Electricdrivesystems -> 6.3.1 Packaging high-voltage battery, e-up! for Your Volkswagen Crafter Van Second Generation (2017-2025)

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High-voltage system - General information - Edition 02.2021  
Replacement of lithium-ion high-voltage batteries - no measures  
necessary for high-voltage battery  
♦ The lithium-ion high-voltage battery can be stored in its origi‐  
nal packaging.  
♦ The removed lithium-ion high-voltage battery is placed in the  
original packaging and sent back in this way.  
♦ For transport within the workshop, suitable aids are required  
due to the heavy weight.  
Replacement of lithium-ion high-voltage batteries - measures  
necessary for high-voltage battery  
1 Classification of lithium-ion high-voltage battery with aid of  
test program according to following criteria  
♦ Thermal irregularities of lithium-ion high-voltage battery  
♦ Visible damage to lithium-ion high-voltage battery  
♦ Functional irregularities of lithium-ion high-voltage battery  
2 Storage of lithium-ion high-voltage batteries if one of the  
points from 1 applies.  
♦ Lithium-ion high-voltage battery stays in vehicle  
♦ Vehicle must be parked outside. Observe the following:  
♦ Park vehicle in safe area according to quarantine arrange‐  
ments ⇒ page 17  
If additional measures are necessary due to the classification of  
the lithium-ion high-voltage battery, the first step is an obligation  
to report or technical repair query in the DISS system. Product  
support will then decide which steps to take and, if necessary,  
will send out a specially trained representative.  
6.3  
Packaging high-voltage batteries  
⇒ h6.3.1 igh-voltage battery, e-up!”, page 34  
⇒ h6.3.2 igh-voltage battery, e-Golf”, page 42  
6.3.1  
Packaging high-voltage battery, e-up!  
Special tools and workshop equipment required  
♦ Workshop hoist -VAS 6100-  
34  
Rep. gr.93 - Electric drive systems  
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High-voltage system - General information - Edition 02.2021  
♦ Support bracket -10 - 222 A-  
♦ Towing bracket -T10528-  
♦ Scissor-type assembly platform -VAS 6131 B-  
♦ Plate -VAS 6131/10-1-  
♦ Supplementary kit -VAS 6131/13-  
6. High-voltage battery  
35  
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High-voltage system - General information - Edition 02.2021  
Overview of procedure  
The procedure for packaging a lithium-ion high-voltage battery  
for the e-up! is broken down into the following work steps:  
A - Prepare scissor-type assembly platform and mounting tool  
B - Place new high-voltage battery on cover of genuine part  
crate  
C - Remove high-voltage battery and place in genuine part  
crate  
D - Place new high-voltage battery from cover of genuine part  
crate on scissor-type assembly platform and install  
E - Close genuine part crate and prepare for transport  
Preparing scissor-type assembly  
– Mount and align supports -1 to 4- on scissor-type assembly  
platform -VAS 6131 B-.  
36  
Rep. gr.93 - Electric drive systems  
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High-voltage system - General information - Edition 02.2021  
Front supports -1 and 2-:  
1 - Support -VAS 6131/10-11-  
2 - Knurled section -VAS 6131/10-5-  
3 - Taper -VAS 6131/10-4-  
4 - Plate -VAS 6131/10-1-  
Rear supports -3 and 4-:  
1 - Support -VAS 6131/13-2-  
2 - Knurled section -VAS 6131/10-5-  
3 - Taper -VAS 6131/10-4-  
4 - Plate -VAS 6131/13-4-  
Preparing support  
– Push support -T10528/1- -2- onto support bracket -10 - 222  
A- -1-.  
– Adjust support -T10528/1- -2- to -dimension a- and lock in  
position.  
6. High-voltage battery  
37  
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High-voltage system - General information - Edition 02.2021  
-Dimension a- = 515 mm  
– Hook support bracket -10 - 222 A- -1- with support -  
T10528/1- -2- onto workshop hoist -VAS 6100-.  
– Push two hooks -10 - 222 A /10- -3- onto first cross member  
-T10528/2- -2- as shown in illustration.  
– Push locking pins -T10528/3- into outer positions 6 -arrows-.  
– Push prepared cross member -T10528/2- in direction of  
-arrow- onto support bracket -10 - 222 A-.  
– End of cross member -T10528/2- must be flush -arrow-.  
– Lock cross member -T10528/2- in position.  
– Push two hooks -10 - 222 A /10- -1- onto second cross  
member -T10528/2- -2- as shown in illustration.  
– Push locking pins -T10528/3- into inner positions 2 -arrows-.  
– Push second prepared cross member -T10528/2- onto sup‐  
port bracket -10 - 222 A-.  
– Leave locking mechanism of cross member -T10528/2-  
loose.  
38  
Rep. gr.93 - Electric drive systems  
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High-voltage system - General information - Edition 02.2021  
Place new high-voltage battery 1 -AX2- on cover of genuine  
part crate.  
– Open genuine part crate.  
– Remove cover and place down on ground with top pointing  
up so that cover can be reached with scissor-type assembly  
platform -VAS 6131 B- and workshop hoist.  
– Loosen securing bolts -arrows- with which high-voltage bat‐  
tery 1 -AX2- is secured in genuine part crate.  
– Remove nuts and washers.  
– Attach lifting eye bolts -T10528/5- to high-voltage battery 1  
-AX2- at positions shown -arrows-.  
– Move workshop hoist -VAS 6100- over high-voltage battery  
1 -AX2- with prepared support -T10528-.  
NOTICE  
Risk of damage to high-voltage battery 1 -AX2-.  
– Do not rest support -T10528- on high-voltage battery 1  
-AX2-.  
– Attach hooks -10 - 222 A /10- to lifting eye bolts -T10528/5-  
-arrows-.  
– Align second, still loose cross member -T10528/2- straight,  
and fix it in position.  
– Lift high-voltage battery 1 -AX2- out of genuine part crate in  
direction of -arrow- with cross member -T10528- -1-.  
6. High-voltage battery  
39  
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High-voltage system - General information - Edition 02.2021  
– Place high-voltage battery 1 -AX2- on top of genuine part  
crate cover.  
NOTICE  
Risk of damage to high-voltage battery 1 -AX2-.  
– Do not rest support -T10528- on high-voltage battery 1  
-AX2-.  
– Detach hook -10 - 222 A /10-.  
– Unscrew lifting eye bolts -T10528/5-.  
Remove high-voltage battery 1 -AX2- and place in genuine part  
crate  
– Assess condition of old high-voltage battery 1 -AX2- in situ ⇒  
page 30 .  
– Remove high-voltage battery 1 -AX2- ⇒ Rep. gr. 93; High-  
voltage battery unit; Removing and installing high-voltage  
battery 1AX2.  
– Visually inspect high-voltage battery 1 -AX2- to ensure that it  
is safe to transport.  
– Take high-voltage battery 1 -AX2- from scissor-type assem‐  
bly platform -VAS 6131 B-.  
– Lower high-voltage battery 1 -AX2- in genuine part crate.  
40  
Rep. gr.93 - Electric drive systems  
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High-voltage system - General information - Edition 02.2021  
Note  
Observe securing bolts -1-.  
– Guide all securing bolts -1- into corresponding holes.  
– Detach hook -10 - 222 A /10-.  
– Unscrew lifting eye bolts -T10528/5-.  
Note  
If any of the securing bolts fail to tighten, they will need to be  
counterheld.  
Ensure when tightening bolts that bottom battery shell is not  
distorted.  
– Start nuts with washers on 4 securing bolts in genuine part  
crate and tighten.  
Place new high-voltage battery 1 -AX2- from cover of genuine  
part crate on scissor-type assembly platform -VAS 6131 B- and  
install.  
– Take high-voltage battery 1 -AX2- off cover of genuine part  
crate.  
6. High-voltage battery  
41  
Arteon 2021 ➤, Arteon Shooting Brake 2021 ➤, Golf 2013 ➤, Golf 2017 ➤, Golf Var ...  
High-voltage system - General information - Edition 02.2021  
– Place high-voltage battery 1 -AX2- on scissor-type assembly  
platform -VAS 6131 B-.  
– Install high-voltage battery 1 -AX2- ⇒ Rep. gr. 93; High-volt‐  
age battery unit; Removing and installing high-voltage bat‐  
tery 1AX2.  
Close genuine part crate and prepare for transport  
Note  
If the sides have been removed, the bottom tabs of the sides  
must be folded over again during assembly.  
– Fit cover of genuine part crate and close using existing clips.  
– Attach tensioning straps.  
– Affix or check hazardous material label and package ID.  
– Fill in and insert shipping documents.  
Notes for transport preparation and hazardous material marking  
(Europe)  
1 - “Protect against water”  
2 - “Attention! Fragile”  
3 - “This side up”  
4 - “Maximum stacking load”  
5 - “Hazardous material label: Hazardous material category  
9 “Various hazardous substances and items” packaging  
group 2”  
6 - “Type label with UN number UN3480 for lithium-ion batter‐  
ies”  
6.3.2  
Packaging high-voltage battery, e-Golf  
Special tools and workshop equipment required  
42  
Rep. gr.93 - Electric drive systems