Electric Drive Power and Control Electronics
Electric Drive Power and Control Electronics
Special tools, testers and auxiliary items required
• Torque Wrench (V.A.G 1331)
• Hose Clamps up to 25 mm (3094)
Read and follow the High Voltage Electrical System General Warnings. Refer to => [ High Voltage Electrical System General Warnings ] Service Precautions.
The new electric drive power and control electronics must be protected before installing on the flange plates if the electric drive power and control electronics (JX1) is being replaced. Refer to => [ Electric Drive Power and Control Electronics, Protecting ] Electric Drive Power and Control Electronics, Protecting.
• 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.
- Disconnect the 12 volt battery under the driver seat.
- Disconnect and remove the Electrical A/C compressor high voltage cable (P3) - 1 -.
- Disconnect the pilot line connector - 1 - and then disconnect and remove the 3 high voltage cables - 2 - - 3 - and - 4 -, one after the other.
• Start with the connector at the very top.
• Press the connector into the mount, pull the locking ring and disconnect the connector.
• Open the securing clip to the side and disconnect the next connector in the same way.
- Remove both high voltage cable holders - arrow - from the Electric drive power and control electronics (JX1) housing.
- Pull the locking mechanism on the connector - 5 - in - direction of arrow - and remove the connector from the electric drive power and control electronics.
• The connector - 5 - ejects automatically from the electric drive power and control electronics when the locking mechanism is pulled.
- Open the cap on the jump start point and remove the B+ cable nut (20 Nm) - 6 -.
- Remove the B+ cable underneath from the threaded connector.
- Remove the nut (20 Nm) - 7 - and remove the ground cable.
- Clamp off booth coolant hoses - 2 - with (3094).
• Catch the escaping coolant in a suitable container.
- Open and remove both hose couplings - arrows -.
- Remove both nuts (10 Nm) - 8 - and lift the electric drive power and control electronics from the rubber bushings inside the bracket just until the nut for the B+ cable is accessible.
- Remove the nut for the B+ cable (20 Nm) - 9 - and remove the B+ cable from the threaded connector.
- Remove the bolt (9 Nm) - 10 - and remove the potential equalization cable (ground cable).
- Remove the electric drive power and control electronics from the vehicle.
Installation
The new electric drive power and control electronics must be protected before installing on the flange plates if the electric drive power and control electronics is being replaced. Refer to => [ Electric Drive Power and Control Electronics, Protecting ] Electric Drive Power and Control Electronics, Protecting.
Install in reverse order of removal. Note the following:
• Check the contact surfaces on the potential equalization cable before installation.
• The contact surfaces must be clean. There must be no rust or grease on them.
• If necessary, clean the contact surfaces using the contact surface cleaning set (VAS 6410).
- Tighten all threaded connections to the tightening specifications.
• Connecting and securing the high voltage cables is possible only in the specified sequence.
• Connect and secure the connector for the high voltage cables in reverse order of removal.
- Connect the 12 volt battery under the driver seat.
- Restart the high voltage system and complete the required documentation. Refer to => [ High Voltage System, Enabling ] High Voltage System, Enabling.
- Bleed the low temperature coolant circuit.
If the electric drive power and control electronics is replaced, complete the following adaptations in the order listed:
1. Adapt the electric drive power and control electronics to the immobilizer.
• Body
• Electrical Equipment
• OBD capable systems
• 51 - Electric drive | J841
• 51 - Electric drive, functions
• Adapt electric drive power and control electronics to immobilizer
2. Code the electric drive power and control electronics.
• Body
• Electrical Equipment
• OBD capable systems
• 51 - Electric drive | J841
• 51 - Electric drive, functions
• 51 - Code control module
3. Calibrate the Electro-drive drive motor (V141).
• Body
• Electrical Equipment
• OBD capable systems
• 51 - Electric drive | J841
• 51 - Electric drive, functions
• 51 - Calibrate electro-drive drive motor
• The Electro-drive drive motor (V141) will be calibrated automatically at the end of GFF once all DTC entries are erased.
The "calibration" must be performed each time the DTC memory for the electric drive power and control electronics, battery regulation control module, engine or transmission is "erased". Otherwise the vehicle will only start after the second try.