Electric Drive Output And Control Electronics, Removing And Installing: Removing

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-- De-energize the high voltage system.

Use only "Guided Fault Finding " to de-energize the high voltage system using the Vehicle Diagnostic Tester.

CAUTION:

Extremely dangerous voltage

Electrocution can cause death or very serious personal injury.

Only a qualified technician (Audi high voltage technician) should de-energize the high voltage electrical system.
The high voltage system must be de-energized without any doubt. Use the Vehicle Diagnostic Tester and "Guided Fault Finding " to make sure the system is de-energized.
The Audi high voltage technician should make sure the high voltage system is disabled and that the system cannot turn on again using the Lock Service Disconnect T40262. The high voltage technician should keep the key and the High Voltage System Maintenance Connector -TW- in a safe place.
The Audi high voltage technician should place a sign on the vehicle.

NOTE:

De-energizing the high voltage system:

Connect the vehicle diagnostic tester

Press the Guided Fault Finding button.

Select the following menu items using the GO TO button.

Function/component selection

Body

Electrical Equipment

OBD-capable Systems

8C - Hybrid battery management -J840

8C - Hybrid battery management, functions

51 - De-energizing the high voltage system (Grp. 93)

-- Disconnect the 12 V Battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Remove the cowl panel trim. Refer to PLENUM CHAMBER COVER, REMOVING AND INSTALLING and remove the windshield wiper arm. Refer to WINDSHIELD WIPER ARMS, REMOVING AND INSTALLING .

-- Be careful not to damage the red warning label on the Electric Drive Power and Control Electronics -JX1-.

Fig 1: Identifying Electric Drive Power & Control Electronics -Jx1- Has A Red Warning Label

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-- Disconnect the cable -2- (B+ cable) from the power distribution panel -1- and move it to the side.

Fig 2: Disconnecting Cable -2- (B+ Cable) From Power Distribution Panel -1- & Move It To Side

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-- Remove the cap and the bolt -3-.

Tightening specification: 7.5 Nm

-- Loosen the power distribution panel -1- and move it toward the windshield with the cables still connected.

Fig 3: Identifying Power Distribution Panel

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-- Disconnect the connectors from the Electric Drive Power and Control Electronics -JX1-.

-- Remove the tower brace. Refer to TOWER BRACE, REMOVING AND INSTALLING .

Fig 4: Sliding Locking Mechanism -1- In -Direction Of Arrow

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-- Slide the locking mechanism -2- in direction of the -arrow- and then release and remove the Electrical A/C Compressor High Voltage Cable -P3- -3- using the High Voltage Release Tool T40258 starting from the right.

Fig 5: Disconnecting Electrical A/C Compressor High Voltage Cable -P3- -3-

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CAUTION:

Only pull the high voltage connectors in an upward direction. Never twist or tilt them. There is the danger the color coding could get damaged.

-- Slide the locking mechanism -1- in direction of -arrow-.

Fig 6: Sliding Locking Mechanism -1- In -Direction Of Arrow

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-- Release and remove the High Voltage Wiring Harness for High Voltage Battery -PX1- /Drive Motor High Voltage Wiring Harness -PX2- -4- starting from the left side using the High Voltage Release Tool T40258.

Fig 7: Disconnecting Electrical A/C Compressor High Voltage Cable -P3- -3-

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CAUTION:

Only pull the high voltage connectors in an upward direction. Never twist or tilt them. There is the danger the color coding could get damaged.

-- Remove both high voltage cable holders from the plenum chamber bulkhead.

Fig 8: Disconnecting Hybrid Battery High Voltage Wiring Harness -1-

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-- Place the High Voltage Wiring Harness for High Voltage Battery -PX1- -1- and the Drive Motor High Voltage Wiring Harness -PX2- /Electrical A/C Compressor High Voltage Cable -P3- -2- over a cover on the engine.

-- Remove the fresh air intake. Refer to FRESH AIR INTAKE, REMOVING AND INSTALLING .

-- Loosen the potential equalization cable -2- from the body -1-.

Fig 9: Potential Equalization Cable To Electric Drive Power And Control Electronics -JX1- -2-

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-- Remove both nuts (9 Nm) -arrows- from the plenum chamber bulkhead.

Fig 10: Identifying Nuts (9 Nm) -Arrows- From Plenum Chamber Bulkhead

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-- Remove the nut for the B+ cable (9 Nm) -1- and remove the B+ cable from the threaded connector.

Fig 11: Identifying Nut For B+ Cable (9 Nm) -1-

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-- Clamp off both coolant lines -2 and 3- with Hose Clamps - Up To 25mm 3094 -1-.

Fig 12: Clamping Off Both Coolant Lines -2 & 3- With 3094 -1

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-- Open and remove both hose couplings -2 and 3-.

NOTE:

Catch any leaking coolant in a suitable container.

-- Lift the Electric Drive Power and Control Electronics -JX1- -4- slightly upward out of the rubber bushings in the bracket.

-- Remove the ventilation hose.

-- Remove the Electric Drive Power and Control Electronics -JX1- upward and out of the vehicle.

Removing the bracket

-- Remove the bolts -2- (7 Nm) and then remove the front bracket -1- from the Electric Drive Power and Control Electronics -JX1-.

Fig 13: Identifying Bolts & Front Bracket

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-- Remove the bolts -2- (7 Nm) and then remove the front bracket -1- from the Electric Drive Power and Control Electronics -JX1-.

Fig 14: Identifying Bolts & Rear Bracket

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