V9324032073520_2 Service Bulletin/Repair Instructions

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Technical Service Bulletin
Transaction No.: 2073520/2
93-24-03 - Service Information, HV Component Measurement Process
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
2073520/2
12/16/2025
93-24-03
Additional model, model

year, and content updates.
2073520/1
05/01/2024
93-24-03
Original publication.
Process and reference information for Volkswagen technicians who have already completed high voltage

expert (HVE) training and applicable prerequisite training courses:

•
Reporting process for review of measurement results to receive repair direction.
•
Performing GFF based high-voltage (HV) components measurements.
CAUTION

Until further notice, the GFF test plan described herein is to be used only for the collection of the

measurements to be uploaded to GFF Paperless for evaluation, with repair direction given through a TAC

case.

– Replacement of parts solely on the basis of repair direction given in the GFF test plan “008C – Check

High Voltage Components” will be considered invalid and not eligible for warranty reimbursement.
NOTICE

At the time of this writing, a GFF test plan for HV component measurements is not yet available for ID.

Buzz (model code EBJ*).

– Therefore, the HV component measurements in the ID.Buzz must be performed using a manual
procedure with QTM support when necessary.

– The GFF test from ID.4 may not be used for ID.Buzz because of a different arrangement of HV

components on the HV wiring harness (see wiring diagram).
Technical Background

Any one of the following diagnostic trouble codes (DTCs) present in the Battery Regulation Control Module J840- (diagnostic address 008C) can indicate the Fuse for High-Voltage Battery Interruption -S415(pyrofuse) has been triggered.

•
P1CAC00: Hybrid/High-Voltage System blasting fuse triggered – Symptom 42572
•
P1CA700: Igniter for hybrid/high-voltage system fuse – Symptom 42503
•
P1CA800: Igniter for hybrid/high-voltage system fuse electrical error – Symptom 42571
Additionally in model year 2021-2022 vehicles only (model code E21*):

•
U10BA00: Local data bus no communication – Symptom 42129
When the pyrofuse in the HV battery has been triggered without any apparent crash-related cause, electrical

measurements of all HV components in the vehicle are required to identify any potential component or wiring

faults which must be repaired before replacement of the J840, SX7, and SX8.
These measurements are only to be performed in conjunction with an open TAC case and may also be

directed in certain cases for further diagnosis of an isolation fault without a blown pyrofuse, in conjunction

with an open TAC case.
CAUTION

The DTC memory must not be deleted prematurely!

– The first scan after a vehicle is received will contain the most information.

– The DTC memory of additional control units can be important for diagnosis.

– Until the HV component measurements are completed, take care to end the GFF session using the

“stop” function (in the data menu) instead of a normal GFF diagnosis exit.
Additionally, if any of the following DTCs are present, then the corresponding GFF test plan for these DTCs

must be performed prior to starting the necessary HV component measurements.

•
Diagnostic address 00CE:

‒
•
P0A1B00: Drive Motor "A" Control Module – Symptom 42180, 42181, 42210, 42214 (static

/sporadic)
Diagnostic address 0051:
‒
•
P0A1B00: Drive Motor "A" Control Module – Symptom 41323, 41345, 41467, 41743 (static

/sporadic)
Diagnostic address 00C6:

‒
B1AD1F0: High-voltage DC voltage sensors Malfunction – Symptom 14745858 (static/sporadic)
‒
P33E000: Target/actual current deviation too large – Symptom 3276828 (static/sporadic)
Production Solution

Not applicable.
Service
DANGER

There is a risk of fatal injury due to high voltage. Electrocution by direct contact or electric arc can cause

severe bodily injury or fatal injury.
CAUTION

Until further notice, the GFF test plan described herein is to be used only for the collection of the

measurements to be uploaded to GFF Paperless for evaluation, with repair direction given through a TAC

case.

– Replacement of parts solely on the basis of repair direction given in the GFF test plan “008C – Check

High Voltage Components” will be considered invalid and not eligible for warranty reimbursement.
Overview of steps:

1.
Validate that the blown pyrofuse is not directly related to a crash event.
2.
Read out all DTC memory and all measured value blocks (MVBs) from address 008C.
3.
Perform GFF test plans for any additional DTCs in 0051, 00CE, or 00C6 as noted above.
4.
Send the diagnostic log to GFF Paperless.
5.
Open a technical support ticket with Volkswagen Group TAC.
6.
Case dispatched from TAC to Quality Technical Manager (QTM) with notification to Product Support.
7.
Receive direction from QTM to either proceed with this bulletin or wait for on-site QTM visit.
8.
De-energize the HV system using ODIS and GFF-based “manual” de-energization if required.
9.
Perform the GFF test plan “008C – Check High Voltage Components.”
10. Review the reference information below for hints and tips when performing the measurements.

11. Repeat measurements for validation of single components that are suspicious or questionable.
12. After measurements are fully completed, send the log to GFF Paperless.

13. Notify the QTM that measurements are ready for review and document the status in the TAC case.

14. Completed measurements will be reviewed between the QTM and Product Support.

15. Direction for repair or steps for further measurements will be provided as necessary.
Measurement procedure hints and tips:

The “step by step” instructions are provided within the GFF test plan. Similar measurements are performed

for each of the HV components. The reference information and examples below are not intended as a

substitute for the steps and content within the GFF test plan, but rather to help the technician to better

understand the procedures that will be performed when working through the GFF-based HV component

measurements, in order to avoid errors or inconclusive results.
Reference Information – Locating the GFF test plan

•
Locate the GFF test plan “008C

– Check high-voltage

components” (Fig. 1).
•
De-energize the vehicle using

the ODIS tester to prepare for

HV component measurements

(Fig. 2).
•
In cases with a blown fuse,

welded contacts are also

possible, and therefore

“manual” de-energization using

the VAS 6558A and associated

HV measurement adapters is

required.
•
After de-energization, observe

the required conditions and

obtain the tools as shown (Fig.

3).
Fig. 1

Reference Information – De-energization and preparation
Fig. 2
•
The VAS 6558A is used for all

electrical measurements except

capacitance.
•
The VAG 1526B multimeter is

not distributed within North

America. Instead, the Fluke 83V or equivalent with a suitable

capacitance measurement

range and resolution may be

used (i.e., maximum

capacitance 9,999 µF,

accuracy ±(1% + 2), maximum

resolution 0.01 nF).
•
Read and follow all preparatory

steps leading up to the HV

component measurements

(Fig. 4).
•
Erroneous measurements can

be caused by a failure to

remove electrical devices from

the vehicle as described.
•
It is not necessary to have a

connection between the vehicle

and the ODIS tester after

starting this test plan if the

steps are performed correctly

and without cancelling or

stopping the test plan.
•
Overview diagram of HV

system as given in GFF test

plan (Fig. 5):
•
Position 1: AX2 - High-Voltage

Battery 1
•
Position 2: UX4 - High-Voltage

Battery Charging Socket 1
•
Position 3: JX1 - Electric Drive

Power and Control Electronics
•
Position 4: - optional - JX4 Electric Drive Power and

Control Electronics 2
•
Position 5: Z132 - Heating

Element (PTC) 3 – Water

Heater (Battery Coolant

Heating)
Fig. 3
Fig. 4
•
Position 6: VX81 - A/C

Compressor
•
Position 7: ZX17 - High-Voltage

Heater (PTC) / Z115 - HighVoltage Heater (PTC) – Air

Heater (Passenger

Compartment Heating)
•
Variant A:
•
Position 8: A19 - Voltage

Converter
•
Position 9: AX4 - High-Voltage

Battery Charger 1
•
Variant B:
•
Position 10: AX4 - High-Voltage

Battery Charger 1 (OCDC)
Fig. 5

Reference Information – Removal of connectors (high voltage and low voltage)

•
During the HV component

measurements, nearly all of the

HV connectors will be

unplugged.
•
Observe this general

precaution and visually inspect

each of the connections (Fig. 6).
•
Disconnect all of the HV

connectors from the HV

battery, but do not remove the

potential equalization cable

from the battery (Fig. 7).
•
In vehicles having the HV

connector “version 2” shown

(Fig. 8) take care to only lift the
Fig. 6
Fig. 7
lock tab slightly to allow it to be

pulled over the ramp piece.
Fig. 8
•
The tab may be lifted up by

gently prying it through the

square hole, or by gently

pushing it using a very small

flat blade screwdriver through

the center of the connector

while observing the lift on the

tab using an inspection mirror

and/or feeling for movement.
•
The red connector lock will

break if it is lifted too far or

forced.
•
See also repair manual > “High

voltage connectors,

disconnecting”
•
Example of the “onboard

supply connector” disconnected

from the AX2 - High-Voltage

Battery 1 (Fig. 9).
•
To avoid erroneous

measurements, this connector

must be unplugged before

performing the HV component

measurements.
•
Example of the vehicle electric

system connector disconnected

from the AX4 - High-Voltage

Battery Charger 1 (Fig. 10).
•
To avoid erroneous

measurements, this connector

must be unplugged before

performing the HV component

measurements.
•
Example of the vehicle electric

system connector disconnected

from the Three-Phase Current
Fig. 9
Fig. 10
Drive - VX54 at the JX1 Electric Drive Power and

Control Electronics (Fig. 11)
•

Fig. 11
Fig. 12
‒
Version: “Base+”

(MY21+)
‒
Engine code ID.4: EBJA,

EBJC
Example of the vehicle electric

system connector (blue arrow)

at the Three-Phase Current

Drive - VX54 at the JX1 Electric Drive Power and

Control Electronics (Fig. 12)

‒
Version: “Performance”

(MY24+)
‒
Engine code ID.4: EDNA
‒
Engine code ID.Buzz:

ECNB
•
To avoid erroneous

measurements, this connector

must be unplugged before

performing the HV component

measurements.
•
Example of the vehicle electric

system connector disconnected

from the Three-Phase Current

Drive 2 - VX97 at the JX4 Electric Drive Power and

Control Electronics 2, if

equipped (Fig. 13).
•
To avoid erroneous

measurements, this connector

must be unplugged before

performing the HV component

measurements.
•
Unless the adapters were just

used for “manual” deenergization and already

checked, it is important to

complete the check of the HV

12 3 4 5

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