Licensed by VOLKSWAGEN AG

Opening high-voltage battery 1 -AX2-

  DANGER

Danger to life from voltages AC ≥ 30 V and DC ≥ 60 V.

Severe or fatal injuries from electric shock/electric arc.

– Wear arc flash protective clothing (at least APC 2, minimum 318 kJ).

– Wear helmet with visor (at least APC 2, minimum 318 kJ).

– Wear insulating protective gloves (at least APC 2, minimum 318 kJ) with glove liners.

– Wear safety shoes.

Special tools and workshop equipment required

♦  Electric cutter -V.A.G 1561A-  

♦  Blade, 27 mm -VAS 6900/1-

♦  High-voltage tool set -VAS 6762-  

♦  Repair set for high-voltage battery -VAS 6900-  

♦  High-voltage tool set -VAS 6883A-
Commercially available vacuum cleaner with
♦ 
plastic nozzle
Procedure

  DANGER

Danger to life due to high voltage.

Severe or fatal injury from electric shock.

– The high-voltage system must be de-

energised by a suitably qualified
technician.

  DANGER

Danger to life from voltages AC ≥ 30 V and

DC ≥ 60 V.

Severe or fatal injuries from electric

shock/electric arc.

– The following work must be supervised

by an additional specialist with
appropriate qualification (at least a
mechanic qualified as EIP).

– The second person may support the HVE

if required by providing assistance
within the framework of his/her
qualification.

– Observe country-specific laws and

regulations.

– Remove high-voltage battery 1 -AX2-

→ Chapter.

– Carry out leakage test high-voltage battery 1

-AX2- → Chapter.

– Remove DC connector mounting if there is

one → Chapter.

– Unscrew bolts -2- from connector mounting  

-1-.

– Unscrew nuts -2- from earthing strip -1- and  

from lower shell of high-voltage battery.

– Remove earth strap -1-.

– Unscrew bolts -2- from upper part of battery  
housing -1-.

– Score tabs -2- of upper part of battery

housing and break off.

– Unscrew bolts -2- from rear left and rear right  

brackets -1-.

– Remove rear left and rear right brackets -1-.

– Fold shielding for upper part of battery

housing upwards.
 – Using a suitable plastic wedge, remove any
wax from area between upper and lower part
of battery housing.

– Remove major wax residue in area of

adhesive bead using lint-free cloth.

– Fit blade, 27 mm -VAS 6900/1- to electric

cutter -V.A.G 1561A-.

– Set speed setting on electric cutter -V.A.G

1561A- to 4.

  CAUTION

Risk of injury from sharp edges, increased

noise and dirt particles.

– Wear protective gloves, safety goggles

and ear protection.

  Note
Hold the electric cutter -V.A.G 1561A- with both
♦ 
hands at its rear end.
Always guide electric cutter -V.A.G 1561A- along
♦ 
upper part of battery housing.
Adhere to the prescribed sequence for cutting
♦  through the bonded seam to prevent the upper
part of the battery housing from shifting.
There are spacers positioned at regular intervals
♦ 
along the upper part of the battery housing.
Overview of spacers on upper part of battery  
housing

1 -  Spacers in bonded seam

– Pull electric cutter -V.A.G 1561A- in area of  

spacers out of bonded seam -arrows-.
 – After passing the spacers, insert electric
cutter -V.A.G 1561A- deeper into bonded
seam again -arrows-.

  NOTICE

Risk of damage to battery modules

– Insert wedges only at the positions

indicated. Otherwise the soft exterior
shell of the battery modules will be
damaged by the tips of the wedges.

– Have a second mechanic insert the wedges -  

VAS 6900/5- at the indicated positions -
arrows- while cutting.

– Cut through bonded seam -1- in direction of

arrow -A-.

– Cut through bonded seam -2- in direction of

arrow -B-.

– Cut through bonded seam -3- in direction of  

arrow -C-.
 – With the aid of a second mechanic, hold  
upper part of battery housing at front and rear
-arrows-.

– Lift upper part of battery housing in direction

of -arrow A-.

– Remove upper part of battery housing in

direction of -arrow B-, and guide it over high-
voltage network wiring junction.

Voltage and insulation measurement

– Perform voltage and insulation measurement

→ Chapter.

– For all further works cover the high-voltage

battery at those positions at which no work is
done.

– For further work in the high-voltage battery 1

-AX2- open electrical circuit → Chapter.