Volkswagen Arteon 2021 Instruction manual

Workshop Manual
Arteon 2021 ➤,
Arteon Shooting Brake 2021 ➤,
Golf 2013 ➤, Golf 2017 ➤,
Golf Variant 2014 ➤, ID.3 2020 ➤,
ID.4 2021 ➤, Jetta 2011 ➤,
Passat 2015 ➤, Passat 2019 ➤,
Passat Variant 2015 ➤,
Passat Variant 2019 ➤, Tiguan 2021 ➤,
Touareg 2010 ➤, Touareg 2015 ➤,
Touareg 2018 ➤, e-Crafter 2019 ➤,
e-Golf 2014 ➤, e-Golf 2017 ➤,
e-up! 2014 ➤, e-up! 2017 ➤, e-up! 2020 ➤
High-voltage system - General information
Engine ID CUK
C
CUK
B
DGE
A
DGE
B
CNL
ACRJA EAG AEAZA EAB A
CGE
A
CGF
A
EBS
A
EBM
A
DFK
A
DGE
BEBJA EBJC EBJD
EBH
A
Edition 02.2021
Service
Service Department. Technical Information

List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
93 - Electric drive systems
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.
Service

Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety measures for working on vehicles with high-voltage system . . . . . . . . . . . . . . . . . . 1
1.2 Safety precautions when working in the vicinity of high-voltage components . . . . . . . . . . 2
1.3 Safety precautions when using testers and measuring instruments during a road test . . . . 2
1.4 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Routing and attachment of lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Rules for cleanliness when working on high-voltage system . . . . . . . . . . . . . . . . . . . . . . . . 3
93 - Electric drive systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1 Hazard classification for the high-voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Induction training/staff qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Identification features of high-voltage vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Working on high-voltage vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.1 Personal protective equipment (PPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2 Workshop procedure for high-voltage vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4 Quarantine arrangements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5 Assessing accident-damaged vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.2 Photographic documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6 High-voltage battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.1 Classifying high-voltage battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.2 High-voltage battery handling and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.3 Packaging high-voltage batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.4 Packaging critical high-voltage batteries with “Warning” status . . . . . . . . . . . . . . . . . . . . . . 54
6.5 Supplementary information on opening and bonding high-voltage batteries . . . . . . . . . . . . 77
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High-voltage system - General information - Edition 02.2021
Contents i

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High-voltage system - General information - Edition 02.2021
ii Contents

00 – Technical data
1 Safety information
(VRL015196; Edition 02.2021)
⇒ m1.1 easures for working on vehicles with high-voltage sys‐
tem”, page 1
⇒ p1.2 recautions when working in the vicinity of high-voltage
components”, page 2
⇒ p1.3 recautions when using testers and measuring instru‐
ments during a road test”, page 2
⇒ p1.4 recautions when working on the cooling system”, page
2
1.1 Safety measures for working on vehicles with high-voltage system
Danger to life from high voltage
The high-voltage system is under high voltage. Severe or fatal
injury from electric shock.
– People having electronic medical devices for life support or
health maintenance in or on their bodies are prohibited from
working on the high-voltage system. Such medical devices
include internal analgesic pumps, implanted defibrillators,
pacemakers, insulin pumps and hearing aids.
– High-voltage system must be de-energised by a suitably
qualified technician.
Risk of injury from unexpected engine/motor start
On electric and hybrid vehicles, it can easily be overlooked that
the vehicle is in “ready” mode. There is a risk of parts of the
body becoming trapped or drawn in.
– Switch off ignition.
– Always store the ignition key outside the vehicle.
Risk of damage to high-voltage cables
Improper handling of high-voltage cables or high-voltage con‐
nectors may result in damage to their insulation.
– Never support body weight on high-voltage cables or high-
voltage connectors.
– Never support any tools on high-voltage cables or high-volt‐
age connectors.
– Never kink or severely bend high-voltage cables.
– Always observe the coding when connecting high-voltage
connectors.
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High-voltage system - General information - Edition 02.2021
1. Safety information 1

1.2 Safety precautions when working in the vicinity of high-voltage compo‐
nents
Danger to life from high voltage
The high-voltage system is under high voltage. Damage to high-
voltage components can result in severe or fatal injury from
electric shock.
– Perform visual check of high-voltage components and high-
voltage cables.
– Never use cutting or forming tools, or any other sharp-edged
tools.
– Never use heat sources such as welding, brazing, soldering,
hot air or thermal bonding equipment.
1.3 Safety precautions when using testers and measuring instruments during
a road test
Risk of injury caused by unsecured testing and measuring in‐
struments
When the front passenger airbag is triggered in an accident, in‐
sufficiently secured testing and measuring instruments become
dangerous projectiles.
– Secure testing and measuring instruments on the rear seat.
or
– Have a second person operate the test and measuring
equipment on the rear seat.
1.4 Safety precautions when working on the cooling system
Danger of scalding by hot coolant
On a warm motor, the cooling system is under high pressure.
Danger of scalding by steam and hot coolant.
– Wear protective gloves.
– Wear protective goggles.
– Reduce excess pressure by covering cap of coolant expan‐
sion tank with cloths and opening it carefully.
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2 Rep. gr.00 - Technical data

2 Repair instructions
⇒ c2.1 orrosion”, page 3
⇒ a2.2 nd attachment of lines”, page 3
⇒ f2.3 or cleanliness when working on high-voltage system”,
page 3
2.1 Contact corrosion
Contact corrosion can occur if non-approved fasteners are used
on the vehicle (bolts, nuts, washers etc.).
For this reason, only connecting elements with a special surface
coating have been fitted.
Furthermore, rubber and plastic components as well as adhe‐
sives are made of non-conductive materials.
If there is any doubt about the suitability of parts, a general rule
is to use new parts ⇒ Electronic parts catalogue (ETKA).
Please note
♦ Only use genuine replacement parts which are tested and
compatible with aluminium.
♦ Only use Volkswagen Genuine Accessories.
♦ Damage resulting from contact corrosion is not covered by
the warranty.
2.2 Routing and attachment of lines
♦ Mark lines prior to removal to prevent them from being inter‐
changed and to ensure that they are fitted in their original
positions. This applies for fuel, hydraulic and vacuum lines
as well as lines for activated charcoal filter system and elec‐
trical wiring. Make sketches or take photographs if necessa‐
ry.
♦ To avoid damaging pipes and wires, ensure adequate clear‐
ance from all moving or hot components in the engine com‐
partment on account of the confined space.
2.3 Rules for cleanliness when working on
high-voltage system
When working on the high-voltage system, pay careful attention
to the following rules for cleanliness:
♦ Thoroughly clean all connections/inspection holes and cor‐
responding surrounding areas before disconnecting/opening
them.
♦ Place removed parts onto a clean surface and cover. Use
lint-free cloths only.
♦ Carefully cover opened components or seal them if repairs
cannot be carried out immediately.
♦ Install only clean components.
♦ Remove packing from replacement parts immediately prior
to installation and not before.
♦ Do not use parts that have been kept unpackaged (for ex‐
ample in toolboxes).
♦ Transportation and protective packaging and sealing caps
must be removed only immediately before fitting.
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2. Repair instructions 3

♦ If system is open, do not work with compressed air. Do not
move the vehicle.
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High-voltage system - General information - Edition 02.2021
4 Rep. gr.00 - Technical data

93 – Electric drive systems
1 Hazard classification for the high-
voltage system
⇒ i1.1 nformation”, page 5
⇒ t1.2 raining/staff qualifications”, page 6
1.1 General information
DANGER
The vehicle’s high-voltage system and the high-voltage bat‐
tery are dangerous and can cause burns or other injuries and
even lead to a fatal electric shock.
– Any work on the high-voltage system, or on systems which
could be indirectly affected by it, may only be carried out
by properly trained and qualified expert personnel.
– In the event of queries or uncertainties regarding the terms
"high-voltage technician" or "high-voltage expert", or those
concerning the high-voltage system, the responsible im‐
porter must be contacted prior to the start of any work.
– Any repair work must be performed in accordance with ap‐
plicable laws and regulations, the recognised engineering
practices, any relevant accident prevention regulations (in
Germany, including but not limited to the Information of
the German Social Accident Insurance (DGUV) 200-005 –
Qualification training for work on vehicles with high-voltage
systems), as well as this workshop manual.
Before work on the high-voltage system is started, a high-volt‐
age technician must de-energise the high-voltage system.
The types of work for which the high-voltage system has to
be de-energised are indicated in the list entitled “Work on the
high-voltage system” in the vehicle-specific manuals.
Work for which the high-voltage system has to be de-energised:
♦ Only the HVT is authorised to certify that the high-voltage
system has been de-energised.
♦ All work measures to be carried out on a high-voltage sys‐
tem may only be carried out by a person qualified to at least
the level of electrically instructed person (EIP).
♦ Regardless of the work to be performed, visually inspect
high-voltage components in the work area.
♦ High-voltage cables must not be overly 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.
♦ Any work involving metal-removing, deforming and sharp-
edged tools or heat sources such as welding, soldering, hot
air, thermal bonding and infrared drying in the vicinity of
high-voltage components and cables is prohibited. In this
case the high-voltage system must be de-energised and the
respective component removed or sufficiently protected.
♦ All listed work refers to the removal and installation or the
renewal of the individual components.
♦ For reasons of safety, the following activities must not be
carried out during charging.
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High-voltage system - General information - Edition 02.2021
1. Hazard classification for the high-voltage system 5

♦ Activities that prolong the charging process.
♦ Activities for which the vehicle must be de-energised and
made safe in accordance with the ensuing hazard rating.
♦ Activities during which the vehicle is moved and cables and
connectors could be placed under strain (pulled).
♦ Activities during which the connected charging cable could
present a danger of tripping and injury.
♦ Activities during which the charging cable could block work
paths and emergency exit routes.
♦ Activities on the 12V battery.
♦ For regular maintenance work, the high-voltage system does
not have to be de-energised.
Note
♦ The hazard ratings can vary from one vehicle to the next.
♦ Refer to the relevant workshop manual for vehicle-specific
information.
1.2 Induction training/staff qualifications
Qualification Volks‐
wagen
DGUV-I 200-005 Scenario
EIP (person with
electrical training)
Chapter 2 Induction training
for non-electrical
work (< 60 VDC)
HVT (high-voltage
technician)
Chapter 3.1 b Working on inher‐
ently safe HV pro‐
duction vehicles
♦ Vehicles are de-
energised exclu‐
sively with certif‐
ication.
♦ Complete con‐
tact protection in
place.
HVE level 1 (high-
voltage expert)
Chapter 3.2 b Working on not in‐
herently safe HV
production vehicles
♦ Vehicles are al‐
so de-energised
without certifica‐
tion or there is
no complete
contact protec‐
tion in place,
e.g. in the event
of an accident.
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High-voltage system - General information - Edition 02.2021
6 Rep. gr.93 - Electric drive systems

Qualification Volks‐
wagen
DGUV-I 200-005 Scenario
HVE level 2 (high-
voltage expert)
Chapter 3.3 Working on live ac‐
cumulators
♦ Working on
parts supplied
with voltage, in‐
evitably with no
contact protec‐
tion, for fault
finding, compo‐
nent replace‐
ment, etc.
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High-voltage system - General information - Edition 02.2021
1. Hazard classification for the high-voltage system 7

2 Identification features of high-volt‐
age vehicles
High-voltage vehicles can be identified by means of the follow‐
ing characteristics:
Model-specific badges on exterior at front and rear and on side
Possible fitting locations of charging socket
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8 Rep. gr.93 - Electric drive systems

1 - Next to badge
2 - After badge
3 - Behind tank flap
Hazard warning signs/notices in engine and interior
Front left of lock carrier
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High-voltage system - General information - Edition 02.2021
2. Identification features of high-voltage vehicles 9

By power and control electronics for electric drive -JX1- in en‐
gine compartment
Rescue information, in engine compartment on plenum cham‐
ber bulkhead
Rescue information, in vehicle interior on fuse carrier under
dash panel
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High-voltage system - General information - Edition 02.2021
10 Rep. gr.93 - Electric drive systems

Model-specific badges in engine compartment on engine com‐
partment cover
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High-voltage system - General information - Edition 02.2021
2. Identification features of high-voltage vehicles 11

Orange-coloured high-voltage cables, e.g. in engine compart‐
ment and on underbody
Note
♦ The electrical wiring of the high-voltage system differs signif‐
icantly from the wiring of the remaining electrical system and
the 12-V system.
♦ Due to the high voltage and current rating the high-voltage
cables have a significantly larger cross section and are con‐
nected via specific contacts. As opposed to the 12-V electri‐
cal system the high-voltage system is not grounded on the
body.
♦ In order to clearly signify the risk resulting from the high
voltage, all cables of the high-voltage system are coloured in
orange.
♦ The high-voltage cables are protected against reverse con‐
nection. They cannot be connected incorrectly since they are
colour-coded and mechanically coded.
♦ Aside from being colour-coded, the components also have
warning labels.
Special displays in dash panel insert
1 - Charge
2 - Ready
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12 Rep. gr.93 - Electric drive systems

LED design modules in bumper, e.g. on e-up! and e-Golf
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High-voltage system - General information - Edition 02.2021
2. Identification features of high-voltage vehicles 13

3 Working on high-voltage vehicles
⇒ p3.1 rotective equipment (PPE)”, page 14
⇒ p3.2 rocedure for high-voltage vehicles”, page 14
3.1 Personal protective equipment (PPE)
Note
Application scenarios can be gleaned from the vehicle-specific
workshop manual.
According to the ⇒ Electronic parts catalogue (ETKA), the fol‐
lowing items of protective clothing and equipment are available:
♦ Safety shoes
♦ Coat for high-voltage experts
♦ Helmet for high-voltage experts
♦ Visor for high-voltage experts
♦ Balaclava for high-voltage experts
♦ Gloves for high-voltage experts
♦ Glove liners for high-voltage experts
♦ Jacket for high-voltage experts
♦ Trousers for high-voltage experts
♦ Protective coveralls for high-voltage experts
For sizes and order numbers, see ⇒ Electronic parts catalogue
(ETKA).
3.2 Workshop procedure for high-voltage
vehicles
⇒ p3.2.1 rocedure for EIPs”, page 14
⇒ p3.2.2 rocedure for HVT”, page 15
⇒ p3.2.3 rocedure for HVE”, page 16
⇒ d3.2.4 e-energisation”, page 16
3.2.1 Workshop procedure for EIPs
Measure
1 Smoke development? Fire? Fluid ingress in high-voltage
battery? High-voltage battery damaged or modified?
If yes:
♦ If possible, park vehicle in safe area according to quar‐
antine arrangements ⇒ page 17
♦ Appoint HVT and transfer responsibility ⇒ page 15
If no:
♦ Continue with 2
2 Mark vehicle as “high-voltage vehicle”
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14 Rep. gr.93 - Electric drive systems

Measure
3 Airbag or belt tensioner triggered?
If yes:
♦ Park vehicle in safe area according to quarantine ar‐
rangements ⇒ page 17
♦ Appoint HVT and transfer responsibility ⇒ page 15
If no:
♦ Continue with 4
4 Switch on ignition
5 HV warning lamp on in dash panel insert?
If yes:
♦ Appoint HVT and transfer responsibility ⇒ page 15
If no:
♦ Continue with 6
6 System de-energisation necessary?
If yes:
♦ Appoint HVT and transfer responsibility ⇒ page 15
If no:
♦ Continue with 7
7 Switch off ignition
8 Outcome of visual inspection of HV components and ca‐
bles in working area OK?
If no:
♦ Appoint HVT and transfer responsibility ⇒ page 15
If yes:
♦ Continue with 9
9 Maintenance and repair of conventional components ac‐
cording to workshop manual
Replacement of HV components / repair in vicinity of HV
components according to workshop manual
After replacement, bring high-voltage system back into op‐
eration:
♦ Appoint HVT and transfer responsibility ⇒ page 15
3.2.2 Workshop procedure for HVT
With product technician
Measure
1 Visual inspection and diagnosis on vehicle, high-voltage
system/high-voltage battery
2 High-voltage battery classification necessary?
If yes:
♦ High-voltage battery classification ⇒ page 26
If no:
♦ Certified de-energisation ⇒ page 16
3 High-voltage battery quarantine necessary?
If yes:
♦ Park vehicle in safe area according to quarantine ar‐
rangements ⇒ page 17
♦ Appoint HVE and transfer responsibility ⇒ page 16
If no:
♦ Certified de-energisation ⇒ page 16
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3. Working on high-voltage vehicles 15

Measure
4 Visual inspection of HV components and cables in working
area
5 HV component repair?
If no:
♦ Appoint EIP, responsibility remains with HVT ⇒ page 14
If yes:
♦ Continue with 6
6 HV component repair – is it de-energised or protected to
prevent contact?
If no:
♦ Appoint HVE and transfer responsibility ⇒ page 16
If yes:
♦ Continue with 7
7 Remove HV component according to workshop manual
and repair
8 Install high-voltage component in vehicle
9 Re-energising high-voltage system
3.2.3 Workshop procedure for HVE
Measure
1 High-voltage battery classification ⇒ page 26
2 Certified de-energisation ⇒ page 16
3 Switch off high-voltage system and make safe
4 If necessary, remove high-voltage battery, pack and pre‐
pare for transport
5 Remove HV component and repair according to workshop
manual
♦ Appoint HVT and transfer responsibility ⇒ page 15
3.2.4 Certified de-energisation
Procedure for HVT Procedure for HVE
1 De-energise system De-energise system
2 Secure to prevent reacti‐
vation
Secure to prevent reacti‐
vation
3 Confirmed de-energised?
If no:
♦ Appoint HVE and
transfer responsibility
⇒ page 16
If yes:
♦ Continue with 4 ⇒
page 15
Confirmed de-energised?
If no:
♦ Switch off high-volt‐
age system and make
safe ⇒ page 16
If yes:
♦ Continue with 4 ⇒
page 16
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High-voltage system - General information - Edition 02.2021
16 Rep. gr.93 - Electric drive systems