
♦ The high-voltage cables must not be extensively bent or
kinked.
♦ In the event of conspicuous findings or uncertainties, the high-
voltage technician (HVT) or the high-voltage expert (HVE)
must be consulted.
♦ Work involving metal-removing, deforming and sharp-edged
tools or heat sources such as welding, soldering, hot air and
thermal bonding in the vicinity of high-voltage components and
cables is prohibited.
♦ All listed work refers to the removal and installation or the re‐
newal of the individual components.
Work on the high-voltage system
When working on the fol‐ Minimum qualification ⇒ page 5
lowing components:
De-energise high-volt‐ High-voltage technician
age system
2 Rep. gr.93 - Electric drive systems

When working on the following compo‐ De-energise high-voltage system be‐ Minimum qualification
nents: fore work is started? ⇒ page 5 :
Yes No
Electric drive motor - V141- X EIP
Power and control electronics for electric X EIP
drive - JX1-
Maintenance connector X EIP
Safety connector 1 - TV44- at rear X EIP
Safety connector 2 - TV45- at front X EIP
High-voltage wire for electrical air condi‐ X EIP
tioner compressor - P3-
High-voltage wiring harness for drive motor X EIP
- PX2-
High-voltage wiring harness for hybrid bat‐ X EIP
tery - PX1-
Removing and installing hybrid battery unit X EIP
- AX1-
Charging hybrid battery - A38- X High-voltage technician
Battery regulation control unit - J840- X High-voltage technician
Fan for hybrid battery X EIP
Exhaust air routing at hybrid battery unit - X EIP
AX1-
Air supply ducts for battery fan X EIP
Electrical air conditioner compressor - X EIP
V470-
Pressure regulator for disengagement X EIP
clutch - N511- (spindle actuator) AG. Volkswagen AG d
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Clutch (disengagement clutch) X ed
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Pressure line for disengagement clutch tho X EIP eo
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Brake fluid for disengagement clutch ss X EIP
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Potential equalisation lines (earth cables) X EIP
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Work on the coolant circuit of the high-volt‐ X EIP
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Conventional work in the vicinity of high-voltage components

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Yes No
Measurement of insulation resistance X High-voltage technician
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Removing and installing hybrid engine cov‐ X EIP

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Spark plugs X EIP

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Left catalytic converter X EIP

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Right catalytic converter X EIP

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Exhaust system X EIP

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Propshaft X EIP
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Removing and installing engine with gear‐ X EIP
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Removing and installing engine X EIP
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Removing and installing gearbox X EIP

Yes No
Auxiliary hydraulic pump for gearbox oil X EIP
(12 V)
Transfer box X EIP
Fuel tank X EIP
Front subframe X EIP
Rear axle assembly X EIP
Underbody trim X EIP
Welding work (uncovering high-voltage X EIP
components and then carrying out visual
inspection)
Body work (with straightening bench) X EIP
Body work (assembly work and dent re‐ X EIP
pairs)
Work involving metal-removing, deforming X EIP
and sharp-edged tools or heat sources
such as welding, soldering, hot air and ther‐
mal bonding in the vicinity of high-voltage
components and cables
Removing and installing left and right head‐ X EIP
lights
Removing and installing headlight bulbs X EIP
General work
When working on the following compo‐ De-energise the high-voltage system Minimum qualification
nents: before starting work? ⇒ page 5 :
G. Volkswagen AG
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Removing and installingse12
d b V battery
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ri tee
Removing and installing ho general control X EIP
aut or
ac
units and electrical
ss battery (12 V)
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Draining and replenishing fluids (coolant X EIP

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and oils)
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Extracting, evacuating or adding refrigerant

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⇒ Air conditioning systems with refrigerant

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R134a; Rep. gr. 00 ; Working with the air

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conditioning service station

spec
Coolant pipe directly at the AC compressor X EIP

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Air conditioning performance test (for X EIP

checking the pressure levels in the refrig‐
erant circuit by means of air conditioning
rrectne
service equipment).
Coolant pipe in the vehicle periphery (work X EIP
ss
which is not directly on the AC compressor,

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without opening the refrigerant circuit, e.g.

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loosening and securing coolant pipe)

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Work in the engine area if the cover plate X EIP

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on the power and control electronics for

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electric drive - JX1- has to be removed

te
sd
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Work in the engine area if the cover plate X High-voltage technician

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and the high-voltage cables on the power

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and control electronics for electric drive -
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JX1- have to be removed . C rig
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When working on the following compo‐ De-energise the high-voltage system Minimum qualification
nents: before starting work? ⇒ page 5 :
Yes No
Work for which the engine is lifted, e.g. en‐ X EIP
gine mounting
Electrohydraulic steering (12 V) X EIP
Electrical power steering pump - V466- X EIP
(12 V)
Emissions inspection X EIP
Painting and drying work up to 80° X EIP
Explanation of qualifications
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Qualification ed Work area ara
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EIP (electrically
au informed per‐ May carry out general work and ra
c
son) ss maintenance on the vehicle.
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May carry out mechanical work

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authorised by the high-voltage

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technician on the de-energised
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high-voltage system.
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HVT (high-voltage technician) Due to his qualifications, the
h re
high-voltage technician has the
hole
spec
same authorisation as an ETP.
es, in part or in w
The HVT is also authorised to:

t to the co
1. De-energise the system
2. Secure it to prevent reactiva‐
tion
rrectness of i
3. Determine that the system is

de-energised (certified meas‐
l purpos
urement)
4. Order the ETP to carry out
nform
ercia
work on the high-voltage sys‐

tem
m
5. Commission the vehicle

com
tion in
HVE (high-voltage expert) The HVE is a trained HVT with

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thi
additional qualification ena‐

s
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do
bling him to decommission the

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high-voltage system in the

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event that the HVT cannot do

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this using the usual tools and
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measurements. If the HVT's au‐
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thorisation for work on the high-
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AG.
must continue the work. The
HVE's task is exclusively to de‐
activate the high-voltage sys‐
tem if this cannot be carried out
with the HVT's usual equipment
or methods.

2 De-energising the high-voltage sys‐

tem
WARNING
You can suffer an electric shock.

An electric shock can be fatal.
Observe general warning instructions for work on the high-
voltage system ⇒ page 1
♦ The system must first be de-energised by a high-voltage
technician before any work is done on the high-voltage
system and before any repair work is done on the body.
The types of work for which this is necessary is indicated
in the table “Work for which the high-voltage system must
be de-energised:” ⇒ page 2
♦ All work on vehicles with a high-voltage system must only
be carried out by electrically instructed persons. The work
must be supervised by a high-voltage technician.
AG. Volkswagen AG d
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– De-energise high-voltage system ⇒ Vehicle diagnostic tester.d byV gu
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3 Re-energising the high-voltage sys‐

tem
WARNING
You can suffer an electric shock.

An electric shock can be fatal.
voltage system ⇒ page 1 AG. Volkswagen A
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♦ The system by
Vmust
olk first be de-energised byna
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gu
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ir se before any work is done on the high-voltage
d ara
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system
uth and before any repair work is done on the ebody.
o
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The
ss types of work for which this is necessary is indicated
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in the table “Work for which the high-voltage system must
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be de-energised:” ⇒ page 2
an
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♦ All work on vehicles with a high-voltage system must only
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be carried out by electrically instructed persons. The work
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– Re-energise high-voltage system ⇒ Vehicle diagnostic tester.
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3.1 Potential equalisation lines
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Note
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♦ The contact surfaces of the potential equalisation line must be

inform
checked prior to installation.

mer
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♦ If necessary, repair the contact surfaces using the contact

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surface cleaning set - VAS 6410- ⇒ Electrical system; General

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6410 .
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Potential equalisation line at hybrid battery unit - AX1- :
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– Specified torque for securing bolt -1-: 9 Nm. cted agen
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– Specified torque for securing nut to body: 9 Nm.

– Check cable tie -arrow-.
3. Re-energising the high-voltage system 7

Potential equalisation line at power and control electronics for

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– Specified torque for securing bolt -10-: 9 Nm.
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– Specified torque for securing nut to body:
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Potential equalisation line -A- at electric drive motor - V141- :
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– Specified torque for securing nut -1- to body: 20 Nm.
rrectness of i
– Specified torque for securing bolt -2-: 20 Nm.
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4 General description of hybrid tech‐
ss c
ce
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un
pt
nology
an
d
itte
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erm
ab
ility
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4.1 Overview of hybrid components
is n
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spec
t to the co
Note
Additional information:
rrectne
s
the Touareg .
s o
cial p
f i
General description:
nform
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The most important components of the Touareg hybrid system
atio
m
are the electric drive motor - V141- , the hybrid battery unit - AX1- ,
o
n
c
i
the high-voltage cables and the power and control electronics for
or
n thi
e
electric drive - JX1- , which contain the voltage converter - A19-

t
sd
va
and the DC/AC converter for drive motor - A37- .

i
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pr
cum
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fo
en
ng
Further components include the electrical air conditioner com‐

t.
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pressor - V470- , the low-temperature cooling system, the fans for
Cop py
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the hybrid battery unit - AX1- , the disengagement clutch, the
py
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pressure sender for disengagement clutch - G738- and the elec‐
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4. General description of hybrid technology 9

1 - High-voltage wire for elec‐

trical air conditioner compres‐
sor - P3-
❑ Removing and installing
⇒ page 46 .
2 - Electrical air conditioner
compressor - V470-
⇒ page 47 .
3 - 3.0l V6 TSI combustion en‐
gine
4 - Electric drive motor - V141-
⇒ page 13 .
5 - Auxiliary hydraulic pump for
gearbox oil
❑ Fitting location: beneath
gearbox housing.
❑ Removing and installing AG. Volkswagen AG d
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box oil ⇒ page 47 . d by V gu
ara
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❑ Removing and installing thor eo
control unit for auxiliary ss au ra
c
hydraulic pump - J922-
ce
le
un
⇒ page 47 .
pt
an
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6 - Air supply duct for hybrid
erm
ab
battery cooling
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⇒ page 26 .
ole,
spec
7 - Hybrid battery unit - AX1-
t to the co
❑ With connection and
distribution box - SX1-
(electronics box) und rrectne
battery regulation con‐
trol unit - J840- ⇒ page 20 .
ss
❑ With battery fan ⇒ page 24 .

o
cial p
f i
❑ Removing and installing hybrid battery unit ⇒ page 14 .

nform
mer
8 - High-voltage wiring harness for hybrid battery - PX1-

atio
om
❑ High-voltage wire for hybrid battery, positive terminal - P1-

n
c
i
or
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❑ High-voltage wire for hybrid battery, negative terminal - P2-

t
sd
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❑ Removing and installing ⇒ page 40 .

p
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9 - Pressure regulator for disengagement clutch - N511-

t.
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pyri by
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10 - High-voltage wiring harness for drive motor - PX2-
co lksw
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❑ High-voltage wire 1 for drive motor - P4-
AG.

11 - Power and control electronics for electric drive - JX1-
❑ Control unit for electric drive - J841-
❑ Voltage converter - A19-
❑ Inverter for drive motor - A37-
❑ DC link capacitor 1 - C25-

12 - Electrical power steering pump - V466-
Not illustrated:
AG. Volkswagen AG d
♦ Hybrid vehicle cooling systemlks⇒wapage
gen 49 oes
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♦ Brake servo vacuum pumprise
d b
- V469- ⇒ page 48 ara
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♦ Disengagement clutch
s au between electric drive motor - V141- ra
c
and combustion engine ⇒ page 14
s
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nl
pt
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4.2 Hybrid vehicle operating modes
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Additional information:
es, in part or in w
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the Touareg .
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⇒ Operating instructions
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4.2.1 Standstill
nf
ercia
Standstill with or without combustion engine running:
orm
m
atio
When the vehicle is stationary, the combustion engine normally
om
n in
switches itself off automatically. If the battery state of charge is
or c
too low or the temperature of the combustion engine coolant is thi

te
sd
a
too low, the combustion engine is not switched off

iv
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o
4.2.2 Driving with electric motor

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Starting off and driving with low load:
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In this case, the combustion engine is switched off and the vehicle
c by lksw
cted agen
is driven by the electric drive motor - V141- , which is supplied Prote AG.
with power by the hybrid battery - A38- . Operating the combustion

engine in ranges with poor efficiency can be avoided as a result
of this. If the battery state of charge falls below a specific value,
the combustion engine starts up to charge the hybrid battery -
A38- .
Electric driving:
The “electric driving” function means that the vehicle is driven for
as long as possible using the electric drive motor - V141- . This is
influenced by the:
♦ Battery state of charge (SOC)
♦ Speed
♦ Battery temperature
♦ Battery current throughput
When the button for extended electric driving mode - E709- in the
centre console is pressed, the vehicle changes over to the elec‐
tronic accelerator map. If driving with the electric drive motor -
V141- is not possible, driver information is output via the dash
panel insert.
Driving with the electric drive motor - V141- is deactivated if at
least one of the following conditions is met:
♦ Ignition off
4. General description of hybrid technology 11

♦ Button for extended electric driving mode - E709- in in the

centre console pressed for the second time
♦ Selector lever set to S
♦ Selector lever in Tiptronic gate
♦ Speed too high (> 60 km/h)
To activate again, the button for extended electric driving mode
must be pressed.
4.2.3 Driving with combustion engine and

electric motor
Normal driving:
In “normal mode”, the vehicle is driven by the combustion engine.
The electric drive motor - V141- operates as an alternator to
charge the hybrid battery - A38- and supply the 12 V vehicle elec‐
trical system. If the hybrid battery - A38- has a sufficient charge,
the electric drive motor - V141- can be engaged to drive the ve‐
hicle as required (boost).
Full acceleration (boost):
For full acceleration, the vehicle is driven by the combustion en‐
gine and the electric drive motor - V141- . Engagement is carried
out automatically under the following conditions:
♦ Kick-down in gear D
♦ Accelerator depressed with selector lever set to S
AG. Volkswagen AG d
♦ Accelerator depressed with selector lever in Tiptronic gate agen oes
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Deceleration or braking: orise nte
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Depending on brake pedal travel, deceleration is carried out
ss awith c
the electric drive motor - V141- and/or the brakes. In “free brake
ce
le
un
pt
pedal travel”, only the electric drive motor - V141- is used to de‐
an
d
itte
celerate. The wheels drive the electric drive motor - V141- , which
y li
rm
ab
acts as a generator in this case and is used for energy recovery.
pe
ility
The recovered energy is stored in the hybrid battery - A38- and
ot
wit
, is n
can be called up at a later point in time. If the “free brake pedal
h re
travel” is exceeded, the electric drive motor - V141- and the
hole
spec
brakes are used to decelerate.
es, in part or in w
t to the co
4.2.4 Recuperation
Recuperation:
Recuperation refers to the recovery of kinetic energy in the form rrectness of i
l purpos
of electric energy. Recuperation is used on braking the vehicle.

The electric drive motor - V141- is used as a generator to generate
electrical current. This is stored in the hybrid battery - A38- or is
nform
ercia
used to supply the ancillary units.

m
a
com
If the hybrid battery - A38- is unable to absorb any more energy

ion in
following a long period of recuperation on a gradient, the com‐

r
te o
thi
bustion engine is started to be able to provide braking effect.

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by lksw
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Prote AG.

5 Hybrid-specific components
5.1 Electric drive motor - V141-
5.1.1 General description

The electric drive motor - V141- is positioned between the com‐
bustion engine and gearbox. It acts directly on the input shaft and
has the following tasks:
♦ Function as a motor to drive the vehicle purely electrically.
♦ Function as an alternator to supply the vehicle electrical sys‐
tem with current and charge the hybrid battery - A38- .
♦ Function as a starter to start the combustion engine.
The disengagement clutch on the electric drive motor - V141- can
be removed and installed ⇒ page 14 ; opening and dismantling
the electric drive motor - V141- are not planned.
5.1.2 Removing and installing electric drive

motor - V141-
WARNING
. Volkswag
Observe general warning instructions
ksw
agenfor work on the
AG en AG
dhigh-
oes
voltage system ⇒ page 1 by V ol not
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Observe instructions on handling high-voltage cables

ility
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⇒ page 39 .
wit
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Removing:
spec
es, in part or in w
t to the co
WARNING
High-voltage in the hybrid vehicle's high-voltage system. Dan‐

rrectness of i
ger of electric shock! Work on the high-voltage system is also

l purpos
necessary for the following work sequence. Now de-energise

the high-voltage system ⇒ page 6 .
nform
mercia
– De-energising the high-voltage system ⇒ page 6

at
om
ion
c
– Removing electric drive motor - V141- ⇒ 6-cyl. injection en‐

in t
or
his
e
gine (hybrid); Rep. gr. 10 ; Separating electric drive motor and

at
do
riv
engine .
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for
en
Installing:
ng
t.
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op py
– Installing electric drive motor - V141- ⇒ 6-cyl. injection engine
. C rig
ht ht
rig
(hybrid); Rep. gr. 10 ; Separating electric drive motor and en‐ py by
co Vo
gine .
by lksw
cted agen
Prote AG.
– Re-energising the high-voltage system and documentation
⇒ page 7 .
5. Hybrid-specific components 13
Note
Calibration of the electric drive motor - V141- is initiated automat‐

ically on completion of GFF after all event memory entries have
been deleted.
Calibration is necessary whenever the event memory of the pow‐

er and control electronics for electric drive - JX1- , the battery
regulation control unit - J840- , the engine or the gearbox has
been cleared. Otherwise, the vehicle will not start until the ignition
is switched on for the second time.
5.1.3 Removing and installing disengagement

clutch
Disengagement clutch is actuated by pressure regulator for dis‐
engagement clutch - N511- and separates combustion engine
from electric drive motor - V141- for purely electric driving.
Removing and installing disengagement clutch ⇒ Automatic
gearbox 0C8 - 8-speed; Rep. gr. 30 .
5.2 Hybrid battery unit - AX1-

G. Volkswage
Hybrid battery unit - AX1-lkprovides
swa
gen A electric drive motor
n AG d
oes
n
- V141-
with the necessary high by Vovoltage to be able to drive theotvehicle
gu
ara
purely electrically.rised nte
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ut
The hybrid battery
ss
a unit - AX1- consists of hybrid battery - A38- r ac
with 240 nickel-metal hybrid cells and connection and distribution
ce
e
nl
pt
box - SX1- (electronics box) with battery regulation control unit -

du
an
itte
J840- . Hybrid battery unit - AX1- has a total voltage of 288 V. To

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protect hybrid battery unit - AX1- , particularly in a rear crash, it is

ility
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surrounded by a frame consisting of welded and bolted aluminium

wit
profiles (battery box for hybrid battery), which conducts impact

, is n
h re
energy into vehicle structure. Frame is also used to lift hybrid bat‐
hole
spec
tery out of vehicle using a workshop hoist and lifting belt.

es, in part or in w
t to the co
Battery fan and battery regulation control unit - J840- can be re‐
moved and renewed; opening and dismantling the battery itself
are not planned.
rrectness of i
l purpos
Note
nf
ercia
Hybrid battery unit - AX1- can only be charged externally using

or
HV battery charger - VAS 6565- .

m
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or c
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Prote AG.

5.2.2 Visual inspection of hybrid battery unit -

AX1-
WARNING
The hybrid battery unit - AX1- must be checked for the follow‐
ing:
♦ Cracks in battery housing or battery box
♦ Deformation of battery housing or battery box
♦ Colour changes due to temperature and tarnishing of
housing
♦ Escaping electrolyte
♦ Damaged high-voltage contacts
♦ Legible and fitted information stickers
♦ Fitted equipotential bonding cable ⇒ page 7
5.2.3 Removing and installing hybrid battery

unit - AX1-
Special tools and workshop equipment required
♦ Workshop hoist - VAS 6100-
AG. Volkswagen AG d
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♦ Torque wrench - V.A.G 1331-

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mer
atio
om
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c
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♦ Retaining strap - T40155-
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Removing:
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WARNING
ab
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spec
t to the co
Note
rrectne
s
⇒ page 39 .
s o
cial p
f inform
mer
WARNING
atio
om
n
c
i
or
n thi
e

t
sd
iva
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pr
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fo

en
ng
t.
yi Co
Cop py
ht. rig
rig ht
– De-energising the high-voltage system ⇒ page 6 py by
co Vo
by lksw
cted agen
– Remove luggage compartment floor Prote AG.
– Remove breakdown kit and vehicle tools from luggage com‐

partment.
– Release and disconnect connectors -1- and -2- for battery
regulation control unit - J840- .

– Release and disconnect connectors -3- and -4-.
– Unscrew securing bolt -1- from hybrid battery unit - AX1- and
remove potential equalisation line (earth cable).
– Separate cable tie -arrow- and lay potential equalisation line
(earth cable) aside.
Note
When removing and installing air supply duct, make sure that air
supply duct's foam seals are not damaged and seal separating
points all around.
– Pull air supply duct towards batteryenand

AG. Vdisengage
olkswagen AGupwards
at catch -1-. olks
wag does
not
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– Raise air supply ductorand
ise pull upwards out of mountings on
d
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battery -2-. au
th eo
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un
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an
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itte
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ab
ility
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spec
t to the co
– Unscrew 8 securing bolts for hybrid battery unit - AX1- .

rrectness o
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f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Unscrew 4 securing bolts -3- and remove both right brackets

from hybrid battery unit - AX1- .
Note
On removing, hybrid battery unit - AX1- must first be raised slightly

and pushed to the right. Otherwise, connection and distribution
box - SX1- (electronics box) hits left side of battery when lifting
out below left load compartment trim.
– Slightly raise hybrid battery unit - AX1- centrally using a short

lifting belt and workshop hoist - VAS 6100- .
– Push hybrid battery unit - AX1- Aslightly toagthe
G. Volksw en Aright
G do and stabilise
agen
with a second personVowhen
lksw lifting out. es n
ot
by gu
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Installing: ed nte
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Note
un
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an
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erm
When inserting hybrid battery unit - AX1- into vehicle, make sure ab
that no lines or connectors are trapped beneath battery. ility
ot p
wit
is n
h re
ole,
spec
– Lift hybrid battery unit - AX1- centrally centrally into vehicle

using a short lifting belt and workshop hoist - VAS 6100- and
t to the co
align with securing holes in bottom of body.

rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
– Use 4 securing bolts -3- to bolt both right securing brackets to

um
r
fo
hybrid battery unit - AX1- .

en
ng
t.
yi Co
op
– Tighten securing bolts -3- to 23 Nm.
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Bolt hybrid battery unit - AX1- using 8 securing bolts -2-.

– Tighten securing bolts -2- to 23 Nm.
Note
points all around.
– Insert air supply duct into mountings on hybrid battery unit -

AX1- -1-, connect to front section and lock at catch -2-.
Note

information; Rep. gr. 97 ; Contact surface cleaning
agen
AG.set
VolkVAS
swagen AG
does
6410 . yV
olksw not
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th or
– Bolt potential equalisation liness (earth cable) to hybrid battery au ac
unit - AX1- using securing bolt -1-.
ce
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nl
pt
du
an
– Tighten securing bolt -1- to 9 Nm.
itte
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erm
ab
– Secure potential equalisation line (earth cable) to hybrid bat‐
ility
ot p
tery unit - AX1- again using cable tie -arrow-.

wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Insert both connectors -3- and -4- until they are felt to engage.
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
o
by c lksw
cted agen
Prote AG.
– Insert both connectors -1- and -2- for battery regulation control
unit - J840- until they are felt to engage.
– Attach connectors -1- and -2- to hybrid battery unit - AX1-
mounting and press lines into retainers along their routing.
– Put breakdown kit and vehicle tools inside.
– Installing luggage compartment floor ⇒ General body repairs,
interior; Rep. gr. 70 ; Load and luggage compartment trim;
Removing and installing load floor .
⇒ page 7 .
5.2.4 Removing and installing battery regula‐

tion control unit - J840-
Battery regulation control unit - J840- is installed in connection
and distribution box - SX1- (electronics box) on side of hybrid
battery unit - AX1- .
Removing:
WARNING

High voltage at connection and distribution box - SX1- (elec‐
tronics box)!
♦ Health risks for persons wearing medical devices.
♦ Severe burns or death.
♦ Work on the battery regulation control unit - J840- may
only be carried out by a high-voltage technician.
♦ Always use insulated tools when working on the battery
AG. Volkswagen AG d
regulation control unitks-wJ840-
agen . oes
not
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ss
Note
ce
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un
pt
an
d
itte
If battery regulation control unit - J840- is renewed, coding must

y li
erm
ab
be read out from old control unit prior to removal ⇒ page 24 .

ility
ot p
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is n
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ole,
WARNING
spec
t to the co

rrectne

ss o

cial p
f inform
– Removing hybrid battery unit - AX1- ⇒ page 15 .

mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
20
co Vo
by lksw
Rep. gr.93 - Electric drive systems cted agen
Prote AG.
– Unscrew 8 securing bolts -1- and remove cover of connection

and distribution box - SX1- (electronics box).
– Loosen both securing bolts -2- from maintenance connector

mounting.
– Separate cable tie -arrow- for electrical cable. AG. Volkswagen AG d

agen oes
olksw not
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– Release and separate 3 connectors -1-, -2-isand
ed b -3- at battery ara
nte
regulation control unit - J840- . thor eo
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pt
du
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itte
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erm
ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co
– Unscrew both securing bolts -3- from battery regulation control
unit - J840- using a magnetic and insulated tool.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
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co lksw
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wage e
– Raise battery regulation control
yV
olksunit - J840- and release and
s no
t gu
separate connectors -4-isand
ed b -5-. ara
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ac
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nl
pt
du
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itte
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ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co
– Lift battery regulation control unit - J840- upwards out of elec‐
rrectness of i
tronics box.
l purpos
– If battery regulation control unit - J840- is renewed, release

and separate connector -6- at battery regulation control unit -
J840- and remove together with wiring harness.
nform
ercia
Installing:
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
– Insert connector -6- with wiring harness until it is felt to engage. p by
o Vo
by c lksw
cted agen
Prote AG.
– Insert battery regulation control unit - J840- into electronics

box and insert both connectors -4- and -5- until they are felt to
engage.
– Position battery regulation control unit - J840- in electronics
box.

– Tighten earth cable (terminal) to battery regulation control unit

- J840- in electronics box.
– Tighten battery regulation control unit - J840- and earth cable
using two securing bolts -3-. wage
es ks not
Vol gu
d by ara
e nte
ris
utho eo
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a c
ss
ce
e
nl
pt
du
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itte
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ab
ility
ot p
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h re
– Tighten mounting for maintenance connector using two se‐ hole
spec
curing bolts -2-.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
– Insert connectors -1-, -2- and -3- into battery regulation control
o
r
rp
cu
unit - J840- until they are felt to engage.
o
m
f
en
ng
t.
yi
– Secure electrical cable with a cable tie -arrow- again.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Before positioning cover for electronics box, check routing of

electronics box wiring harness lines.
Note
Rubber grommet of wiring harness -arrow- must be attached

properly in electronics box housing.
lkswage es n
o ot g
byV ua
d ran
ir se tee
o
Touareg 2010 ➤ , Touareg 2015au ➤
th or
ac
Hybrid electrical system - Edition 03.2016 ss
ce
le
un
pt
an
d
– Position electronics box cover and tighten with the 8 securing
itte
y li
bolts -1-.
rm
ab
pe
ility
ot
– Installing hybrid battery unit - AX1- ⇒ page 15 .
wit
, is n
h re
hole
spec
⇒ page 7 .
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
5.2.5 Renewing battery regulation control unit

m
a
com
t
- J840-
ion in
r
te o
thi
– Renew battery regulation control unit - J840- ⇒ Vehicle diag‐
s
iva
do
nostic tester.
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rp
cum
fo
en
g
5.2.6 Removing and installing battery fan

n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
Note
c by lksw
cted agen
Prote AG.
♦ Battery fan 1 - AX1- and battery fan 2 - V457- are installed

behind an exhaust air duct on rear of hybrid battery unit -
V458- .
♦ When removing and installing battery fans, make sure that
exhaust air duct's foam seal is not damaged and seal the con‐
tact surface all around.
♦ Observe general warning instructions for work on the high-

Removing:
WARNING


– Removing hybrid battery unit - AX1- ⇒ page 15 .

– Unscrew 6 securing bolts -1- and remove exhaust air duct.
– Unclip connector for fan to be removed from connector bracket

on hybrid battery unit - AX1- .
– Unscrew 3 securing bolts -2- for relevant fan and remove fan
from hybrid battery unit - AX1- .
Installing:
Note
♦ Bolts with locking fluid are used to secure fan and exhaust air
duct.
♦ New bolts must be used when installing.
– Position relevant fan on hybrid battery unit - AX1- and tighten

with 3 securing bolts -2-.
– Tighten securing bolts for fan to hybrid battery unit - AX1- to
10 Nm.
– Engage connector for fan in connector bracket on hybrid bat‐
tery unit - AX1- .
AG. Volkswagen AG d
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an
itte
– Position exhaust air duct on hybrid battery unit - AX1- and bolt
y li
erm
ab
with 6 securing bolts -1-.

ility
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– Tighten securing bolts for exhaust air duct to hybrid battery

wit
, is n
h re
unit - AX1- to 10 Nm.

hole
spec
– Installing hybrid battery unit - AX1- ⇒ page 15 .

es, in part or in w
t to the co

⇒ page 7 .
rrectness of i
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5. Hybrid-specific components
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Touareg 2010 ➤ , Touareg 2015 ➤swagen AG. V does
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Hybrid electrical system - Edition
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5.2.7 Removing and installing air supply ducts ss
au ra
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for battery fan
ce
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nl
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Hybrid battery unit - AX1- is supplied with cooling air taken in from
erm
ab
vehicle interior via air supply duct. Air supply duct is designed in
ility
two sections; front section (red) is installed beneath left-hand ot p
wit
, is n
section of rear seat bench; rear part (blue) is inserted directly into
h re
hybrid battery unit - AX1- .
hole
spec
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WARNING
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nf
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Note
rm
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or c
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points all around.

iv
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Removing air supply duct rear part: Cop py
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– Removing luggage compartment floor ⇒ General body re‐ p by
co Vo
lksw
pairs, interior; Rep. gr. 70 ; Load and luggage compartment
by
cted agen
Prote
trim; Removing and installing load floor .
AG.
– Pull air supply duct towards hybrid battery unit - AX1- and dis‐
engage upwards at catch -1-.
– Raise air supply duct and pull upwards out of mountings on
hybrid battery unit - AX1- -2-.
Installing air supply duct rear part:

– Insert air supply duct into mountings on hybrid battery unit -
AX1- -1-, connect to front section and lock at catch -2-.

Removing air supply duct front part:

– Removing air supply duct rear part: ⇒ pageen26
AG.. Volkswagen AG
ag does
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– Removing left-hand section of rear Vol
by seat bench ⇒ General gu
ara
body repairs, interior; Rep. gr.ris72
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– Unscrew securing nut -1-ssifa fitted. ra
c
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– Raise air supply duct and pull out backwards through floor
nl
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Installing air supply duct front part:
t to the co
– Push air supply duct forwards through floor covering and po‐
sition on stud.
rrectness of i
– Bolt air supply duct with securing nut -1-.
l purpos
– Installing left-hand section of rear seat bench ⇒ General body

repairs, interior; Rep. gr. 72 ; Rear seats .
nf
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– Installing air supply duct rear part: ⇒ page 26 .
rm
m
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n in
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5.2.8 Charging hybrid battery - A38-
f
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WARNING p by
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Prote AG.
High voltage at connection and distribution box - SX1- (elec‐
tronics box)!
♦ Severe burns or death.
♦ Only a high-voltage expert, an electrician qualified for de‐
fined activities (hybrid) or a high-voltage technician is
permitted to charge the hybrid battery .
♦ To charge hybrid battery , use charger - VAS 6565- with
relevant leads.
Charging process on the hybrid battery - A38- may only be carried

out by the following persons:
♦ HVE, high-voltage expert
♦ EfDA, electrician for defined activities (hybrid)
♦ High-voltage technician (HVT)
To charge hybrid battery - A38- , use charger - VAS 6565- with
relevant leads.
– Charge hybrid battery - A38- ⇒ Vehicle diagnostic tester.
5.3 Power and control electronics for elec‐

tric drive - JX1-
AG. Volkswagen AG d
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5.3.1 General description d b ara
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Power and control electronics for electric drive -sV141-
sa act as the c
link between electric drive motor - AX1- and hybrid battery unit -
ce
le
un
pt
JX1- . The electronics include the voltage transformer - A19- , the
an
d
itte
inverter for the drive motor - A37- and the electric drive control
y li
rm
ab
unit - J841- .
pe
ility
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For driving with electric drive motor - A37- , DC/AC converter for
, is n
h re
drive motor - V141- converts hybrid battery's - A38- 288 V direct
hole
current into 288 V alternating current. Voltage converter - A19-
spec
es, in part or in w
converts high voltage into low voltage to supply 12 V vehicle
t to the co
electrical system. Power and control electronics for electric drive
- JX1- are water-cooled and are installed on front left of engine
compartment.
rrectness of i
Following high-voltage cables emerge from power and control
l purpos
electronics for electric drive - JX1- :

♦ High-voltage wire for hybrid battery, positive terminal - P1- to
nform
ercia
hybrid battery unit - AX1- ⇒ page 40

m
a
♦ High-voltage wire for hybrid battery, negative terminal - P2- to
com
tio
hybrid battery unit - AX1- ⇒ page 40
n in
r
te o
thi
♦ High-voltage wire 1 for drive motor - P4- to three-phase current
s
iva
do
drive - VX54- ⇒ page 43
r
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fo
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♦ High-voltage wire 2 for drive motor - P5- to three-phase current

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drive - VX54- ⇒ page 43 Cop py
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♦ High-voltage wire 3 for drive motor - P6- to three-phase current p by
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drive - VX54- ⇒ page 43
by
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Prote AG.
♦ High-voltage wire for electrical air conditioner compressor -
P3- to electrical air conditioner compressor - V470-
⇒ page 46
Note
♦ Fuse for electrical air conditioner compressor - JX1- is inte‐

grated into power and control electronics for electric drive -
V470- .
♦ Fuse cannot be exchanged. Power and control electronics for
electric drive - JX1- cannot be dismantled any further. If dam‐
aged, renew power and control electronics for electric drive -
JX1- .
If the power and control electronics unit for the electric drive - JX1-
is replaced, the following adaptations must always be carried out
in the following sequence:
1. Adapt power and control electronics for electric drive - JX1- to
immobiliser ⇒ Vehicle diagnostic tester.
2. Code power and control electronics for electric drive - JX1-
⇒ Vehicle diagnostic tester.
3. Calibrate electric drive motor - V141- ⇒ Vehicle diagnostic test‐
er.

Note

been deleted.

been cleared. Otherwise, the vehicle will not start until the ignition n AG. Volkswagen AG do
is switched on for the second time. olkswage es n
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5.3.2 Visual inspection of power and control aut
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electronics for electric drive - JX1- ss c
ce
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un
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an
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WARNING
erm
ab
ility
ot p
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The power and control electronics for electric drive - JX1- are
is n
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to be checked for the following:
ole,
spec
♦ Traces of liquid on the water connections
t to the co
♦ Damage to housing and plug contacts
♦ Preserved flange plates ⇒ page 36
rrectne
♦ Coolant level in compensation tank of low-temperature
coolant circuit
ss o
cial p
♦ Fitted equipotential bonding cable ⇒ page 7
f inform
mer
atio
m
5.3.3 Removing and installing cover plate for

o
n
c
i
or
n
high-voltage terminal on power and con‐
thi
te
sd
iva
trol electronics unit for electric drive -
o
pr
cum
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fo
JX1-
en
ng
t.
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Cop py
. rig
Removal of cover plate on power and control electronics for elec‐
t
gh ht
yri by
tric drive - JX1- forms part of the work involved in de-energising cop Vo
by lksw
the high-voltage system. cted agen
Prote AG.
WARNING


Removing:
– Removing cover on left of engine compartment ⇒ Power unit;
Rep. gr. 10 ; Removing and installing engine .
– Unscrew 3 securing bolts -4- and securing nuts -5- and remove
cover plate from power and control electronics for electric drive
- JX1- .
Installing:
– Position cover plate for high-voltage terminal on power and

control electronics for electric drive - JX1- and tighten 3 se‐
curing bolts -4- to 9 Nm.
– Screw on securing nuts -5- and tighten to 9 Nm.
5.3.4 Removing and installing power and con‐

trol electronics for electric drive - JX1-
AG. Volkswagen AG d
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WARNING by Vo gu
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Observe general warning instructions sfor
a work on the high-
th
u ra
voltage system ⇒ page 1 s c
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un
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an
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Note
ot
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hole

spec
⇒ page 39 .
es, in part or in w
t to the co
Caution
rrectness of i
If the power and control electronics for electric drive - JX1- are
l purpos
renewed, the new power and control electronics for electric

drive must be preserved before installing on the flange plates
nform
ercia
⇒ page 36 .
m
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tion in

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♦ Hose clamps up to 25 mm dia. - 3094-
Removing: AG. Volkswagen AG d

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If the power and control electronics for electric drive - JX1- are ss c
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renewed, the new power and control electronics for electric

nl
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drive must be preserved before installing on the flange plates
an
itte
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⇒ page 36 .
erm
ab
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WARNING
spec
es, in part or in w
t to the co
necessary for the following work sequence. Now de-energise rrectness of i
l purpos

nform
ercia
– Disconnecting 12 V battery beneath driver seat ⇒ Electrical

m
at
system; Rep. gr. 27 ; Disconnecting and reconnecting battery .

om
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c
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or
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ate
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priv
cum
for
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Cop py
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rig ht
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co Vo
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Prote AG.
AG. Volkswagen AG d
Touareg 2010 ➤ , Touareg 2015 ➤ agen oes
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Hybrid electrical system - Edition 03.2016 d by gu
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– Release high-voltage wire for electrical air conditioner
ss a com‐
u ra
c
pressor - P3- to -1- and pull off.
ce
le
un
pt
an
d
itte
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rm
ab
pe
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ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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– Release pilot line connector -1- and pull off, then release and
pull off 3 high-voltage cables -2- -3- and -4- in succession.
nform
mercia
a
Note
com
tion in
r
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♦ Start with uppermost connector.
s
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♦ Press connector into mounting, pull locking ring and pull con‐
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nector off.
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♦ Fold locking bow aside and disconnect next connector in the
C py
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same way.
ht
pyri by
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cted agen
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– Pull off both high-voltage cable retainers -arrow- from housing

rib of power and control electronics for electric drive - JX1- .
– Pull catch on connector -5- in -direction of arrow- and pull con‐

nector off from power and control electronics for electric drive
- JX1- .
Note
When pulling catch, connector -5- is automatically ejected from

connection on power and control electronics for electric drive -
JX1- .

– Open cap of jump starting point and unscrew securing nut

(20 Nm) -6- for B+ line.
AG. Volkswagen AG d
– Remove underlying B+ line from connection
lksw
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ab
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– Unscrew securing nut (20 Nm) -7- and remove earth cable.
es, in part or in w
t to the co
rrectness of i
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nf
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n in
or c
thi
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– Pinch off both coolant pipes -arrows- with hose clamps up to
m
f
en
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t.
25 mm - 3094- . Cop
yi Co
py
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rig ht
py by
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Note by c lksw
cted agen
Prote AG.
Collect escaping coolant in a suitable container.
– Open and pull off both hose connectors -arrows-.
– Unscrew both securing nuts (10 Nm) -8- and raise power and
control electronics for electric drive - JX1- slightly out of rubber
mountings in bracket to obtain access to securing nut for B+
line.
– Unscrew securing nut for B+ line (20 Nm) -9- and pull B+ line
from connection threads.
AG. Volkswagen AG d
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ab
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
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t.
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Cop py
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gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Unscrew securing bolt (9 Nm) -10- and remove potential

equalisation line (earth cable).
– Lift power and control electronics for electric drive - JX1- up‐
wards out of vehicle.
Installing:
Caution
If the power and control electronics for electric drive wage

-nJX1-
AG. Voare
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does
renewed, the new power and control electronics yV
olks for electric not
gu
drive must be preserved before installing edon
b the flange plates ara
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⇒ page 36 . tho eo
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pt
Install in the reverse order of removal. When doing this, note the
an
d
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following:
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Note
h re
ole,
spec
t to the co
rrectne
ss o
6410 .
cial p
f inform
mer
– Tighten all threaded connections to specified torques.
atio
om
n
c
i
or
n thi
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Note
t
sd
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pr
cum
r
fo
♦ High-voltage lines can only be connected and secured in

en
ng
t.
specified sequence.
yi Co
Cop py
t. rig
♦ Connect and lock high-voltage line connectors in reverse se‐
gh ht
pyri by
quence to removal.
co Vo
by lksw
cted agen
Prote AG.
– Reconnecting 12 V battery beneath driver seat ⇒ Electrical

⇒ page 7 .
– Bleeding low-temperature cooling circuit ⇒ 6-cyl. injection en‐
gine (hybrid); Rep. gr. 19 ; Cooling system .
in the following sequence:
er.
Note

been deleted.

been cleared. Otherwise, the vehicle will not start until the ignition
is switched on for the second time.
5.3.5 Preserving power and control electron‐

ics for electric drive - JX1-
If the power and control electronics for electric drive - JX1- are
renewed, the new power and control electronics for electric drive
must be preserved with wax spray D 322 000 A2 on the flange
plates.
– Mask power and control electronics for electric drive - JX1-
with adhesive tape in area 1.
AG. Volkswagen AG d
Note agen oes
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Make sure that plastic caps -B- have been fitted and pilot linethor nte
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connector -C- has been connected before spraying on wax.s a u ra
c
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ab
pe
ility
ot
wit
, is n
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hole
– Lightly spray areas -A- with wax D 322 000 A2 and allow to
spec
dry for 30 min.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
5.3.6 Renewing power and control electronics

r
rp
cum
fo
for electric drive - JX1-

en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
p by
co Vo
by lksw
in the following sequence: Prote
cted AG.
agen

er.

5.4 B+ line with fuse
5.4.1 Removing and installing B+ line with

fuse
WARNING

ger of electric shock! Before starting work, visually inspect
high-voltage components in working area. Observe general
warning instructions ⇒ page 1 .

Removing:
WARNING
High-voltage in the hybrid vehicle's high-voltage system. n ADan‐

G. Volkswagen AG d
ger of electric shock! Work on the high-voltageVsystem wage is also oes
olks not
necessary for the following work sequence. edNow de-energise
by gu
ara
the high-voltage system. ris nte
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au ra
c
ss
ce
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nl
pt

du
an
itte
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– Disconnecting 12 V battery beneath driver seat ⇒ Electrical

erm
ab
ility

ot p
wit
, is n
– Remove cover plate for high-voltage connection on power and

h re
hole
control electronics for electric drive - JX1- ⇒ page 29 .

spec
es, in part or in w
– Open cap of jump starting point and unscrew securing nut

t to the co
(20 Nm) -6- for B+ line.

– Remove underlying B+ line from connection threads.
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
ht. rig
rig ht
py by
co Vo
37
by lksw
cted agen
Prote AG.
5. Hybrid-specific components
– Remove nuts -arrows-. Unscrew bolts -1- and -2- and remove
bracket -3- from engine compartment.
AG. Volkswagen AG d
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byV gu
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ris nte
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aut ra
ss c
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
– Unscrew both securing nuts (10 Nm) -8- and raise power and
wit
, is n
control electronics for electric drive - JX1- slightly out of rubber
h re
mountings in bracket to obtain access to securing nut for B+
hole
spec
line.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
– Unscrew nut -arrow-. Remove B+ line with fuse -4- from vehi‐
or c
cle.
thi
te
sd
iva
o
Installing:
r
rp
cu
o
m
f
en
ng
Installation is carried out in the reverse sequence of removal:

t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
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agen Touareg 2010 oes➤ , Touareg 2015 ➤
no
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Hybrid electrical systemt -guEdition
ara 03.2016
e nte
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th or
5.5 High-voltage cables ss
au ac
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
WARNING
hole
spec
es, in part or in w
Handling high-voltage cables:
t to the co
♦ Do not support yourself or your tools on high-voltage ca‐
bles and their components.
rrectness of i
♦ Work involving metal-removing, deforming and sharp-
l purpos
edged tools in the vicinity of high-voltage components and

cables is prohibited.
nf
ercia
♦ Work involving heat sources such as welding, soldering,
or
hot air and thermal bonding in the vicinity of high-voltage
m
m
atio
components and cables is prohibited.
om
n in
or c
♦ High-voltage cables must not be extensively bent or
thi
e
kinked.
t
sd
iva
o
r
rp
cu
♦ In the event of queries or uncertainties, contact your re‐
o
m
f
en
ng
sponsible high-voltage technician.

t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
The following high-voltage cables connect the high-voltage com‐ by c lksw
cted agen
ponents: Prote AG.
High-voltage wiring harness for hybrid battery - PX1- (direct volt‐

age 288 V)
♦ Routing of hybrid battery unit - AX1- to power and control
electronics for electric drive - JX1-
♦ Consists of high-voltage wire for hybrid battery, positive ter‐
minal - P1-
♦ And high-voltage wire for hybrid battery, negative terminal -
P2-
♦ Removing and installing high-voltage wiring harness for hybrid
battery - PX1- ⇒ page 40
High-voltage wiring harness for drive motor - PX2- (alternating
voltage up to 500 V)
♦ Routing from power and control electronics for electric drive -
JX1- to electric drive motor - V141-
♦ Consists of high-voltage wire 1 for drive motor - P4-
♦ and high-voltage wire 2 for drive motor - P5-
♦ and high-voltage wire 3 for drive motor - P6-
♦ Removing and installing high-voltage wiring harness for drive
motor - PX2- ⇒ page 43
High-voltage wire for electrical air conditioner compressor - P3-
(direct voltage 288 V)
♦ Routing from power and control electronics for electric drive -
JX1- to electrical air conditioner compressor - V470-
♦ Removing and installing high-voltage wire for electrical air
conditioner compressor - P3- ⇒ page 46
AG. Volkswagen AG d
agen oes
olksw not
byV gu
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Touareg 2010 ➤ h,oTouareg 2015 ➤
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t
Hybrid electrical
s au system - Edition 03.2016 ra
c
s
ce
e
nl
pt
5.5.2 Visual check of high-voltage cables
du
an
itte
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erm
ab
ility
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WARNING
wit
, is n
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hole
The high-voltage cables must be checked for the following:
spec
es, in part or in w
♦ Damage to the orange-coloured insulation
t to the co
♦ Dirty plug contacts
rrectness of i
♦ Cable deformation
l purpos
♦ Damage to and scratches on plug-in sockets and plates

of the high-voltage cable
nf
ercia
orm
m
5.5.3 Removing and installing high-voltage
atio
om
n in
wiring harness for hybrid battery - PX1-
or c
thi
te
sd
a
High-voltage wiring harness for hybrid battery - PX1- consists of

iv
o
r
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cu
the following lines:
o
m
f
en
ng
t.
yi
♦ High-voltage wire for hybrid battery, positive terminal - P1-
Co
Cop py
ht. rig
♦ High-voltage wire for hybrid battery, negative terminal - P2-
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
WARNING

Note

⇒ page 39 .


Removing:
WARNING


– Removing front and rear noise insulation ⇒ General body re‐
pairs, exterior; Rep. gr. 50 ; Noise insulation .
– Removing left underbody trim ⇒ General body repairs, exte‐
rior; Rep. gr. 50 ; Underbody trim .
– Loosen heat shield fasteners.
– Pull off both high-voltage cable retainers -arrow- from housing
rib of power and control electronics for electric drive - JX1- .
AG. Volkswagen AG d
– Unscrew 3 nuts (9 Nm) -1- for line trim. lksw
agen oes
not
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by
– Separate cable ties, open line trim -arrows- isedand remove high- ara
nte
voltage wiring harness for hybrid batteryut
ho-r
PX1- from line trim. eo
ra
s a c
– Remove line trim upwards out of engine
s compartment.
ce
le
un
pt
– Thread high-voltage wiring harness downwards out of engine

an
d
itte
y li
compartment.
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Open both corrugated tube clips -2-, separate cable tie

-arrow- and unclip high-voltage wiring harness.
Caution
If the fuel tank is more than one-quarter full, empty it ⇒ Rep.

gr. 20 ; Fuel tank; Emptying fuel tank .
– Remove lower protective cover and securing straps on left

side of tank ⇒ Rep. gr. 20 ; Fuel tank; Assembly overview -
fuel tank .
– Lower fuel tank ⇒ Rep. gr. 20 ; Fuel tank; Assembly overview
- fuel tank .
Note agen
AG. Volkswagen AG d
oes
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♦ Due to reasons of clarity,
rise the following illustrations show the ante
d ar
high-voltage cableutwith the fuel tank removed.
ho eo
ra
s a c
♦ The fuel tank does not have to be removed in order to remove
s
ce
le
and install the high-voltage cable.

un
pt
an
d
itte
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erm
ab
ility
ot p
– Open 2 expanding rivets -3- on line trim and pull off.
wit
is n
h re
– Release 2 expanding anchors -arrows- on front line trim from
ole,
holes in body.
spec
– Release 2 expanding anchors -arrows- on rear line trim from

t to the co
holes in body.
rrectness o
cial p
f inform
mer
atio
om
– Open both corrugated tube clips -2- and unclip high-voltage

n
c
i
or
wiring harness.
thi
te
sd
iva
– Removing luggage compartment floor ⇒ General body re‐

pr
cum
r
fo
pairs, interior; Rep. gr. 70 ; Load and luggage compartment

en
ng
t.
trim; Removing and installing load floor .
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Unscrew 3 nuts (4 Nm) -4- and remove line shield upwards

from studs -arrow 1-.
– Unclip line passage and guide downwards through body floor
-arrow 2-.
– Guide both connectors for hybrid battery unit - AX1- through
opening in body floor -arrow 3- and remove high-voltage wiring
harness for hybrid battery - PX1- downwards from vehicle.
Installing:
following:
For correct longitudinal positioning in vehicle, a plastic eyelet is

mounted on high-voltage wiring harness for hybrid battery - PX1-
in area of line shield in luggage compartment. On installation, this
plastic eyelet must be mounted on centre stud of line shield in
luggage compartment.
Note
♦ All cable ties which have been released or separated during

removal must be reattached in the same position on installa‐
tion.
♦ Tighten all threaded connections to specified torques.
♦ When installing line passage in luggage compartment floor,
make sure that it engages and seals securely.
AG. Volkswagen AG d
agen oes
olksw not
– Re-energising the high-voltage system and ddocumentation
by V gu
ara
⇒ page 7 . orise nte
eo
th
au ra
ss c
ce
le
un
wiring harness for drive motor - PX2- pt

an
d
itte
y li
rm
High-voltage wiring harness for drive motor - PX2- consists of the ab

pe
ility
ot
following lines: wit

, is n
h re
♦ High-voltage wire 1 for drive motor - P4-
hole
spec
es, in part or in w

t to the co

High-voltage wiring harness for drive motor - PX2- is connected
rrectness of i
to electric drive motor - V141- in a sealed connection box.

l purpos
WARNING
nform
ercia

m
a
com

ion in
r
te o
thi
s
iva
do
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rp
cum
fo
Note
en
ng
t.
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Cop py
t.
rig
gh ht
yri by
⇒ page 39 . cop Vo
by lksw
cted agen
Prote AG.
Removing:
WARNING

Note
To obtain access to connections of high-voltage wiring harness

for drive motor - PX2- on electric drive motor - V141- , electric
drive motor - V141- must be removed until gearbox is
lksseparated
wagen AG
from combustion engine together with electric AG. Vomotor.
gendrive does
wa
ks ol n ot g
yV ua
e db ran
– Removing electric drive motor ho
ris - V141- from combustion en‐ tee
gine together with electrics adrive
ut motor ⇒ 6-cyl. injection engine or
ac
(hybrid); Rep. gr. 10 ; Separating
s and assembling engine and
ce
e
electric drive motor with gearbox .

nl
pt
du
an
itte
y li
– Unscrew 4 securing bolts -1- and push cover of connection

erm
ab
box open -in direction of arrow-.

ility
ot p
wit
, is n
h re
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Unscrew 3 securing nuts -2- for high-voltage cables.

– Unscrew 3 securing bolts -3- for line retainers.
– Pull high-voltage cables -4- -5- and -6- upwards out of con‐
nection box in succession with slight rotational movements.
Installing:
following:
– Tighten 3 securing bolts -3- for line retainers

en AG. V
olkswato
ge8
n ANm.
G
wag does
olks not
byV gu
ara
ed nte
ris
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Tighten 3 securing nuts -2- for high-voltage cables to 20 Nm.

rrectness of i
Note
l purpos
Connection box cover seal must be renewed after opening.

nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– After renewing cover seal, push cover of connection box

closed in -direction of arrow- and tighten 4 securing bolts -1-
to 7 Nm.
⇒ page 7 .

wire for electrical air conditioner com‐
pressor - P3-
Note
♦ Observe general warning instructions

agen
AG. Vfor
olkswork
wagenon
AG dthe
o
high-
voltage system ⇒ page y1Volksw es n
ot g
b ua
ed ran
♦ Observe instructionsoris on handling high-voltage cables tee
⇒ page 39 . au
th or
ac
ss
ce
e
nl
Removing:
pt
du
an
itte
y li
erm
ab
WARNING
ility
ot p
wit
, is n
h re

hole
spec

es, in part or in w

t to the co

rrectness of i

l purpos
– Release high-voltage wire for electrical air conditioner com‐

pressor - P3- -1- at power and control electronics for electric
drive - JX1- and pull off.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
orise Touareg
nte 2010 ➤ , Touareg 2015 ➤
h eo
aut Hybrid electrical
ra
c
system - Edition 03.2016
ss
ce
e
nl
– Release high-voltage wire for electrical air conditioner com‐
pt
du
an
pressor - P3- at electrical air conditioner compressor - V470-
itte
y li
and pull off -arrow-.
erm
ab
ility
– Remove high-voltage wire for electrical air conditioner com‐ ot p
wit
, is n
pressor - P3- upwards out of vehicle.
h re
hole
spec
Installing:
es, in part or in w
t to the co
following:
rrectness of i
Note
l purpos
When connecting high-voltage cables, make sure that locking ring
nf
ercia
on connector has engaged securely.
orm
m
atio
m

o
n in
or c
⇒ page 7 .
thi
te
sd
iva
o
r
rp
cu
5.6 Electrical air conditioner compressor -
o
m
f
en
ng
t.
V470-
yi Co
Cop py
t. rig
gh ht
Electrical air conditioner compressor - V470- is installed on front yri
p by
o Vo
by c
left in engine compartment and ensures pleasant interior temper‐
lksw
cted agen
atures even when combustion engine is switched off, as it is
Prote AG.
operated electrically.
Removing and installing electrical air conditioner compressor -
V470- ⇒ Heating, air conditioner; Rep. gr. 87 .
5.7 Auxiliary hydraulic pump for gearbox oil

Auxiliary hydraulic pump for gearbox oil is bolted to gearbox be‐
neath gearbox casing, and occasionally supports mechanical oil
pump (e.g. during boost or when transmitting high torques at low
rpm).
Removing and installing auxiliary hydraulic pump for gearbox oil
⇒ Automatic gearbox 0C8 - 8-speed; Rep. gr. 37 .
5.7.1 Removing and installing control unit for

auxiliary hydraulic pump - J922-
Control unit for auxiliary hydraulic pump - J922- is installed in front
right wheel housing on bulkhead behind right front wheel.
Note
Observe general warning instructions for work on the high-voltage

system ⇒ page 1
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
s c
Removing: s
ce
e
nl
pt
du
– Switch off ignition and all electrical consumers, and remove
an
itte
y li
ignition key.
erm
ab
ility
ot p
– Removing front right wheel housing liner ⇒ General body re‐
wit
, is n
pairs, exterior; Rep. gr. 66 ; Wheel housing liners .
h re
hole
– Open cap -1-, pull black primary lock of bow and fold bow up‐
spec
wards.
es, in part or in w
t to the co
Note
rrectness of i
Connector is automatically ejected on folding bow up, and elec‐
l purpos
trical connection is separated.
nform
ercia
– Release and disconnect both connectors -2- and -3-.

m
at
om
ion
c
in t
or
his
ate
do
riv
– Unscrew both bolts -arrows- and remove control unit for aux‐
p
cum
or
iliary hydraulic pump - J922- -1- together with bracket out of

f
en
ng
t.
wheel housing.
yi Co
Cop py
ht. rig
Installing: rig ht
py by
co Vo
by lksw
Install in the reverse order of removal. When doing this, note the cted agen
Prote AG.
following:
– Tighten both securing bolts for bracket to body to 9 Nm.
5.8 Vacuum pump for brakes - V192-

vacuum pump for brakes - V192- is installed on front right of en‐
gine. It is operated electrically, and ensures the required braking
assistance when driving electrically with the combustion engine
switched off.
Removing and installing brake servo vacuum pump ⇒ Brake sys‐
tems; Rep. gr. 47 .
5.9 Electrical power steering pump - V466-

Electrical power steering pump - V466- is mounted on front left in
wheel housing, and ensures the required steering assistance
when driving electrically with the combustion engine switched off.

Removing and installing electrical power steering pump - V466-

⇒ Running gear, axles, steering; Rep. gr. 48 .
5.10 Pressure regulator for disengagement

clutch - N511-
Pressure regulator for disengagement clutch - N511- is installed
behind front left wheel housing liner. Driven electrically,Vitolactuates
kswagen
the disengagement clutch between the combustion agen engine and AG does
AG.
ksw
electric drive motor - V141- . by
Vol not
gu
a d ran
se
Removing and installing pressurethregulator
or
i
for disengagement tee
or
clutch - N511- ⇒ Automatic gearbox
ss au
0C8 - 8-speed; Rep. gr. 30 . ac
ce
le
5.11 Hybrid vehicle cooling system

un
pt
an
d
itte
y li
rm
ab
pe
ility
WARNING
ot
wit
, is n
h re
Cooling system is pressurised when engine is warm!
hole
spec
Danger of scalding due to hot steam and hot coolant.
es, in part or in w
t to the co
Decrease pressure by covering the cap of the coolant expan‐
sion tank with cloths and opening it carefully.
rrectness of i
l purpos
Additional cooling system components are installed in vehicles

with hybrid technology to cool hybrid components and ensure the
function of the cooling system even during purely electric driving
nform
ercia
with the combustion engine switched off.

m
a
com
t
♦ Coolant pump for high-temperature circuit - V467-
ion in
r
te o
♦ Coolant pump for low-temperature circuit - V468-
thi
s
iva
do
r
Removing and installing parts of cooling system ⇒ 6-cyl. injection

rp
cum
fo
engine (hybrid); Rep. gr. 19 ; Cooling system .

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

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Service

Service Department. Technical Information

All rights reserved.

Copyright © 2016 Volkswagen AG, Wolfsburg D3E8028E634

5.4 B+ line with fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

5.6 Electrical air conditioner compressor V470 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

5.9 Electrical power steering pump V466 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

5.10 Pressure regulator for disengagement clutch N511 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

1 General warning instructions for work

on the high-voltage system

(VRL008934; Edition 03.2016)

importer prior to starting any work.

⇒ Self-study programme No. 450 ; The high-voltage system in

Before work on the high-voltage system is started, a high-voltage

technician must de-energise ⇒ page 5 the high-voltage system

The following must be observed when the high-voltage system

1. General warning instructions for work on the high-voltage system 1

Handling high-voltage cables:

Work for which the high-voltage system has to be de-energised:

♦ All work on a hybrid vehicles must only be carried out by per‐

2 Rep. gr.93 - Electric drive systems

Conventional work in the vicinity of high-voltage components

Removing and installing hybrid engine cov‐ X EIP

Spark plugs X EIP

Left catalytic converter X EIP

Right catalytic converter X EIP

Exhaust system X EIP

Removing and installing gearbox X EIP

1. General warning instructions for work on the high-voltage system 3

Draining and replenishing fluids (coolant X EIP

Extracting, evacuating or adding refrigerant

⇒ Air conditioning systems with refrigerant

R134a; Rep. gr. 00 ; Working with the air

conditioning service station

Coolant pipe directly at the AC compressor X EIP

Air conditioning performance test (for X EIP

which is not directly on the AC compressor,

without opening the refrigerant circuit, e.g.

loosening and securing coolant pipe)

Work in the engine area if the cover plate X EIP

on the power and control electronics for

electric drive - JX1- has to be removed

Work in the engine area if the cover plate X High-voltage technician

and the high-voltage cables on the power

4 Rep. gr.93 - Electric drive systems

May carry out mechanical work

authorised by the high-voltage

HVT (high-voltage technician) Due to his qualifications, the

The HVT is also authorised to:

3. Determine that the system is

work on the high-voltage sys‐

5. Commission the vehicle

HVE (high-voltage expert) The HVE is a trained HVT with

additional qualification ena‐

bling him to decommission the

high-voltage system in the

event that the HVT cannot do

1. General warning instructions for work on the high-voltage system 5