Removal and Replacement

Hybrid Battery High Voltage Wiring Harness (PX1)

Special tools, testers and auxiliary items required

• Torque Wrench (V.A.G 1331)

The following wires make up the hybrid battery high voltage wiring harness:






• Hybrid battery high voltage cable, positive terminal (P1)

• Hybrid battery high voltage cable, negative terminal (P2)

Read and follow the High Voltage Electrical System General Warnings. Refer to => [ High Voltage Electrical System General Warnings ] Service Precautions.

• Pay attention to the tips for handling high voltage cables. Refer to => [ High Voltage Cables ] Description and Operation.

Removal

Hybrid vehicle high voltage in the high voltage system. Danger of electrocution! The following procedure requires working on the high voltage system. Disable the high voltage system now. Refer to => [ High Voltage System, Disabling ] High Voltage System, Disabling.

- Disable the high voltage system. Refer to => [ High Voltage System, Disabling ] High Voltage System, Disabling.

- Remove the front and rear noise insulation.

- Remove the left underbody panel.

- Loosen the heat shield.

- Remove both high voltage cable holders - arrow - from the Electric drive power and control electronics (JX1) housing.






- Remove the 3 nuts (9 Nm) - 1 - from the harness protector.






- Cut the cable tie, open the harness protector - arrows - and remove the hybrid battery high voltage wiring harness from the harness protector.

- Remove the harness protector from the engine compartment.

- Guide the high voltage cable set downward and out of the engine compartment.

- Open both clips - 2 -, cut the cable tie - arrow - and unclip the high voltage cable set.






Drain the fuel tank if it is more than 1/4 full.

- Remove the lower protective cover and the mounting straps on the left side of the fuel tank.

• The following illustrations show the high voltage cable with the fuel tank removed.

• It is not necessary to remove the fuel tank in order to remove and install the high voltage cable.

- Open and remove the 2 expanding rivets - 3 - from the harness protector.






- Remove the 2 expanding anchors - arrows - from the holes in the body on the front harness protector.

- Remove the 2 expanding anchors - arrows - from the holes in the body on the rear harness protector.

- Open both clips - 2 - and remove the high voltage cable set.






- Remove the luggage compartment floor..

- Remove the 3 nuts (4 Nm) - 4 - and remove the harness protector from the threaded pins - arrow 1 -.






- Unclip the wiring guide and remove it downward through the body floor panel - arrow 2 -.

- Guide both hybrid battery unit connectors through the opening in the body floor panel - arrow 3 - and remove the hybrid battery high voltage wiring harness downward from the vehicle.

Installation

Install in reverse order of removal. Note the following:

The hybrid battery high voltage wiring harness has a plastic loop near the harness protector inside the luggage compartment, which can be used to correctly position the length. This plastic loop must be mounted on the center thread pin on the harness protector inside the luggage compartment during installation.






• All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.

• Tighten all threaded connections to the tightening specifications.

• Make sure the wiring guide inside the luggage compartment floor is installed securely and sealed.

- Restart the high voltage system and complete the required documentation. Refer to => [ High Voltage System, Enabling ] High Voltage System, Enabling.