9818 - PIWIS Tester II
Suitable battery charger, e.g. VAS 5908 - Battery charger 90A (charging current limit of max.
60 A required, charger must be set as described in  Workshop Manual '9X00IN Battery trickle
charging'.)
9027 - Release pin
T40262 - Locking cap

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VAS 6558/9-6 - High-voltage test adapter HVA 280
Suitable air-conditioning recycling unit, e.g. VAS 6456A - A/C service station with rinsing
device
9001 - Socket wrench for engine cover caps
3370 - Hook
VAS 6096/2 - Vacuum pump
9696 - Filling device
9005 - Hose

Additional tools required for replacing the ground cable and bellows:
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Suitable unit lifting platform, e.g. VAS 6832 - Master Gear unit elevating platform
9011 - Retaining device for front-axle cross member
9032 - Retaining device for wheel carrier
VAS 6941 - Clamping pliers
V.A.G 1275A - Hose clip pliers
9028 - Impact puller
9028/1 - Clamping sleeve
9034 - Retaining device
9034/1 - Press tool
Torque wrench, 40 – 200 Nm (30 – 148 ftlb.), e.g. V.A.G 1332 - Torque wrench, 40-200 Nm
(30-148 ftlb.)
Torque angle torque wrench, e.g. VAS 6942 - Torque/torque angle screw tool

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Installation
Position:

1
2
3

Installation position of ground cable
– Ground cable for front electric machine (check routing)
– Line bracket for ground cable (check that it is fitted securely)
– Front electric machine

Checking routing of ground cable for front electric machine
Procedure:

1

Raise the vehicle on a lifting platform  Workshop Manual '4X00IN Lifting the vehicle'.
1.1

Position the vehicle between the arms of the lifting platform and push it onto the 9453 access ramps.

1.2

Remove underbody covers and fit mounting plates 9002 - Lifting platform holders, 
Workshop Manual '518119 Removing and installing jacking points'.

1.3

Jack and raise the vehicle at the mounting plates.

1.4

Depending on the result of the check, secure the vehicle at the lifting platform arms with
9454 - strapping belts for carrying out the next steps.

2

Remove front right wheel  Workshop Manual '440519 Removing and installing wheel'.

3

Remove centre underbody cover (at the sides) at the right  Workshop Manual '51931901
Removing and installing cover for centre underbody (at the sides)'.

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Check routing of ground cable  Checking routing of
ground cable -1- for the front electric machine.
To do this, turn the steering fully to the right and
visually inspect the front right drive shaft  Checking
routing of ground cable -3- through the cut-out in
the monocoque to see whether the ground cable
 Checking routing of ground cable -1- is routed
above or below the line bracket  Checking
routing of ground cable -2-.

•

The line bracket  Checking routing of ground
cable -2- for the ground cable  Checking routing
of ground cable -1- is visible through the cut-out in
the monocoque: The ground cable is routed above
the line bracket. The routing does not have to be
reworked. Continue with  Step 5.

•

The ground cable  Checking routing of ground
Checking routing of ground cable
cable -1- is visible through the cut-out in the
monocoque: The ground cable is routed below the line bracket  Checking routing of ground cable
-2-. The ground cable is not routed correctly and must be reworked. To do this, continue with
 Technical Information 'WF4900 Reworking routing of ground cable for front electric machine'.

•

If the line bracket  Checking routing of ground cable -2- has become detached from the pin
cap on the monocoque, the routing of the ground cable must be reworked. To do this, continue
with  Technical Information 'WF4900 Reworking routing of ground cable for front electric
machine'.

5

Install centre underbody cover (at the sides) at the right  Workshop Manual '51931901 Removing
and installing cover for centre underbody (at the sides)'.

6

Fit front right wheel  Workshop Manual '440519 Removing and installing wheel'.

7

Lower the vehicle and remove it from the lifting platform  Workshop Manual '4X00IN Lifting the
vehicle'.

8

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7.1

Lower the vehicle onto the 9453 - access ramps with the lifting platform.

7.2

Remove mounting plates 9002 - Lifting platform holders and install the covers on the
underbody  Workshop Manual '518119 Removing and installing jacking points'.

Enter the campaign in the Warranty and Maintenance booklet.
End of action required. For invoicing, see Scope 1 under  Technical Information 'WF4900
Invoicing'.

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Reworking routing of ground cable for front electric machine
Procedure:

1

Observe warning notes for working on the high-voltage vehicle electrical system  Workshop
Manual '2X00IN General warning notes for working on the high-voltage vehicle electrical system'.

2

De-energise the high-voltage system and complete the relevant documentation  Workshop Manual
'2X00IN Isolating high-voltage electrical system from power supply/Starting high-voltage electrical
system (diagnostics)'.
If absence of electric charge could not be verified automatically or if the function could not be run
(see display in the 9818 PIWIS Tester II), the voltage must be measured manually.
For instructions, see  Workshop Manual '2X00IN Isolating high-voltage electrical system from
power supply/Starting high-voltage electrical system (manual)'.

3

Secure the vehicle at the lifting platform arms with 9454 - strapping belts for carrying out the next
steps  Workshop Manual '4X00IN Lifting the vehicle'.

4

Remove underbody covers.
4.1

Remove front left wheel and both rear wheels  Workshop Manual '440519 Removing and
installing wheel'.

4.2

Remove centre underbody cover (at the sides) at the left  Workshop Manual '51931901
Removing and installing cover for centre underbody (at the sides)'.

4.3

Remove front wheel housing liner (front part) at the right  Workshop Manual '50561901
Removing and installing front wheel housing liner (front part)'.

4.4

Remove front wheel housing liner (rear part) at the left and right  Workshop Manual
'50561905 Removing and installing front wheel housing liner (rear part)'.

4.5

Remove front underbody cover  Workshop Manual '519219 Removing and installing cover
for front underbody'.

4.6

Remove centre underbody cover  Workshop Manual '51931900 Removing and installing
cover for centre underbody'.

NOTICE
No rear-axle support when cover for rear underbody panelling is removed
•

Hairline cracks in unit carrier

•

Axle adjustment values on rear axle deviate from setpoint values



Do not fit rear wheels until cover for rear underbody panelling is installed.



Do not remove vehicle from the lifting platform until cover for rear underbody panelling is
installed.
4.7

Remove rear underbody cover  Workshop Manual '519419 Removing and installing cover
for rear underbody'.

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Drain coolant for medium/low-temperature cooling system.
5.1

Remove trim panel for roll-over bar at the left and right  Workshop Manual '663519
Removing and installing trim panel for roll-over bar'.

5.2

Remove engine cover  Workshop Manual '108319 Removing and installing engine cover'.

5.3

Drain coolant for medium- and low-temperature cooling system  Workshop Manual
'193817 Draining and filling coolant - medium- and low-temperature cooling system'.

6

Remove low-voltage battery  Workshop Manual '270619 Removing and installing battery'.

7

Drain the air conditioning system  Workshop Manual '870317 Draining and filling refrigerant'.

8

Remove luggage compartment pan.

9

8.1

Remove front luggage compartment trim panels  Workshop Manual '700519 Removing
and installing front luggage compartment trim panel'.

8.2

Remove luggage compartment lamp  Workshop Manual '964019 Removing and installing
luggage compartment lamp'.

8.3

Remove cover for transverse lock support  Workshop Manual '703919 Removing and
installing cover for lock support'.

8.4

Remove headlights at the left and right  Workshop Manual '941519 Removing and
installing headlights'.

8.5

Remove front apron  Workshop Manual '631519 Removing and installing front apron'.

8.6

Remove wiper arm  Workshop Manual '922519 Removing and installing wiper arm'.

8.7

Remove front trim panel  Workshop Manual '700219 Removing and installing front trim
panel'.

8.8

Remove cowl panel cover  Workshop Manual '664419 Removing and installing cowl panel
cover'.

8.9

Remove luggage compartment pan  Workshop Manual '502019 Removing and installing
floor front section'.

Remove pressure accumulator for front axle lift system  Workshop Manual '438219 Removing and
installing pressure accumulator for front axle lift system'.

10 Remove front power electronics  Workshop Manual '279119 Removing and installing power electronics (front)'.

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11 Visually inspect the bellows  Visual inspection for
damage -2- on the inner right drive shaft and the
ground cable  Visual inspection for damage -1for the front electric machine for damage.
•

There is no visible damage to the bellows and
ground cable: The bellows and ground cable do not
have to be replaced. Continue with  Step 12.

•

The bellows or ground cable show signs of
chafing  Visual inspection for damage -circleor drive shaft grease is already leaking out of
the bellows: The bellows on the drive shaft and
the ground cable must be replaced. To do this,
continue with  Technical Information 'WF4900
Replacing bellows on inner right drive shaft and
ground cable for the front electric machine'.

12 Rework routing of ground cable for front electric
machine.
12.1

Cut tie-wraps on the line bracket  Removing
line bracket -2- for the ground cable 
Removing line bracket -1-.

12.2

Unscrew line bracket  Removing line
bracket -2- from the pin cap on the
monocoque and remove it.

Visual inspection for damage

Removing line bracket

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Technical Information