V9323012069601_3 Service Bulletin/Repair Instructions

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Technical Service Bulletin
Transaction No.: 2069601/3
93-23-01 - High-Voltage Battery Repair Hints, Tips, and Suggested Practices
Condition

Applicable Vehicles

Model(s)
Year
Eng. Code
Trans. Code
VIN Range

From
VIN Range To
ID.4
2021 – 2026
All
All
All
All
ID.Buzz
2025 – 2026
All
All
All
All
Revision Table

Instance Number
Published Date
Version Number
Reason For Update
2069601/1
2/23/2023
93-23-01
Original publication.
2069601/2
2/23/2023
93-23-01
Instance number change

only.
2069601/3
12/3/2025
93-23-01
Updates to applicable

vehicles and additional

informational content
Information for Volkswagen technicians – High-voltage battery repair hints, tips, and suggested practices.
Technical Background

The process of performing a high-voltage battery repair requires planning and strategy to synchronize all of

the necessary resources in an efficient manner.

While it is not possible to foresee every situation and circumstance which may be encountered, this bulletin

presents various hints, tips, and suggestions, which are presented only as an aid for Volkswagen technicians

who have already completed high voltage expert (HVE) and all prerequisite training courses.

Note:

This bulletin is a reference only, and shall not be considered to supersede or replace any published repair

manual procedures, ODIS-based instructions, Guided Fault Finding conclusions, or other technical bulletins.
Production Solution

Not applicable.
Service

Planning and Preparation
•
Prevent open-battery idle-time – Check that all necessary parts were ordered and received in good

condition, with all necessary tools and personal protective equipment (PPE) ready and the scissor-lift

table completely functional, before removing or opening the high-voltage battery.
•
Shortcuts – Avoid the use of “cheat sheets” or saved lists of parts or repair steps based on prior

repairs. Delays arise when part numbers have changed, or if incompatible parts are ordered in

error. The exact parts required must be determined for each vehicle by referencing the repair manual

to determine single-use parts, and the ETKA parts catalog to order the correct parts.
•
Cleanliness – Ensure a clean work area is available, and plan a location where the removed top cover

can be set aside and protected after removal (for battery housing versions with a potentially reusable

top cover). The blue sealant used on the top cover remains tacky. If it becomes dirty or contaminated

by other substances, then it must be cleaned off before application of additional sealant.
•
Lift suitability – Ensure that the lift has suitable weight capacity and clearance for positioning the

scissor-lift table, lowering the battery from the vehicle, and rolling it to the work location. Check that

the lift arms and pads which contact the vehicle can accommodate battery removal and installation

according to the repair manual. – see “High-Voltage Battery 1 AX2, Removing and Installing”
•
Moving vehicle with battery removed – If circumstances require moving the vehicle off the lift while the

high-voltage battery is removed, then multiple people must work together to push the vehicle in a

careful and controlled manner, and no person may enter the vehicle while the high-voltage battery is

removed. – see “High-Voltage Battery 1 AX2, Removing and Installing”
•
MEB battery repair videos – Several short training videos about various MEB battery repair procedures

are available for reference and may be found online at VW Hub > Academy > VW Cup > Training

Library. To locate these videos, search “MEB Battery Repair” from the search box.
Noteworthy Repair Manual Content Updates

The repair manual may be updated at any time. Always review all repair manual procedures before starting a

battery repair and follow them step-by-step.

Training materials are a useful reference for understanding repair concepts, but must never be used as a

substitute for current repair manual procedures.

Noteworthy changes between 2021 ID.4 launch and original 2023 publication of this bulletin:

•
Use the pipe brush VAS 294 029 or equivalent to remove old sealant from the M24 screw threads in

the housing and then vacuum the debris – see “High-Voltage Battery 1 AX2, Opening”
•
The original blue sealant need only be removed from the top cover if it is contaminated with dirt or

other substances – see “Battery Housing Upper Section, Checking for Re-Use”
•
Additional blue sealant is then applied over top of clean and uncontaminated original sealant on the

top cover – see “High-Voltage Battery 1 AX2, Sealing”
•
The leak test of the housing is done in-car before removal and after reinstallation instead of on the

removed battery – see “High-Voltage Battery 1 AX2, Removing and Installing”
•
The leak test is performed and documented with ODIS, according to the GFF test to check the housing

with vacuum instead of pressure – see “High-Voltage Battery 1 AX2 Leak Test”
•
In the steps for top cover removal, wearing arc-flash and voltage protective apparel (PPE) appears

after screw and bolt removal – see “High-Voltage Battery 1 AX2, Opening”
•
Always confirm no potential short circuit exists by measuring voltage with VAS6762/45 tester before

installing the last HV connector between SX8 and J991 – see “Circuit, Disconnecting”
Noteworthy changes after the original 2023 publication of this technical bulletin:

•
New housing versions were introduced starting in MY24 and the headings and illustrations must be

used to identify the battery version being repaired – see “Overview - Removed High-Voltage Battery”
•
The top cover in earlier housing versions (i.e., Version 0 and Version 1 in the repair manual) generally

remain reusable – see “Battery Housing Upper Section, Checking for Re-Use”
•
The top cover in later housing versions (i.e., Version 1.1 and Version 2 in the repair manual) may be a

single-use part if noted as such – see “Overview - Removed High-Voltage Battery”
•
Additional small covers over screws in later housing versions (i.e., indicated as Version 1.1 and

Version 2 in the repair manual) are single-use – see “Overview - Removed High-Voltage Battery”
•
In some housing versions, repair of M5 screw threads for securing the inner portion of the top cover is

possible – see “High-Voltage Battery Threads, Servicing, Battery Housing Upper Section
•
In some housing versions, repair of M8 screw threads for securing cell modules into housing is

possible – see “High-Voltage Battery Threads, Servicing, Battery Module”
•
In case of a failed leak test of an installed battery using vacuum, tightness of the lower hollow screws

(aka banjo bolts) should be checked – see “High-Voltage Battery Leak Detection”
•
Further diagnosis in case of a failed leak test uses pressure instead of vacuum and a leak-detection

spray (e.g., soapy water) to identify leak location – see “High-Voltage Battery Leak Detection”
•
When necessary, use compressed shop air to flush the HV battery with the top cover lifted from the

lower housing at the end opposite the connection board – see “High-Voltage Battery 1 AX2, Flushing”
Cell Balancing – Cell Module Replacement

•
Never install any cell module without first ensuring it is properly and precisely balanced to match the

cells in the battery which are not being replaced. It is never appropriate to install cell modules which

are not properly balanced.
•
Balancing time – The amount of balancing time varies in proportion to the difference between the cell

voltages in the battery pack and those of the new cell module. If the problem which requires a cell

module to be replaced does not render the high-voltage battery inoperable, then it is advantageous to

charge or discharge the high-voltage battery in the vehicle before removing it, so that the state of

charge (SOC) of the battery pack is closer to the SOC of the new module (typically 25-30%).
•
Charging rate – The VAS 6910 provides 5X higher current charging (50A) than discharging

(10A). Therefore, it takes less time to charge a new cell module to the target voltage of the rest of the

pack than to discharge it by a comparable amount when using the VAS 6910 module balancer.
•
Voltage precision – Determine the target voltage for the VAS 6910 module balancer, balance the new

cell module, and install it shortly thereafter. Consider that if the problem which requires a cell module to

be replaced does not render the high-voltage battery inoperable, then the cell voltages in the battery

pack may change (such as through operation of heat or air conditioning, 12V consumers, or

autonomous recharging of the 12V battery from the high-voltage battery).
•
Balancer software – The VAS 6910 operates from standalone software (i.e., “VAS DSS”) and is not

currently integrated with ODIS. Ensure the most recent and up-to-date software package for the VAS
6910 module balancer is used, which includes the addition of any new part numbers for recently

introduced cell modules which can be balanced using the VAS 6910. The software is now available for

download from VW Hub > Elsa2go > Infomedia.

•
The updated version VAS 6910A module balancer may be used instead of the original VAS 6910. The

updated version offers increased performance and integration with ODIS, but is not currently required

for cell modules that are within the capabilities of the VAS 6910 module balancer (under 60 Volts).
•
Check whether any additional technical bulletins apply to cell module replacement in the vehicle being

repaired, including but not limited to build-status documentation described in Technical Bulletin

2074770/*: 93-24-06 - Service Information, Important Step for Replacing HV Battery Cell Modules.
Top Cover – Large Hollow Screws

•
Use hand tools only! – Power tools increase the likelihood of aluminum housing thread damage.
•
Large hollow screw removal – The large M24 threads are coated with an encapsulated

sealant. Remove the hollow screws with care. If resistance is felt, work the screw back and forth

slowly.
•
Large hollow screw thread cleaning – In addition to brushing out the old sealant with the pipe brush

VAS 294 029 or equivalent, a removed old screw in good condition may be used as a cleaning

aid. The large tap VAS 274013 should only be used with extreme care if absolutely necessary.
•
Hollow screw thread damage – The cosmetic appearance of the threads is not critical. However, if the

specified torque cannot be achieved when the new hollow screws are fully installed, then the complete

lower housing must be replaced – no approved repair exists!
•
Hollow screw installation – If the screw stops turning and torque increases before the shoulder of the

screw is seated against the top cover, stop and check threads before reattempting installation.
•
Inspect new hollow screws – Check threads for damage and do not use screws which have any

significant gouges or nicks in the thread that could cause housing thread damage.
Top Cover – Small Screws (Outer Perimeter)

•
Use hand tools only! – Power tools increase the likelihood of aluminum housing thread damage.
•
A 1/4-inch drive speeder handle with the appropriate Torx bit is a good option, which allows quicker

removal than a ratchet without increasing risk of damage.
•
Perimeter screws on cover (pointed tip flow-drill screws) – Remove with care to avoid

damage. Screws are typically replaced with all new screws of the original type, according to the repair

manual.
•
Repair with over-size screws is possible if thread damage occurs. Refer to repair manual, and obtain

ETKA bulletin 9-174 from the parts department for reference.
Top Cover – Small Screws (Inner)

•

•
Use hand tools only! – Power tools increase the likelihood of aluminum housing thread damage.
A 1/4-inch drive speeder handle with the appropriate Torx bit is a good option, which allows quicker

removal than a ratchet without increasing risk of damage.

•
Central screws on cover (machine screws with wax) – Remove with care to avoid damage. Screws are

typically replaced with all new screws of the original type, according to the repair manual.
•
Repair of damaged M5 threads is permissible if repair instructions are present in the repair manual and

thread inserts are listed in the ETKA catalog for the HV battery housing version being repaired.
ODIS Service & Guided Fault Finding

•
Obtain a readout of all measured value blocks (not just cell voltages) from the Battery Regulation

Control Module -J840- (diagnostic address 008C) before removing and opening the battery. Save the

log locally and send it to GFF Paperless. This is important documentation to have available for

reference if needed and is much easier to obtain before the battery repair has started.
•
From the measured value blocks, record the “ASSY part number” (battery assembly part number) and

“Serial number of H-V / hybrid battery” starting with “288” for reference. These may be requested

within various GFF test plans. Every HV battery has an assembly part number and serial number

which is stored in memory and printed on the identification label or etched on the battery housing.
•
Certain DTCs including voltage-sensing errors and contactor stuck-open/closed faults remain static

even if the condition is intermittent and may hold the battery in non-operational shutdown-mode. Such

DTCs cannot be erased by the GFF test “008C – Read/Erase DTC Memory” or upon exiting GFF

diagnosis and should be handled using the corresponding GFF test plan. If such DTCs remain after a

battery repair has already been completed, then the suitable GFF test plan “008C – Controller

Configuration” or “008C – Replace control unit” can be effective for erasing these DTCs.
•
ODIS may be used with the battery removed from the vehicle to validate that no unexpected faults or

abnormal measured block values remain, before sealing the battery top cover and reinstalling the

battery into the vehicle. Communication with the Battery Regulation Control Module -J840- is possible

using either the VAS 671007 Extension Cables for High Voltage Battery or the VAS 5581A High

Voltage Diagnostics Box. When using the VAS 5581A High Voltage Diagnostics Box to communicate

with a standalone HV battery, select “GW” (Gateway) mode and start a new GFF session from

“Component Diagnosis” with manual VIN entry.
Battery Control Unit Replacement (J840+SX7+SX8 Repair Kit)

•
Note the software version of the Battery Regulation Control Module -J840- from the identification of

diagnostic address 008C in ODIS before starting the battery repair. The new control unit being installed

must have the same software version as that being removed, unless a technical bulletin or other

published information states to use a different version.
•
The Battery Regulation Control Module -J840-, High-Voltage Battery Control Module, Negative

Terminal -SX7-, and High-Voltage Battery Control Module, Positive Terminal -SX8- are a matched set

and must always be removed and replaced together (sold as a repair kit for service).
•
The valid battery assembly part number and serial number are printed on the identification label or

etched onto the housing of each high-voltage battery. If a repaired battery has already been

reinstalled, these may be found in the measured value blocks read out in a prior GFF log from the start

of diagnosis.
•
When replacing the Battery Regulation Control Module -J840- always run the necessary GFF test

“008C - Control Module, Replacing” before removal of the old control unit. If this is not done, then the

battery assembly part number and serial number will not be copied from the old control unit to the new

one and must thereafter be entered manually.

•
If necessary, the valid battery assembly part number and serial number can be entered manually. If

manual entry cannot be performed successfully within the GFF test “008C - Control Module,

Replacing” then it is possible to enter the correct values to “ASSY part number” and “Serial number of

H-V / hybrid battery” manually from Self Diagnosis (OBD) > Diagnostic address 008C > Adaptations.
•
Software configuration with a valid target data container (ZDC) in the new Battery Regulation Control

Module -J840- is necessary for operation of the battery and requires a valid HV battery assembly part

number and serial number. The software configuration can be performed by diagnostic address 008C if

it was not completed during “008C – Control Module, Replacing.” Without valid software configuration,

the measured values may display alternating blocks of valid/invalid cell voltages and DTCs such as

“data set missing” and “data record invalid” will be present.
Cell Module Control Unit Replacement (J1208, J1212, J1216, J1429, etc.)

•
Note the software version of each Battery Module Control Module (CMCe) -J1208-, -J1212-, -J1216-,

and if applicable -J1429- from the sub-bus identification of each under diagnostic address 008C before

starting the battery repair. The new control unit being installed must have the same software version as

that being removed, unless a technical bulletin or other published information states to use a different

version.
•
If one more Battery Module Control Module (CMCe) -J1208-, -J1212-, -J1216-, or -J1429- is installed

that has software incompatible with the Battery Regulation Control Module -J840-, then “software

incompatibility” DTCs will be present in diagnostic address 008C.
•
The GFF test plan “008C – Controller configuration” (module addressing) must be used after

replacement of a CMCe control unit. The GFF procedure includes a bus-sleep step. Without a proper

bus-sleep at the step where it is indicated, the configuration will not be saved. Incomplete configuration

will result in multiple invalid cell voltage readings and the HV battery will not operate.
Accuracy of Service Parts Selection

•
Batteries assembled in different plants can look nearly identical in physical appearance, yet have

different properties and performance characteristics. This includes not only the functional electrical

parts, but also single-use parts such as screws, bolts, gaskets, etc.
•
Use only the specified parts for the specific battery being repaired, according to the ETKA

catalog. Nothing which is designed for one battery may be interchanged with another battery unless it

is a common part number for both, according to the ETKA parts catalog.
•
It is never appropriate to judge compatibility of cell modules on the basis of physical characteristics,

voltage, or connector fitment. Only the part number may be used to determine a suitable replacement

part, according to the ETKA parts catalog.
•
Never install a new cell module from one supplier into a battery pack containing cell modules from a

different supplier. Cell modules from different suppliers may contain cells with different chemistries or

different series-parallel configurations that are not interchangeable.
Warranty

Information only.
Required Parts and Tools

Not applicable.
Additional Information

All part and service references provided in this Technical Bulletin are subject to change and/or removal.

Always check with your Parts Dept. and Repair Manuals for the latest information.

© 2025 Volkswagen Group of America, Inc. All rights reserved. Information contained in this document is

based on the latest information available at the time of printing and is subject to the copyright and other

intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors.

All rights are reserved to make changes at any time without notice. No part of this document may be

reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical,

photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites,

without the prior expressed written permission of the publisher.

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