Volkswagen Golf / Golf GTI / Golf Variant. Manual - part 83

 

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Volkswagen Golf / Golf GTI / Golf Variant. Manual - part 83

 

 

WARNING

Read and follow the information below when de-energizing the

high voltage system to reduce the risk of fatal injury.

♦ Only a qualified technician (high voltage technician)

should disable the high voltage system.

♦ The high voltage technician (HVT) makes sure the system

is de-energized and cannot be re-energized again.

♦ The high voltage technician assures that the system can‐

not be re-energized again by safely storing the key, the

High Voltage System Maintenance Connector - TW- and

the pilot line connector.

♦ The high voltage technician (HVT) puts a sign on the ve‐

hicle saying the voltage is disabled.

♦ Only hybrid electrically instructed persons may perform all

work (maintenance, tire changing, Convenience System)

on vehicles with a high voltage system. If there is any un‐

certainty, discuss with the responsible high voltage tech‐

nician.

♦ A high voltage technician must disable the system before

any work can be performed on the high voltage electrical

system or any other service work to the body.

♦ Only a high voltage expert (HVE) may perform repairs to

the vehicle if it is not possible to disable the high voltage

electrical system.

♦ Individuals with electrical medical equipment must not

work on vehicles with a high voltage electrical system. Ex‐

amples of electrical medical equipment include pain med‐

ication pumps, implanted heart defibrillators, pacemakers,

insulin pumps and hearing aids.

WARNING

Working with high voltage cables:

♦ Do not support yourself or lay tools on the high voltage

cables or on any of its components.

♦ When working near high voltage components and high

voltage cables, do not use tools that generate heat, that

have sharp edges or that are used for cutting or shaping,

such as welding, soldering, hot air or thermal adhesive

equipment.

♦ When working near high voltage components and high

voltage cables, do not use tools that generate heat such

as welding, soldering, hot air or thermal adhesive equip‐

ment.

♦ Do not excessively bend or flex high voltage cables.
♦ Always contact a high voltage technician (HVT) if there are

questions or if something is not clearly understood.

Check the contact surfaces on the potential equalization cables

before installation.
The contact surfaces must be clean. There must be no rust or

grease on them.
Follow all guidelines for clean working conditions.

GTI 2014 ➤

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1. General Information     

5

Observe the following precautions when working on the high volt‐

age system:
♦ Only technicians who are trained in electrical systems should

work on high voltage system (hybrid) vehicles.

♦ When working on a hybrid vehicle, always inspect the hybrid

components in the area where the work is being performed.

♦ Do not excessively bend or flex high voltage cables.
♦ Always contact a high voltage technician or a high voltage ex‐

pert specializing in electrical systems if something is not un‐

derstood or if there are questions.

♦ All the work described below is referencing removing, instal‐

ling and replacing the individual components.

Working on the High Voltage System

During the Following Work Minimum Qualifications, refer to

⇒ page 9

De-energizing the high volt‐

age system

High voltage technician

Re-energizing the high volt‐

age system

High voltage technician

When Working on the Following Compo‐

nents

The High Voltage System Must Be

De-energized By A High Voltage

Technician Prior To Beginning the

Work?

Minimum Qualifications,

refer to 

⇒ page 9

Yes

No

Electro-Drive Drive Motor - V141-

X

Technician trained in

electrical systems

Electric Drive Power and Control Electron‐

ics - JX1-

X

 

Technician trained in

electrical systems

High Voltage System Maintenance Con‐

nector - TW-

 

X

Technician trained in

electrical systems

Electric A/C Compressor High Voltage Ca‐

ble - P3-

X

 

Technician trained in

electrical systems

Drive Motor High Voltage Wiring Harness -

PX2-

X

 

Technician trained in

electrical systems

High Voltage Wiring Harness For High Volt‐

age Battery - PX1-

X

Technician trained in

electrical systems

Hybrid Battery Unit - AX1- , Removing and

Installing

X

 

Technician trained in

electrical systems

Charging the Hybrid-Battery - A38- with

High Voltage Battery Charger - VAS6565-

X

 

High voltage technician

Battery Regulation Control Module - J840-

X

 

High voltage technician

Battery Fan 1 - V457-

 

X

Technician trained in

electrical systems

Air guides next to the Hybrid Battery Unit -

AX1-

 

X

Technician trained in

electrical systems

Air guides under the Hybrid Battery Unit -

AX1-

X

 

Technician trained in

electrical systems

Electrical A/C Compressor - V470-

X

 

Technician trained in

electrical systems

Drive Motor Temperature Sensor - G712-

X

 

Technician trained in

electrical systems

Drive Motor Rotor Position Sensor 1 -

G713-

X

 

Technician trained in

electrical systems

GTI 2014 ➤

Generic Scan Tool - Edition 04.2015

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     Rep. Gr. ST - Generic Scan Tool

When Working on the Following Compo‐

nents

The High Voltage System Must Be

De-energized By A High Voltage

Technician Prior To Beginning the

Work?

Minimum Qualifications,

refer to 

⇒ page 9

Yes

No

Three-Phrase Current Drive - VX54-

X

 

Technician trained in

electrical systems

Electrical Drive Button - E656-

 

X

Technician trained in

electrical systems

Fuse Electrical A/C Compressor - V470- in

Electric Drive Power and Control Electron‐

ics - JX1-

X

 

Technician trained in

electrical systems

Potential equalization cable (Ground [GND]

wires)

X

Technician trained in

electrical systems

Working on the coolant circuit for the high

voltage components

X

 

Technician trained in

electrical systems

Measuring insulation resistance

X

 

High voltage technician

Working when the system is de-energized

and the ignition is on

X

Technician trained in

electrical systems

Conventional Work Near High Voltage Components

When Working on the Following Compo‐

nents

The High Voltage System Must Be

De-energized By A High Voltage

Technician Prior To Beginning the

Work?

Minimum Qualifications,

refer to 

⇒ page 9

Yes

No

Spark plugs

 

X

Technician trained in

electrical systems

Catalytic converter

X

Technician trained in

electrical systems

Exhaust System

 

X

Technician trained in

electrical systems

Coolant reservoir

 

X

Technician trained in

electrical systems

Front brakes

 

X

Technician trained in

electrical systems

Decoupler

X

 

Technician trained in

electrical systems

Internal Combustion Engine, Removing

and Installing

X

Technician trained in

electrical systems

Transmission without Electro-Drive Drive

Motor - V141- , Removing and Installing

X

Technician trained in

electrical systems

Fuel Tank

X

Technician trained in

electrical systems

Front subframe

X

Technician trained in

electrical systems

Rear axle

 

X

Technician trained in

electrical systems

Underbody Trim

X

Technician trained in

electrical systems

Welding (Cover high voltage components

with non-combustible materials and then

perform a visual inspection)

X

Technician trained in

electrical systems

Vehicle Body Work (Using an Alignment

Bench)

X

Technician trained in

electrical systems

GTI 2014 ➤

Generic Scan Tool - Edition 04.2015

1. General Information     

7

When Working on the Following Compo‐

nents

The High Voltage System Must Be

De-energized By A High Voltage

Technician Prior To Beginning the

Work?

Minimum Qualifications,

refer to 

⇒ page 9

Yes

No

When working near high voltage compo‐

nents and high voltage cables, do not use

tools that generate heat, that have sharp

edges or that are used for cutting or shap‐

ing, such as welding, soldering, hot air or

thermal adhesive equipment (Cover high

voltage components with non-combustible

materials and then perform a visual inspec‐

tion).

X

 

Technician trained in

electrical systems

Left Front Headlamp - MX1- , Removing

and Installing

 

X

Technician trained in

electrical systems

Right Front Headlamp - MX2- , Removing

and Installing

 

X

Technician trained in

electrical systems

Headlamp Bulbs, Removing and Installing

X

Technician trained in

electrical systems

General Work

When Working On the Following Compo‐

nents

The High Voltage System Must Be

De-energized By A High Voltage

Technician Prior To Beginning the

Work?

Minimum Qualifications,

refer to 

⇒ page 9

Yes

No

12V Battery, removing and installing

 

X

Technician trained in

electrical systems

General controls modules and electric com‐

ponents, 12V, removing and installing

 

X

Technician trained in

electrical systems

Fluids, coolant and fluids, draining and fill‐

ing

 

X

Technician trained in

electrical systems

Refrigerant extracting, evacuating, filling

X

Technician trained in

electrical systems

Refrigerant pipes directly to the A/C com‐

pressor

X

Technician trained in

electrical systems

A/C System, flushing

 

X

Technician trained in

electrical systems

Peripheral refrigerant line (work that does

not involve the A/C compressor directly

without opening the refrigerant circuit, for

example, loosening and tightening the re‐

frigerant line)

 

X

Technician trained in

electrical systems

Work with the engine raised, engine mount

X

Technician trained in

electrical systems

Emissions test

 

X

Technician trained in

electrical systems

Follow the instructions in the paint hand‐

book when performing any paint/drying

work

 

X

Technician trained in

electrical systems

GTI 2014 ➤

Generic Scan Tool - Edition 04.2015

8

     Rep. Gr. ST - Generic Scan Tool

 

 

 

 

 

 

 

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