Skoda Enyaq 5A, 5AC, 5AZ Repair Manual – PDF DOWNLOAD

Service

Workshop Manual

Citigo-e iV 2020 ➤, Enyaq 2021 ➤, Enyaq Coupe 2021 ➤, Octavia IV 2020 ➤, Superb III 2015 ➤ High voltage system - general information Engine ID

EBM DGE DGE EBJA EBJC EBR A B A A

Edition 05.2022

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Service Department. Technical Information

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Service List of Workshop Manual Repair Groups

Repair Group 00 - Technical data 93 - Electric drive systems

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Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2022 ŠKODA AUTO a. s.

D4B80A50A5C

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High voltage system - general information - Edition 05.2022

Contents 00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1.1 1.2 1.3 1.4 2 2.1 2.2 2.3

1

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety measures when working on the high-voltage system . . . . . . . . . . . . . . . . . . . . . . . .

Safety measures when working near high-voltage components . . . . . . . . . . . . . . . . . . . .

Safety measures for test drives with testing and measuring devices . . . . . . . . . . . . . . . . . .

Safety precautions when working on cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cable routing and securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rules of cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 2 2 3 3 3 3

93 - Electric drive systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

1 1.1 1.2 2 3 3.1 3.2 4 5 5.1 5.2 6 6.1 6.2 6.3 6.4 6.5

Hazard classification of the high-voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Training / personnel qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Identification features of high-voltage vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dealing with high-voltage vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Personal protective equipment (PPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Workshop procedure for high-voltage vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quarantine concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assessment of accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Photo documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High-voltage battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Classify high-voltage battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Handle and store high-voltage battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Packaging high-voltage batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Packaging critical high-voltage batteries with status “Warning” . . . . . . . . . . . . . . . . . . . . . .

Additional information on opening and bonding high-voltage batteries . . . . . . . . . . . . . . . .

5 5 6 8 13 13 13 17 22 22 22 26 26 33 34 42 62

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Contents

i

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High voltage system - general information - Edition 05.2022

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ii Contents

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High voltage system - general information - Edition 05.2022

00 –

Technical data

1

Safety instructions

(SRL001996; Edition 05.2022) ⇒ m1.1 easures when working on the high-voltage system”, page 1 ⇒ m1.2 easures when working near high-voltage components”, page 1 ⇒ m1.3 easures for test drives with testing and measuring devi‐ ces”, page 2 ⇒ p1.4 recautions when working on cooling system”, page 2

1.1

Safety measures when working on the high-voltage system

Danger to life due to high voltage.

The high-voltage system carries high voltage. Death or severe injury from electric shock.

People with electronic / medical life and health-preserving de‐ vices in or on the body must not carry out any work on the high-voltage system. Life and health-preserving devices include internal pain reliever pumps, implanted defibrillators, pacemak‐ ers, insulin pumps and hearing aids.

Have the high-voltage system switched off by a suitably quali‐ fied person ⇒ /1.2 personnel qualification”, page 6 .

Risk of injury due to unexpected engine start.

With electric and hybrid vehicles, it is difficult to detect an acti‐ vated readiness to drive. When working in the engine compart‐ ment and starting the engine unexpectedly, there is a risk of body parts getting caught or being pulled in.

– Switch off ignition.

– Place the ignition key outside of the vehicle interior.

Risk of damage to high-voltage cables.

Improper handling can damage the insulation of high-voltage cables or high-voltage plug connections.

Never rely on high-voltage cables and high-voltage plug con‐ nections.

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability Never support toolsof information using high-voltage and high-voltage with respect to the correctness in this document. cables Copyright by ŠKODA AUTO A. S.

connectors.

Never bend or curve high-voltage cables.

Observe coding when plugging the high-voltage connectors to‐ gether.

1.2

Safety measures when working near high-voltage components

Danger to life due to high voltage.

The high-voltage system carries high voltage. Death or serious physical injury from electric shock if high-voltage components and high-voltage cables are damaged.

– Carry out a visual inspection of the high-voltage components and high-voltage cables.

1. Safety instructions

1

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High voltage system - general information - Edition 05.2022 Never use cutting, deforming or sharp-edged tools.

Never weld, solder, thermally glue or use hot air.

1.3

Safety measures for test drives with testing and measuring devices

Distraction can cause accidents.

Using testers and measuring instruments during driving opera‐ tion causes distraction.

There is a risk of injury if testers and measuring instruments are not secured adequately.

Increased risk of injury from unsecured testers and measuring instruments must be prevented.

Measuring instruments can turn into dangerous projectiles on airbag activation.

Testers and measuring instruments must always be secured on the rear seat using a seat belt and operated by a 2nd person from there.

1.4

Safety precautions when working on cooling system

Risk of injury due to hot steams.

– Wear protective gloves.

– Wear safety goggles.

Relieve any possible pressure prior to the repair.

When the engine is warm, the cooling system is under over‐ pressure.

When the expansion tank is opened, hot steam and coolant can escape.

– Cover the cap of the coolant expansion tank with a cloth and open carefully.

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2 Rep. gr.00 - Technical data

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High voltage system - general information - Edition 05.2022

2

Repair instructions

⇒ c2.1 orrosion”, page 3 ⇒ r2.2 outing and securing”, page 3 ⇒ o2.3 f cleanliness”, page 3

2.1

Contact corrosion

The use of unsuitable connection elements (screws, nuts, washers, etc.) can cause contact corrosion.

This is why only connection elements with a special surface coatings are fitted.

Therefore, the rubber or plastic parts and the adhesives are made from electrically non-conductive materials.

If there is any doubt about the suitability of parts, generally use new original parts ⇒ Electronic catalogue of original parts “ETKA”. ♦ Only use genuine parts. These parts have been inspected and are resistant to aluminium. ♦ Only use Škoda accessories. ♦ Any damage resulting from contact corrosion is not covered by the terms of the warranty.

2.2

Cable routing and securing

Install lines of all kinds so that the original routing can be re‐ stored. ♦ Hydraulic lines ♦ Brake fluid lines ♦ for coolant line ♦ Vacuum lines ♦ Electrical lines To rule out mix ups and ensure the original fitting position, mark the lines before disassembly.

Make photos or sketches where necessary.

To avoid damage to lines, ensure sufficient clearance from all moving or hot components.

Insulation or heat shield mats must be installed again in their original position.

2.3

Rules of cleanliness

Carefully observe the following rules for cleanliness when work‐ ing on the high-voltage system: ♦ Thoroughly clean the connection points/maintenance open‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted ings and their surroundings before releasing/opening.

unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability

with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S. ♦ Place removed parts on a clean surface and cover. Use lint-free cloths.

♦ Carefully cover or close opened components if the repair is not completed immediately. ♦ Install only clean original parts. ♦ Only take spare parts out of the packaging immediately be‐ fore installation.

2. Repair instructions

3

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High voltage system - general information - Edition 05.2022 ♦ Do not use any parts which have been stored unwrapped (e.g. in tool boxes etc.). ♦ Existing transport and protective packaging and caps must be removed immediately before installation. ♦ When the system is opened: do no use compressed air. Do not move the vehicle.

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4 Rep. gr.00 - Technical data

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High voltage system - general information - Edition 05.2022

93 –

Electric drive systems

1

Hazard classification of the highvoltage system

⇒ i1.1 nformation”, page 5 ⇒ /1.2 personnel qualification”, page 6

1.1

General information DANGER

The high-voltage network of the vehicle and the high voltage battery are dangerous and can be the cause of burns, other injuries and fatal electric shock.

– Work on the high-voltage system and systems that can be indirectly influenced by it may only be carried out by suitably qualified and trained specialist personnel.

– If you have any questions or are not sure about the terms high-voltage technician (HVT), high-voltage expert (HVE) or the high-voltage system, you must consult the responsi‐ ble importer before starting any work.

– Repair activities must always be carried out in compliance with the relevant statutory regulations, other legal provi‐ sions, the recognised rules of technology, any relevant accident prevention regulations and this guideline.

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page 6 .

Before starting work on the high-voltage system, a person who has at least the qualification of »high-voltage technician (HVT) « must de-energise the high-voltage system ⇒ Rep. gr. 93; Dis‐ connecting the voltage to the high-voltage systems.

The high-voltage system can be de-energised in following situa‐ tions: Refer to the list of vehicle-specific guides ⇒ Rep. gr. 00; Hazard classification of the high-voltage systemfor work where the highvoltage system is to be de-energized. ♦ All listed works are related removing, installing or replacing the individual components. ♦ A person who has at least the qualification of »high-voltage technician (HVT)« is authorised to de-energise the high-volt‐ age system in a certified manner. ♦ Work on a high-voltage vehicle may only be carried out by people who possess at least the qualification »Electrically instructed person (EIP)«. ♦ For each activity, the high-voltage relevant components in the activity / work area must be visually inspected. ♦ The high-voltage cables must not be bent or kinked. ♦ In the event of abnormalities or ambiguities, the high-voltage technician (HVT) or the high-voltage expert (HVE) must be consulted. ♦ Work in the vicinity of high-voltage components and highvoltage cables with cutting, deforming, sharp-edged tools or heat sources, such as welding, soldering, hot air, ther‐ mal bonding, are prohibited. In this case, the high-voltage

1. Hazard classification of the high-voltage system

5

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High voltage system - general information - Edition 05.2022 system must be de-energized and the relevant component removed or sufficiently protected. ♦ When maintenance work is carried out regularly, the highvoltage system does not have to be de-energised.

For safety reasons, the following activities must not be carried out during the charging process: ♦ Activities that prolong the loading process. ♦ Activities for which the vehicle must be de-energized accord‐ ing to the following risk classification ⇒ Rep. gr. 00; Hazard classification of the high-voltage system. ♦ Activities that could result in tensile loads on cables and plugs. ♦ Activities on the 12V battery.

Note ♦ When charging, make sure that the charging cable does not

block work and escape routes.

♦ Watch out for tripping hazards when moving near the charg‐

ing cable.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability withcarried respect to out the correctness information diagnos‐ in this document. Copyright by ŠKODA AUTO A. S. The following work can be with theof vehicle

tic tester during the charging process:

♦ Read event log and measured values. ♦ Vehicle and control unit identification.

The hazard classifications can vary for the vehicle type.

The vehicle-specific information can be found in the vehiclespecific guide ⇒ Rep. gr. 00; Hazard classification of the highvoltage system.

1.2

Training / personnel qualification

Requirements for personnel qualifications for work on vehicles with high-voltage systems can differ due to the corresponding national regulations and standards!

Personnel qualifications for work on vehicles with high-voltage systems in Germany is regulated by the regulation DGUV-I 200-005. Škoda qualification

Application

EIP - Electrically instructed person

General work and mainte‐ nance. Work on the certified voltage-free high-voltage sys‐ tem awarded by the high-volt‐ age technician (HVT).

6 Rep. gr.93 - Electric drive systems

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High voltage system - general information - Edition 05.2022 Škoda qualification

Application

HVT (high-voltage technician)

Deactivate/activate the HV system. ♦ Ensure that it can be certi‐ fied as de-energised. ♦ Re-engaging protection. ♦ Determined that it is deenergised. ♦ Start up the vehicle.

Work on intrinsically safe HV production vehicles. ♦ Vehicles are only certified as de-energised. ♦ Complete contact protec‐ tion available. ♦ Assign persons with lower qualifications to work on the certified activated HV system.

HVE (high-voltage expert)

Work on HV production vehi‐ cles that are not intrinsically safe. ♦ Disconnect the HV system from power sources using methods other than com‐ mercial means. ♦ Vehicles are not switched to voltage-free certified, or complete contact protection is no longer available, e.g. in the event of an accident.

Work on live energy storage. ♦ Working on parts that are not necessarily contactprotected, which are live, for troubleshooting, replac‐ ing components, etc.

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1. Hazard classification of the high-voltage system

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High voltage system - general information - Edition 05.2022

2

Identification features of high-volt‐ age vehicles

High-voltage vehicles can be clearly identified using the follow‐ ing features: Type plates on the Citigo-e IV rear vehicle

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Type plate on the Superb III iV vehicle at the rear

8 Rep. gr.93 - Electric drive systems

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High voltage system - general information - Edition 05.2022 Possible installation locations for charging socket

1 - Superb III in front 2 - Citigo-e IV in rear Octavia IV iV front left

Danger signs in the engine and interior

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2. Identification features of high-voltage vehicles

9

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High voltage system - general information - Edition 05.2022 Lock carrier front left Power and control electronics for electric drive -JX1-, Engine compartment

Rescue notice engine compartment on the water box front wall

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10 Rep. gr.93 - Electric drive systems

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High voltage system - general information - Edition 05.2022 Rescue notice interior under the switch panel on the fuse carrier

Orange high-voltage cables in the engine compartment and on the underbody

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The electrical cables of the high-voltage system differ signifi‐ cantly from the cables of the rest of the vehicle electrical system and the 12-volt vehicle electrical system.

Due to the high voltage and currents, they have a significantly larger cross section and are connected via special plug con‐ tacts. The high-voltage system has no electrical potential to the body like the 12-volt electrical system.

In order to draw attention to the danger of high voltage, all ca‐ bles of the high-voltage system are coloured completely orange.

The high-voltage cables are protected against polarity reversal.

They cannot be installed incorrectly because they are colourand mechanically coded.

In addition to the coloured identification, warnings are given by signage on the components.

2. Identification features of high-voltage vehicles

11

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High voltage system - general information - Edition 05.2022 Special displays in the dash panel insert

Mileage display.

1 - 1 - Charge 2 - 2 - Ready

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12 Rep. gr.93 - Electric drive systems

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High voltage system - general information - Edition 05.2022

3

Dealing with high-voltage vehicles

⇒ p3.1 rotective equipment (PPE)”, page 13 ⇒ p3.2 rocedure for high-voltage vehicles”, page 13

3.1

Personal protective equipment (PPE) Note

Use cases can be found in the vehicle-specific guidelines.

The following protective equipment is available according to the ⇒ Electronic parts catalogue (ETKA): ♦ Safety shoes ♦ Coat for high-voltage experts ♦ Helmet for high-voltage experts ♦ Visor for high-voltage experts ♦ Protective hood for high-voltage experts ♦ Gloves for high-voltage experts ♦ Liner gloves for high-voltage experts ♦ Jacket for high-voltage experts

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♦ Pants for high-voltage experts ♦ Protective suit for high-voltage experts Sizes and order numbers can be found in the ⇒ Electronic parts catalogue (ETKA).

3.2

Workshop procedure for high-voltage vehicles

⇒ p3.2.1 rocedure for electrically instructed person (EPO)”, page 13 ⇒ p3.2.2 rocedure for high-voltage technicians (HVT)”, page 14 ⇒ p3.2.3 rocedure for high voltage experts (HVE)”, page 15 ⇒ v3.2.4 oltage isolation”, page 16

3.2.1

Workshop procedure for electrically in‐ structed person (EPO)

Activity 1. Smoke development? Fire? Liquid in the HV battery? HV battery damaged or changed?

If so: ♦ If possible, park the vehicle safely in accordance with the quarantine concept ⇒ c4 oncept”, page 17 . ♦ Hire high-voltage technicians (HVT) and transfer re‐ sponsibility ⇒ p3.2.2 rocedure for high-voltage techni‐ cians (HVT)”, page 14 .

If not: ♦ Continue with 2.

2. Mark vehicle as “High-voltage vehicle”.

3. Dealing with high-voltage vehicles

13

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High voltage system - general information - Edition 05.2022 Activity 3. Airbag or belt tensioner triggered?

If so: ♦ If possible, park the vehicle safely in accordance with the quarantine concept ⇒ c4 oncept”, page 17 . ♦ Hire high-voltage technicians (HVT) and transfer re‐ sponsibility ⇒ p3.2.2 rocedure for high-voltage techni‐ cians (HVT)”, page 14 .

If not: ♦ Continue with 4.

4. Switch on ignition.

5. HV warning light in dash panel insert on?

If so: ♦ Hire high-voltage technicians (HVT) and transfer re‐ sponsibility ⇒ p3.2.2 rocedure for high-voltage techni‐ cians (HVT)”, page 14 .

If not: ♦ Continue with 6.

6. Is de-energization required?

If so: Hire a high-voltage technician (HVT) and transfer responsibility to them ⇒ p3.2.2 rocedure for high-voltage technicians (HVT)”, page 14 . If not: ♦ Continue with 7.

7. Switch off ignition.

8. Visual inspection of the HV components and cables in the work area in order?

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted If not: unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability ♦ Hire high-voltage technicians and transferin re‐ with respect to the(HVT) correctness of information this document. Copyright by ŠKODA AUTO A. S. sponsibility ⇒ p3.2.2 rocedure for high-voltage techni‐ cians (HVT)”, page 14 .

If so: ♦ Continue with 9.

9. Maintenance and repair of conventional components ac‐ cording to repair guidelines.

Exchange of the HV component / repair near HV compo‐ nents according to the repair guide.

After replacement, restart the high-voltage system: ♦ Hire high-voltage technicians (HVT) and transfer re‐ sponsibility ⇒ p3.2.2 rocedure for high-voltage techni‐ cians (HVT)”, page 14 .

3.2.2

Workshop procedure for high-voltage technicians (HVT)

Note

If there is no high-voltage expert (HVT) available in the service company, the vehicle may need to be transported to a service company with a higher authorization if this is possible for safety reasons.

Activity 1. Visual inspection and diagnosis on the vehicle, HV sys‐ tem / high-voltage battery.

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High voltage system - general information - Edition 05.2022 Activity 2. HV battery classification necessary?

If so: ♦ HV battery classification ⇒ h6.1 igh-voltage battery”, page 26 .

If not: ♦ Certified voltage isolation ⇒ v3.2.4 oltage isolation”, page 16 .

3. HV battery quarantine necessary?

If so: ♦ Park the vehicle safely in accordance with the quaran‐ tine concept ⇒ c4 oncept”, page 17 . ♦ Hire high voltage experts (HVE) and transfer responsi‐ bility ⇒ p3.2.3 rocedure for high voltage experts (HVE)”, page 15 .

If not: ♦ Certified voltage isolation ⇒ v3.2.4 oltage isolation”, page 16 .

4. Visual inspection of the HV components and cables in the work area.

5. Repair HV component?

If not: ♦ Assign an electrically instructed person (EIP), respon‐ sibility remains with the high-voltage technician (HVT) ⇒ p3.2.1 rocedure for electrically instructed person (EPO)”, page 13 .

If so: ♦ Continue with 6.

6. Repair HV component - voltage-free or protected against accidental contact?

If not: ♦ Hire high voltage experts (HVE) and transfer responsi‐ bility ⇒ p3.2.3 rocedure for high voltage experts (HVE)”, page 15 .

If so: ♦ Continue with 7.

7. Remove the HV component according to the repair guide.

8. Install the high-voltage component in the vehicle.

9. Put the high-voltage system back into operation.

3.2.3 Activity

Workshop procedure for high voltage experts (HVE) Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted

unless authorised by ŠKODA AUTOigh-voltage A. S. ŠKODA AUTO A. S. doespage not guarantee or accept any liability 1. HV battery classification ⇒ h6.1 battery”, with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S. 26 .

2. Certified voltage isolation ⇒ v3.2.4 oltage isolation”, page 16 .

3. Switch off and secure the high-voltage system.

4. Possibly. Remove the high-voltage battery, pack it and make it ready for transport.

3. Dealing with high-voltage vehicles

15

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High voltage system - general information - Edition 05.2022 Activity 5. Remove HV components and repair according to repair guidelines. ♦ Hire high-voltage technicians (HVT) and transfer re‐ sponsibility ⇒ p3.2.2 rocedure for high-voltage techni‐ cians (HVT)”, page 14 .

3.2.4

Certified voltage isolation Process for high-voltage technicians (HVT)

1.

2.

3.

Process for high voltage experts (HVE)

Cut the voltage ⇒ Rep. Cut the voltage ⇒ Rep. gr. 93; Voltage discon‐ gr. 93; Voltage discon‐ nection of the high-volt‐ nection of the high-volt‐ age system. age system.

Re-engaging protection. Re-engaging protection.

Is there no voltage?

Is there no voltage?

If not: If not: ♦ Hire high voltage ex‐ ♦ Switch off and secure perts (HVE) and trans‐ the high-voltage sys‐ fer responsibility ⇒ tem ⇒ p3.2.3 roce‐ p3.2.3 rocedure for dure for high voltage high voltage experts experts (HVE)”, page (HVE)”, page 15 .

15 .

If so: ♦ Continue with 4 ⇒ p3.2.2 rocedure for high-voltage tech‐ nicians (HVT)”, page 14 .

If so: ♦ Continue with 4 ⇒ p3.2.3 rocedure for high voltage experts (HVE)”, page 15 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

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High voltage system - general information - Edition 05.2022

4

Quarantine concept

Special tools and workshop equipment required ♦ Warning sign: Warning of dangerous electrical voltage -VAS 6649-

♦ Warning sign: Warning of dangers from batteries -VAS 6786-

♦ Prohibition sign: No entry -VAS 6881Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

♦ Prohibition sign: No fire -VAS 6882-

4. Quarantine concept

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High voltage system - general information - Edition 05.2022 ♦ Temperature measuring device -VAS 6886-

♦ Cut-off -VAS 6884Concept for setting up a quarantine place Note

If the service company does not have a suitable area, the vehicle must be transported to a suitably equipped service company. The responsibility for the transport lies with the sending service company,

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

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High voltage system - general information - Edition 05.2022 1 - VAS 6786 warning sign »Warning of Dangers from Batteries« 2 - VAS 6649 warning sign »Danger High Voltage« 3 - VAS 6882 prohibition sign »No Fire« 4 - VAS 6881 prohibition sign »Do Not Enter« 5 - Parking space including hazard marking 6 - Outer security zone ♦ Minimum distance 5 m to the nearest building or oth‐ er vehicle, unless this is regulated by another na‐ tional regulation.

7 - Suitable open space (e.g. parking space)

Handling high-voltage vehicles which have been in an accident DANGER In the event of serious damage to the high-voltage battery or in case of doubt, the diagnosis should only be carried out after consultation with a high-voltage expert (HVE).

NOTICE

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

♦ Generally, the following points must be observed and fol‐ lowed. ♦ A high-voltage technician (HVT) must be informed when a defective high-voltage vehicle or one which has been in an accident is delivered. ♦ If possible, unload vehicles with a lithium-ion high-voltage battery directly on a suitable surface (e.g. parking space). ♦ Service partners immediately contact the nearest high-volt‐ age service partner or importer.

4. Quarantine concept

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High voltage system - general information - Edition 05.2022 ♦ High-voltage vehicle must be marked with the warning sign: Danger high voltage -VAS 6649- (further identification re‐ quired in quarantine). ♦ Secure the high-voltage vehicle against unauthorized ac‐ cess! ♦ Vehicles which have been in serious accidents and removed lithium-ion high-voltage batteries must be protected against rain and moisture in particular. ♦ It is recommended use a sealed base plate.

Note

The requirements for sealed base plates can differ due to the relevant national regulations and standards!

Proceed further – Record the complaint immediately in DISS. – Look closely at the accident vehicle and assess the following evaluation criteria.

Evaluation criteria

Importance

Are there any signs of a fire?

If a question is answered with "YES": Are sparks, smoke or steam in particular recogniza‐ Attention danger! ► Follow measure (a) ⇒ page 20 .

If all questions are answered with no: ble? ► continue with (b) ⇒ page 21 .

Can you hear unusual noises inside the high-voltage battery (e.g. crackling or hissing)?

Is there a pungent smell?

Are liquids leaking from the high-voltage battery Protected by copyright.

Copying for private or commercial purposes, in part or in whole, is not permitted and / or is there any suspicion of liquids inside the unless authorised ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability battery system (e.g. electrolyte, leaked by coolant)? with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S. Is there any serious mechanical damage with open electrical cables or contacts on the high-voltage bat‐ tery?

Is the high-voltage battery accessible for temperature measurements (e.g. high-voltage battery accessible due to missing or damaged body parts) and is the surface temperature of the high-voltage battery more than 80°C?

Note

Use Temperature measuring device -VAS 6886- to measure the temperature. a) Observe the following measures under "ATTENTION DANGER!": Keep a safe distance and watch the vehicle / battery.

Establish readiness to extinguish the fire and, if there are any signs of fire, call the fire brigade and evacuate the building if necessary.

Do not inhale smoke gases.

In the event of mechanical damage to the high-voltage battery with open, accessible contacts or conduc‐ tors, do not touch the vehicle and high-voltage battery.

Whenever possible, quarantine the vehicle / battery.

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High voltage system - general information - Edition 05.2022 a) Observe the following measures under "ATTENTION DANGER!": Block off and inform the responsible high voltage experts (PDB) or the importer.

b) If the high-voltage vehicle is non-dangerous, then take the following steps: Run the "Guided functions" test program to classify / assess the condition of the lithium-ion high-voltage battery via ⇒ o6.1.2 f lithium-ion high-voltage batteries using ODIS”, page 30 .

Follow the instructions in the test program.

All steps are pictured and described in the ⇒ Vehicle diagnostic tester.

Note ♦ If possible, carry out work stages outside the workshop or on

a suitable surface.

♦ For a diagnosis, it may be necessary to repair the 12V elec‐

trical system.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

4. Quarantine concept

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High voltage system - general information - Edition 05.2022

5

Assessment of accident vehicles

⇒ 5.1 , page 22 ⇒ d5.2 ocumentation”, page 22

5.1

General

The quality of the documentation is of great importance for assessing damage to the battery lower shell. Depending on where the damage is and how deep the dents or scratches are, different measures are recommended: ♦ Paint repair ♦ Replace the lower shell ♦ Replacement of components within the battery

5.2

Photo documentation

Special tools and workshop equipment required ♦ Camera ♦ Duct tape ♦ Digital depth caliper ♦ Centimetre measurement Procedure – Classification of the lithium-ion high-voltage battery using ODIS ⇒ o6.1.2 f lithium-ion high-voltage batteries using ODIS”, page 30 .

Note

The position of the lifting platform should be as high as pos‐ sible, because the entire battery mustProtected later be visibleCopying in thefor private or commercial purposes, in part or in whole, is not permitted by copyright. unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability pictures. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

– Remove underbody panelling ⇒ Body - exterior assembly work; Rep. gr. 66; Underbody panelling.

– Clean the damaged area extensively.

– Align the camera parallel to the underbody.

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– Take photos of the entire battery lower shell -1-, several photos if necessary to get a better overview.

– For the exact localization of the dent -4-, mark the position -3- of the lowest point.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

For support points on the battery bottom shell e.g. use edges.

– Document length and width of the damaged area using two adhesive strips -1-.

Note ♦ The markings are to be made on the bottom shell. One

drawing is not enough!

♦ The direction of travel should be visible on every photo and

numbered in the event of multiple damages.

– Mark direction of travel with “F →” -2- and number in the event of multiple damages.

Take close-up pictures from different angles. These help to bet‐ ter assess the extent of the damage.

5. Assessment of accident vehicles

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High voltage system - general information - Edition 05.2022 Overview of battery bottom shell -1- and area of damage -2-

Examples of different perspectives

– Mark the outline of the dent or damage exactly with a pen.

Sample photos Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

Example 1 Example 2

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High voltage system - general information - Edition 05.2022

Example 3

– MeasureProtected depth by ofcopyright. dent with Digital depth caliper.

Copying for private or commercial purposes, in part or in whole, is not permitted

unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

– Take a photo of the measurement.

5. Assessment of accident vehicles

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6

High-voltage battery

⇒ h6.1 igh-voltage battery”, page 26 ⇒ a6.2 nd store high-voltage battery”, page 33 ⇒ h6.3 igh-voltage batteries”, page 34 ⇒ c6.4 ritical high-voltage batteries with status Warning”, page 42 ⇒ i6.5 nformation on opening and bonding high-voltage batter‐ ies”, page 62

6.1

Classify high-voltage battery

⇒ o6.1.1 f the classification of lithium-ion high-voltage batteries”, page 26 ⇒ o6.1.2 f lithium-ion high-voltage batteries using ODIS”, page 30

6.1.1

Basics of the classification of lithiumion high-voltage batteries

Classification of lithium-ion batteries The lithium-ion high-voltage batteries installed by Škoda in elec‐ tric and hybrid vehicles are highly complex components or sys‐ tems that can be affected by defects, failures or partial failures of the system during their service life.

The lithium-ion high-voltage battery can also be damaged in traffic accidents.

Since lithium-ion high-voltage batteries are dangerous goods due to the substances they contain, the condition of the batter‐ ies has a decisive influence on the handling of high-voltage vehicles in service and in the workshop process.

This applies particularly to: ♦ the qualification requirements for service employees (EIP, HVT, HVE) ♦ the repairability of the lithium-ion high-voltage battery ♦ the transport and packaging process for lithium-ion high-volt‐ age batteries ♦ the quarantine and reporting processes to be carried out in special cases Classification and evaluation criteria for classification In order to identify whether and to what extent the lithium-ion high-voltage battery has an increased hazard potential, it must be classified.

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High voltage system - general information - Edition 05.2022 The following three states can be assigned to the lithium-ion high-voltage battery:

1 - NORMAL (not critical) 2 - WARNING (critical) 3 - DANGER (hazardous) The classification is based on the following assessment dimen‐ sions: ♦ optical and sensory criteria ♦ functional and electrical criteria ♦ thermal criteria The following classification and measure matrix provides a pre‐ cise breakdown and overview of the criteria.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

6. High-voltage battery

27

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High voltage system - general information - Edition 05.2022 Classification matrix Evaluation criteria optically, sensory ♦ No relevant mechani‐ cal damage ♦ No leakage of liquids

Classification functional, electrical thermal ♦ High-voltage bat‐ ♦ Temperature within tery can be diag‐ tolerance nosed ♦ No relevant en‐ tries in the event memory

• NORMAL Not critical: No action needs to be taken.

Fulfilment of ALL criteria leads to classification “Normal” → ♦ Relevant mechanical damage (e.g. dent, crack, opening, defec‐ tive seal) ♦ Corrosive damage ♦ Pungent smell

♦ High-voltage bat‐ ♦ tery cannot be di‐ agnosed

Temperature above tolerance

♦ Relevant entries in the event memory

• WARNING Critical: Failure to follow recom‐ mended measures can result in serious injury / death

Fulfilling ONE criterion leads to classification “Warning” → ♦

Leakage of liquids and / or suspected liq‐ uids in the high-volt‐ age battery system

♦ Temperature ≥ 80 ° C

♦ Smoke / steam

• DANGER Hazardous: Failure to observe recommended measures leads to serious injuries / death.

♦ Fire, sparks ♦ Noises (hissing, crack‐ ling) ♦ Mechanical damage with Protected openlybyaccessible copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability contacts / conductors with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

Fulfilling ONE criterion leads to classification “Danger” →

Measure matrix Classification

NORMAL

Immediate action

♦ Not necessary

Further measures and processes Repair * Interim storage / Packaging and quarantine transport ♦ Repair if neces‐ Interim storage ♦ Original pack‐ sary ♦ Original pack‐ aging aging ♦ outside of drive‐ ways ♦ not stacked, at ground level ♦ indoors or wa‐ ter-protected outdoors

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WARNING

♦ Quarantine ♦ Immediate transfer to the outside area or to the quaran‐ tine area / quar‐ antine cabinet

↑ Conversion to non-critical condition possible by repair‐ ing, where applica‐ ble ♦ Disposal if repair ♦ Inform those re‐ ♦ is not possible sponsible ac‐ cording to the reporting proc‐ ess

♦ Where applica‐ ble, use person‐ al protective equipment (PPE)

DANGER

Special trans‐ port box neces‐ sary (disassem‐ bly may be nec‐ essary)

♦ Transfer the ve‐ ♦ Packing only by hicle / high-volt‐ trained person‐ age battery to a nel suitable foot‐ print outside ♦ water-protected when the highvoltage battery is removed

Further action coordinated by high voltage experts (HVE). ↑ Transfer by qualified personnel Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted ♦ Keep a safe dis‐ ♦ A repair is not Call quarantine ♦ no packing unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does ♦ not guarantee or accept any liability with respect in this document. Copyright by ŠKODA AUTO A. S. tanceto the correctness of information possible and fire depart‐ ment if neces‐ ♦ no transporta‐ ♦ Where applica‐ tion sary ble, call the fire brigade immedi‐ ♦ Watch the highately (e.g. in the voltage battery event of fire) ♦ Do not inhale smoke gases ♦ Block off wide area and inform those responsi‐ ble according to the reporting process (e.g., HVT, HVE, im‐ porter) ♦ If possible, quarantine im‐ mediately

*) According to repair guide / repair level

Classification process ♦ The classification is carried out with the aid of software in the form of the "Guided functions" ⇒ Vehicle diagnostic tester. ♦ In this context, measured values of the cell voltages and temperature sensors are recorded, the event memory is read out and the communication with the control unit for battery control is checked. ♦ The classification via ODIS can be carried out both for lithi‐ um-ion high-voltage batteries installed in the vehicle and for removed high-voltage batteries ⇒ o6.1.2 f lithium-ion highvoltage batteries using ODIS”, page 30 .

6. High-voltage battery

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High voltage system - general information - Edition 05.2022 ♦ Basically only the high voltage expert (HVE) may reclassify the battery based on the case-specific evaluation. ♦ For further details, please refer to the respective repair guide.

Flowchart Criteria: 1. Has a fire broke out?

Optical, 2. Have sparks, smoke or steam been detected? sensory, functional, 3. Noises in the high-voltage battery (e.g. hissing, electrical crackling)? and ther‐ 4. Pungent smell? mal as‐ sessment 5. Liquid leakage or suspected liquids in the highvoltage battery system?

6. Severe mechanical damage to the high-voltage battery.

7. Temperature and cell voltage measurement?

8. Functional test in high-voltage battery? ↓ Categori‐ NORMAL (not critical) sation of WARNING (critical) the classi‐ fication DANGER (hazardous)

6.1.2

Classification of lithium-ion high-volt‐ age batteries using ODIS

Classification using ODIS can be carried out both for lithium-ion high-voltage batteries installed in the vehicle and for removed high-voltage batteries.

The following special tools are required to classify the condition of a lithium-ion high-voltage battery that has been removed and disconnected from the vehicle system: Special tools and workshop equipment Protected by copyright.

Copying required for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability

♦ High-voltage diagnostic 5581or -VAS 5581Awith respectbox to the-VAS correctness of information in this document. Copyright by ŠKODA AUTO A. S.

♦ Adapter cable -VAS 5581/1- or Adapter cable -VAS 5581/1A♦ Adapter cable -VAS 5581/3- or Adapter cable -VAS 5581/3A♦ Adapter cable -VAS 5581/5Condition assessment with high-voltage battery installed in the vehicle – connect to the vehicle ⇒ Vehicle diagnostic tester.

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High voltage system - general information - Edition 05.2022 Workflow in ODIS – Open ODIS. – Continue with Start diagnosis .

– In the window for manual entry of the basic vehicle charac‐ teristics, select manual .

– Remove tick for work with guided troubleshooting .

– Select the "8C Hybrid Battery Management" entry from the control unit list.

Right-click to open the options.

– Select 008C - Condition assessment of the highvoltage battery .

– Confirm with Execute .

Follow the further instructions and questions regarding the con‐ dition of the high-voltage battery to the end.

– Select Protocol .

– Select Save .

– Select Long log in the dialogue window.

Note

The long log contains the readings.

– Confirm with the OK button.

– Save the log as an HTML file including all necessary data.

Condition assessment with the high-voltage battery removed from the vehicle Note

The following process steps illustrate the start of diagnostics for the condition assessment of removed lithium-ion high-voltage batteries using ODIS. – Connect the high-voltage diagnostic box -VAS 5581- or VAS 5581A- -3- with the vehicle-specific test adapters -2- to the communication plug of the high-voltage battery -1-.

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– Turn on the High-voltage diagnostic box -VAS 5581- or -VAS 5581A- -3-.

– Activate terminal 15 F1 .

6. High-voltage battery

31

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High voltage system - general information - Edition 05.2022 – Activate terminal 30 F2 .

– Adjust CAN-R select with F3 on “120-R”.

– Connect with ⇒ Vehicle diagnostic tester.

Note ♦ The further procedure for assessing the condition is dis‐

played to the user on the ⇒ Vehicle diagnostic tester.

♦ All steps are pictured and described in the ⇒ Vehicle diag‐

nostic tester .

Workflow in ODIS – Open ODIS. – Continue with Start diagnosis .

Note

The system automatically searches for the associated VIN / FIN, but will not find a VIN / FIN due to the battery diagnosis if the high-voltage battery is removed.

– Confirm error message asking you to manually identify the vehicle with OK .

– In the window for manual entry of the basic vehicle charac‐ teristics, select manual .

– Enter the VIN / FIN from the vehicle.

– Remove tick for work with guided troubleshooting .

– Confirm information message to confirm the deselection of "Guided troubleshooting" with Yes .

– Select the "8C Hybrid Battery Management" entry from the control unit list.

Right-click to open the options.

– Selection Guided functions .

– Establish communication connection by selecting Identify control unit .

Note

If the control unit is not found, identify it manually.

– Retrieve the options again by right-clicking on "8C Hybrid Battery Management".

– Select 008C - Condition assessment of the highvoltage battery .

– Confirm with Execute .

Follow the further instructions and questions regarding the con‐ dition of the high-voltage battery to the end.

– Select Protocol .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted

authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability – unless Select Save . with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

– Select Long log in the dialogue window.

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High voltage system - general information - Edition 05.2022 Note

The long log contains the readings.

– Confirm with the OK button.

– Save the log as an HTML file including all necessary data.

6.2

Handle and store high-voltage battery

The lithium-ion high-voltage batteries are classified as hazard‐ ous goods. Transport and storage are therefore subject to cer‐ tain restrictions, which may vary from country to country. Ac‐ cording to the classification of a lithium-ion high-voltage battery, various types of packaging are necessary.

Interim storage of lithium-ion high-voltage batteries ♦ The lithium-ion high-voltage batteries must not be stored outdoors or in the direct work area. ♦ The lithium-ion high-voltage battery must be protected against mechanical and thermal influences and against moisture. ♦ The location of the intermediate storage must not be ac‐ cessible to unauthorized workshop employees or customers (e.g. warehouse).

Replacement of the lithium-ion high-voltage battery - no meas‐ ures required for the high-voltage battery ♦ The removed lithium-ion high-voltage battery is placed in the original packaging. ♦ The lithium-ion high-voltage battery can be stored or re‐ turned in its original packaging. ♦ Due to the large weight, suitable tools are required for trans‐ port within the workshop.

Replacement of the lithium-ion high-voltage battery - measures required for the high-voltage battery 1. Classification of the lithium-ion high-voltage battery using the test program according to the following criteria: ♦ Thermal abnormality of the lithium-ion high-voltage battery. ♦ Optical damage to the lithium-ion high-voltage battery. ♦ Functional abnormalities of the lithium-ion high-voltage bat‐ tery.

2. Storage of lithium-ion high-voltage batteries if one of the points in 1. applies. ♦ Lithium-ion high-voltage battery remains in the vehicle. ♦ Park the vehicle safely in accordance with the quarantine concept ⇒ c4 oncept”, page 17 .

If additional measures are necessary based on the classification for the lithium-ion high-voltage battery, the first thing to do is to make a notification or request a technical repair via the DISS system. Product Support then decides on the further procedure and, if necessary, sends a specially qualified employee.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

6. High-voltage battery

33

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High voltage system - general information - Edition 05.2022

6.3

Packaging high-voltage batteries

⇒ t6.3.1 he high-voltage battery, Citigo-e iV”, page 34

6.3.1

Packing the high-voltage battery, Citi‐ go-e iV

Special tools and workshop equipment required ♦ Workshop crane, e.g. -VAS 6100-

♦ Interceptor -10-222A- or -10-222B-

♦ Supporting device -T10528A♦ Scissor lift table -VAS 6131B-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

♦ Plate -VAS 6131/10-1-

34 Rep. gr.93 - Electric drive systems

Citigo-e iV 2020 ➤, Enyaq 2021 ➤, Enyaq Coupe 2021 ➤, Octavia IV 2020 ➤, Superb ...

High voltage system - general information - Edition 05.2022 ♦ Assimilation -VAS 6131/13-2- composed of Supplementary set -VAS 6131/13-

Overview of workflow

The process for packaging a lithium-ion high-voltage battery for the Citigo-e iV can be broken down into the following steps: A - Prepare the scissor lift table and mount tool.

B - Place the new high-voltage battery on the lid of the OT box.

C - Remove the high-voltage battery and place it in the OT box.

D - Place and install a new high-voltage battery from the lid of the OT box on the scissor lift table.

E - Close the OT box and prepare it for transport.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

6. High-voltage battery

35

Citigo-e iV 2020 ➤, Enyaq 2021 ➤, Enyaq Coupe 2021 ➤, Octavia IV 2020 ➤, Superb ...

High voltage system - general information - Edition 05.2022 Prepare the scissor lift table and mount tool

– Build and align mounts -1- to -4- on scissor lift table -VAS 6131B-.

Mounts front -1- and -2-

1 - Mount -VAS 6131/10-112 - Knurled piece -VAS 6131/10-5Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability

3 - Mounting shank -VASof6131/10-4with respect to the correctness information in this document. Copyright by ŠKODA AUTO A. S. 4 - Plate -VAS 6131/10-1Mounts rear -3- and -4-

1 - Mount -VAS 6131/13-2-

36 Rep. gr.93 - Electric drive systems

Citigo-e iV 2020 ➤, Enyaq 2021 ➤, Enyaq Coupe 2021 ➤, Octavia IV 2020 ➤, Superb ...

High voltage system - general information - Edition 05.2022 2 - Knurled piece -VAS 6131/10-53 - Mounting shank -VAS 6131/10-44 - Plate -VAS 6131/10-1Prepare for mount

– Push mount -T10528/1- -2- on the Interceptor -10-222A- or -10-222B- -1-.

– Adjust and fix themount -T10528/1- -2- to dimension -a-.

•

Size -a- 515 mm

– Hang interceptor -10-222A- or -10-222B- with mount T10528/1- to the workshop crane e.g. -VAS 6100-.

– Slide the 2 hooks -10-222A/10- -3- onto the first crossbeam -T10528/2- -2- as shown.

– Plug the external locking bolts -T10528/3- into position 6 -arrows-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted

–unless Push interceptor -10-222Aor -10-222Bon prepared authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does notthe guarantee or accept any liability with respect to-T10528/2the correctness ofin information this document. Copyright by ŠKODA AUTO A. S. traverse -Arrowindirection-.

6. High-voltage battery

37

Citigo-e iV 2020 ➤, Enyaq 2021 ➤, Enyaq Coupe 2021 ➤, Octavia IV 2020 ➤, Superb ...

High voltage system - general information - Edition 05.2022 •

The crossbeam -T10528/2- must be flush -arrow-.

– Fix the crossbeam -T10528/2- in this position.

– Slide the 2 hooks -10-222A/10- onto the second crossbeam -T10528/2- as shown.

– Push second prepared traverse -T10528/2- -2- on the inter‐ ceptor -10-222A- or -10-222B- and do not secure yet.

– Plug the internal locking bolts -T10528/3- into position 2 -arrows-.

Place new High-voltage battery 1 -AX2- on the lid of the OT box.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

– Open the OT box.

– Remove the lid and place it on the floor with the top facing upwards so that the lid can be reached with Scissor lift table -VAS 6131B- and by the workshop crane.

– Remove fastening nuts -Arrows-with which the High-voltage battery 1 -AX2- is fixed in the OT box.

– Remove nuts and washers.

– Fasten the eyebolts -T10528/5- at the points shown -arrowsonto high-voltage battery 1 -AX2-.

– Drive arm of the workshop crane, e.g. -VAS 6100- with the ready prepared hitch -T10528A- using the High-voltage bat‐ tery 1 -AX2-.

38 Rep. gr.93 - Electric drive systems

Citigo-e iV 2020 ➤, Enyaq 2021 ➤, Enyaq Coupe 2021 ➤, Octavia IV 2020 ➤, Superb ...

High voltage system - general information - Edition 05.2022

NOTICE Damage to the high-voltage battery 1 -AX2- possible.

Do not place the hitch -T10528A- onto the high-voltage battery 1 -AX2-.

– Suspend the hook -10-222A/10- in the eyebolts -T10528/5-arrows-.

– Align the second still removed traverse -T10528/2- -1- so that the hook -10-222A/10- stands vertically and fix.

– Lift High-voltage battery 1 -AX2- in -Arrow direction- out of OT box.

– Place High-voltage battery 1 -AX2- on the top of the lid of the OT box.

NOTICE Damage to the high-voltage battery 1 -AX2- possible.

Do not place the hitch -T10528A- onto the high-voltage battery 1 -AX2-.

– Remove hook -10-222A/10-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

6. High-voltage battery

39

Citigo-e iV 2020 ➤, Enyaq 2021 ➤, Enyaq Coupe 2021 ➤, Octavia IV 2020 ➤, Superb ...

High voltage system - general information - Edition 05.2022 Remove High-voltage battery 1 -AX2- and place in the OT box – Carry out condition assessment of the High-voltage battery 1 -AX2- when installed ⇒ o6.1.2 f lithium-ion high-voltage batteries using ODIS”, page 30 .

– Remove High-voltage battery 1 -AX2-⇒ Rep. gr. 93; Highvoltage battery unit; remove and installHigh-voltage battery 1 -AX2- .

– Make visual inspection of the High-voltage battery 1 -AX2- to ensure the final portability.

– Mount High-voltage battery 1 -AX2- from Scissor lift table -VAS 6131B-.

– Lower High-voltage battery 1 -AX2- into OT box.

NOTICE Observe fixing screws -1-!

Make sure that all fixing screws -1- lead through the associated holes of the High-voltage battery 1 -AX2-.

– Remove hook -10-222A/10-.

– Unscrew eye bolts -T10528/5-.

NOTICE ♦ If a fixing screw turns, it is necessary to tighten the fixing screw. ♦ When tightening the screws, make sure that the bottom battery shell does not warp.

– Screw the nuts with washers onto the 4 fixing screws in the OT box and tighten them.

40 Rep. gr.93 - Electric drive systems

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

Citigo-e iV 2020 ➤, Enyaq 2021 ➤, Enyaq Coupe 2021 ➤, Octavia IV 2020 ➤, Superb ...

High voltage system - general information - Edition 05.2022

Put new High-voltage battery 1 -AX2- from the lid of the OT box onto the Scissor lift table -VAS 6131B- and install.

– Mount High-voltage battery 1 -AX2- from the lid of the OT box.

– Put High-voltage battery 1 -AX2- on Scissor lift table VAS 6131B-.

– Install High-voltage battery 1 -AX2- ⇒ Rep. gr. 93; High-volt‐ age battery unit; remove and install High-voltage battery 1 -AX2- .

Close the OT box and prepare it for transport – Put on the lid of the OT box and close it with the existing clips.

– Attach lashing straps.

– Attach and check the labelling of hazardous goods and packages.

– Fill out and enclose the transport documents.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted Advice on transport preparation and hazardous goods labelling unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability (Europe) with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

6. High-voltage battery

41

Citigo-e iV 2020 ➤, Enyaq 2021 ➤, Enyaq Coupe 2021 ➤, Octavia IV 2020 ➤, Superb ...

High voltage system - general information - Edition 05.2022 1-

“Protect from moisture”

2-

“Caution fragile”

3-

“This side up”

4-

“Limitation of the mass of the stack load”

5-

Hazardous goods label: hazardous goods class “9A”, brand size at least 100x100 mm

6-

Lettering “UN 3480” Text height at least 12 mm Note

Logistics information can be found at: https: //eportal.skoda.vwg/b2bpub‐ lish/content/b2b/skoda/cs/aftersales/gp/programme/bezpe_nost‐ ni-listy--aktualni-/li-ion-baterie/p_eprava- li-ion-baterie.html

6.4

Packaging critical high-voltage batter‐ ies with status “Warning”

⇒ c6.4.1 ritical high-voltage batteries with status Warning, Mod‐ ule”, page 42 ⇒ c6.4.2 ritical high-voltage batteries with status warning, Su‐ perb III iV, Octavia IV iV”, page 48 ⇒ c6.4.3 ritical high-voltage batteries with status Warning, Citi‐ go-e iV”, page 56

6.4.1

Packaging critical high-voltage batter‐ ies with status “Warning”, Module

DANGER Danger to life due to high voltage.

Death or severe injury from electric shock.

– Wear arc-proof clothing.

– Wear an insulated helmet with face shield.

– Wear protective gloves.

– Wear safety shoes. ♦ Only after prior instruction (for the respective certified trans‐ port box), at least one responsible high voltage expert (HVE). ♦ In addition, hazardous goods instruction is required for per‐ sons who are involved in the transport of hazardous goods Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted according tounless 1.3 authorised ADR. by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

♦ Both lithium-ion high-voltage batteries and lithium-ion highvoltage battery modules may only be packed if they are prepared for transport! See transport regulations D / BAM / GGVSEB.

This guide describes the packaging processes for critical highvoltage batteries classified with the status “Warning”.

To determine whether and to what extent a lithium-ion high-volt‐ age battery poses an increased hazard potential, it must be classified ⇒ h6.1 igh-voltage battery”, page 26 .

42 Rep. gr.93 - Electric drive systems

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• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

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Citigo-e iV 2020 ➤, Enyaq 2021 ➤, Enyaq Coupe 2021 ➤, Octavia IV 2020 ➤, Superb ...

High voltage system - general information - Edition 05.2022 Process according to a central concept for Europe Part 1 1. - High-voltage battery classified as critical.

2. - Quarantine critical high-voltage battery ⇒ c4 oncept”, page 17 . Fasten foil thermometer to the High-voltage battery 1 -AX2so that a possible temperature change inside the battery is recognizable.

3. - High voltage expert (HVE) contacts the service provider and coordinates the delivery date for the transport container (after prior consultation with the importer).

4. - High-voltage battery shows no reaction for at least 5 days, especially no temperature increase.

5. - Commissioning service providers.

Part 2 6. - Delivery of the transport container including hollow glass granulate.

7. - After prior training, packaging of the high-voltage battery by high-voltage experts (HVE).

8. - Info to importer about provision for removal.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted

unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability 9. - Removal of the packaged high-voltage battery. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

10. - Invoice to importer.

Transport box

Note ♦ In the illustration, e.g. the Lion Guard transport box. ♦ Service providers' transport boxes may vary.

A special transport box is required to ship lithium-ion high-volt‐ age batteries classified as critical for the Superb III iV, Octavia IV iV and Citigo-e iV models.

The boxes are currently available in 2 sizes: M and XL. Description Transport container size M enables the shipment of one HV battery of the following models: ♦ Superb III iV ♦ Octavia IV iV ♦ Individual modules of the HV battery or several modules 6. High-voltage battery

43

Citigo-e iV 2020 ➤, Enyaq 2021 ➤, Enyaq Coupe 2021 ➤, Octavia IV 2020 ➤, Superb ...

High voltage system - general information - Edition 05.2022 Transport container size XL enables the shipment of HV batter‐ ies of the following models: ♦ Citigo-e IV ♦ Superb III iV ♦ Octavia IV iV ♦ Individual modules of the HV battery or several modules Packaging Special tools and workshop equipment required ♦ Foil thermometer (irreversible) Temperature range: at least 40 to 60 ° C

♦ Warning sign: Warning of dangers from batteries -VAS 6786-

♦ Warning sign: Warning of dangerous electrical voltage -VAS 6649Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

♦ Cut-off -VAS 6884♦ Personal protective equipment (PPE) Procedure – Secure all contacts of the battery modules against external short circuits.

– Close all openings for equipment, except for electrolyte.

44 Rep. gr.93 - Electric drive systems

Citigo-e iV 2020 ➤, Enyaq 2021 ➤, Enyaq Coupe 2021 ➤, Octavia IV 2020 ➤, Superb ...

High voltage system - general information - Edition 05.2022 – Remove any build-up of hazardous substances and electro‐ lyte on the outside of the battery modules.

Apply foil thermometers -1- on the battery modules

– Stick at least 5 foil thermometers -1- on the housing of the battery modules as shown in the illustration.

NOTICE Battery modules may sustain damage.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability Protect with therespect modules from heat and direct sunlight. to the correctness of information in this document.

Copyright by ŠKODA AUTO A. S.

– Document the values in writing or by photo immediately after sticking and before shipping.

– Observe the battery modules for at least 5 days before transportation.

– Record the temperature of the battery modules and the am‐ bient temperature.

If there is an increase in temperature during this time, wait for the reaction before another observation is carried out for at least 5 days.

– Repeat this process until no further reactions are observed.

– Pack the module in a suitable material (e.g. plastic bag and adhesive tape).

– Open the latches of the transport box.

– Remove the lid of the transport box and take out the bag with the hollow glass granulate.

The amount of hollow glass granulate is sufficient.

– Visual inspection of the all-round rubber seal -1- as well as the relief valves -2- for external damage.

6. High-voltage battery

45

Citigo-e iV 2020 ➤, Enyaq 2021 ➤, Enyaq Coupe 2021 ➤, Octavia IV 2020 ➤, Superb ...

High voltage system - general information - Edition 05.2022

– Pour the hollow glass granulate into the bottom of the trans‐ port box up to a layer thickness of at least 200 mm.

– Place the module in the transport box. Some modules have to be vertical.

Distance -a- to the side edges and between modules should be at least 200 mm.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

– Check whether there is at least 200 mm space between the modules and the upper edge of the transport box for a surrounding layer of the hollow glass granulate.

– Pour in the hollow glass granulate so that the free spaces and the entire transport box are filled to the top.

46 Rep. gr.93 - Electric drive systems

Citigo-e iV 2020 ➤, Enyaq 2021 ➤, Enyaq Coupe 2021 ➤, Octavia IV 2020 ➤, Superb ...

High voltage system - general information - Edition 05.2022

NOTICE ♦ Make sure that the surrounding rubber seals are not dam‐ aged. ♦ If the lid closes with difficulty, turn the lid 180 ° if necessa‐ ry.

– Place the lid on the transport box and close tightly with the circumferential tension locks, re-tighten the locks if necessa‐ ry.

– Place the warning label for hazardous substances and apply on both long sides of the transport box.

♦ Hazardous goods class “9A” ♦ Lettering “UN 3480” ♦ “This side up” ♦ Lettering “Lithium-ion high-voltage batteries damaged / de‐ fective” Advice on transport preparation and hazardous goods labelling (Europe)

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

1-

“Protect from moisture”

2-

“Caution fragile”

3-

“This side up”

4-

“Limitation of the mass of the stack load”

6. High-voltage battery

47

Citigo-e iV 2020 ➤, Enyaq 2021 ➤, Enyaq Coupe 2021 ➤, Octavia IV 2020 ➤, Superb ...

High voltage system - general information - Edition 05.2022 5-

Hazardous goods label: hazardous goods class “9A”, brand size at least 100x100 mm

6-

Lettering “UN 3480” Text height at least 12 mm Note

Logistics information can be found at: https: //eportal.skoda.vwg/b2bpub‐ lish/content/b2b/skoda/cs/aftersales/gp/programme/bezpe_nost‐ ni-listy--aktualni-/li-ion-baterie/p_eprava- li-ion-baterie.html

6.4.2

Packaging critical high-voltage batter‐ ies with status “warning”, Superb III iV, Octavia IV iV

DANGER Danger to life due to high voltage.

Death or severe injury from electric shock.

– Wear arc-proof clothing.

– Wear an insulated helmet with face shield.

– Wear protective gloves.

– Wear safety shoes. ♦ Only after prior instruction (for the respective certified trans‐ port box), at least one responsible high voltage expert (HVE). ♦ In addition, hazardous goods instruction is required for per‐ sons who are involved in the transport of hazardous goods according to 1.3 ADR. ♦ Both lithium-ion high-voltage batteries and lithium-ion highvoltage battery modules may only be packed if they are prepared for transport! See transport regulations D / BAM / GGVSEB. This guide describes the packaging processes for critical highvoltage batteries classified with the status “Warning”.

To determine whether and to what extent a lithium-ion high-volt‐ age battery poses an increased hazard potential, it must be by copyright. classified ⇒ h6.1 igh-voltageProtected battery”, pageCopying 26 . for private or commercial purposes, in part or in whole, is not permitted

unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability

withconcept respect to the Process according to a central forcorrectness Europeof information in this document. Copyright by ŠKODA AUTO A. S.

Part 1 1. - High-voltage battery classified as critical.

2. - Quarantine critical high-voltage battery ⇒ c4 oncept”, page 17 . Fasten foil thermometer to the High-voltage battery 1 -AX2so that a possible temperature change inside the battery is recognizable.

3. - High voltage expert (HVE) contacts the service provider and coordinates the delivery date for the transport container (after prior consultation with the importer).

4. - High-voltage battery shows no reaction for at least 5 days, especially no temperature increase.

5. - Commissioning service providers.

48 Rep. gr.93 - Electric drive systems

Citigo-e iV 2020 ➤, Enyaq 2021 ➤, Enyaq Coupe 2021 ➤, Octavia IV 2020 ➤, Superb ...

High voltage system - general information - Edition 05.2022 Part 2 6. - Delivery of the transport container including hollow glass granulate.

7. - After prior training, packaging of the high-voltage battery by high-voltage experts (HVE).

8. - Info to importer about provision for removal.

9. - Removal of the packaged high-voltage battery.

10. - Invoice to importer.

Transport box

Note ♦ In the illustration, e.g. the Lion Guard transport box. ♦ Service providers' transport boxes may vary.

A special transport box is required to ship lithium-ion high-volt‐ age batteries classified as critical for the Superb III iV, Octavia IV iV and Citigo-e iV models.

The boxes are currently available in 2 sizes: M and XL. Description Transport container size M enables the shipment of one HV battery of the following models: ♦ Superb III iV ♦ Octavia IV iV ♦ Individual modules of the HV battery or several modules Transport container size XL enables the shipment of HV batter‐ ies of the following models: ♦ Citigo-e IV ♦ Superb III iV ♦ Octavia IV iV ♦ Individual modules of the HV battery or several modules Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability

Packaging with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S. Special tools and workshop equipment required

6. High-voltage battery

49

Citigo-e iV 2020 ➤, Enyaq 2021 ➤, Enyaq Coupe 2021 ➤, Octavia IV 2020 ➤, Superb ...

High voltage system - general information - Edition 05.2022 ♦ Supporting device -3033-

♦ Workshop crane, e.g. -VAS 6100-

♦ Tensioning strap -T40155A-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

♦ Adapter -T10542A-

50 Rep. gr.93 - Electric drive systems

Citigo-e iV 2020 ➤, Enyaq 2021 ➤, Enyaq Coupe 2021 ➤, Octavia IV 2020 ➤, Superb ...

High voltage system - general information - Edition 05.2022 ♦ Shackle -VAS 691 009A-

♦ High-voltage tool set -VAS 6762-

♦ Foil thermometer (irreversible) Temperature range: at least 40 to 60 ° C

♦ Warning sign: Warning of dangers from batteries -VAS 6786-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

6. High-voltage battery

51

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• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

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Citigo-e iV 2020 ➤, Enyaq 2021 ➤, Enyaq Coupe 2021 ➤, Octavia IV 2020 ➤, Superb ...

High voltage system - general information - Edition 05.2022 ♦ Warning sign: Warning of dangerous electrical voltage -VAS 6649-

♦ Cut-off -VAS 6884♦ Personal protective equipment (PPE) Procedure – Secure all contacts of the High-voltage battery 1 -AX2against external short circuit.

– Close all openings for equipment, except for electrolyte.

– Remove build-up of hazardous substances as well as the electrolyte on the outside of the High-voltage battery 1 AX2-.

Apply foil thermometers -1- on High-voltage battery 1 -AX2-.

– Stick at least 7 foil thermometers -1- on High-voltage battery 1 -AX2-.

NOTICE Damage high-voltage battery is possible.

Protectedto by the copyright.

Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

Protect the high-voltage battery from heat and direct sunlight.

– Document the values in writing or by photo immediately after sticking and before shipping.

– Observe High-voltage battery 1 -AX2- for at least 5 days before transportation.

– Record the temperature of the High-voltage battery 1 -AX2and the ambient temperature.

If there is an increase in temperature during this time, wait for the reaction before another observation is carried out for at least 5 days.

– Repeat this process until no further reactions are observed.

– Open the latches of the transport box.

52 Rep. gr.93 - Electric drive systems

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High voltage system - general information - Edition 05.2022 – Remove the lid of the transport box and take out the bag with the hollow glass granulate.

The amount of hollow glass granulate is sufficient.

– Visual inspection of the all-round rubber seal -1- as well as the relief valves -2- for external damage.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

– Pour the hollow glass granulate into the bottom of the trans‐ port box up to a layer thickness of at least 200 mm.

– Hang spindle -3033/8- in position -1- and -2- the interceptor -3033-.

– Hang interceptor -3033- -2- to the workshop crane e.g. -VAS 6100- -3-.

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High voltage system - general information - Edition 05.2022

Note

If the High-voltage battery 1 -AX2- is in a horizontal position (e.g. at ground level), then first turn with the only adapters -T10542A- attached on only one side. The adapters -T10542Awill then be attached staggered.

– Adapter -T10542A- -1- staggered, screw on screws of the High-voltage battery 1 -AX2- as shown in thebyillustration and Protected copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability tighten to 20 Nm. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

– Stand High-voltage battery 1 -AX2- -1- upright on the hollow glass granulate diagonally in the middle.

The distance to the side walls should be at least 120 mm.

When packing two High-voltage batteries 1 -AX2- the battery distance to the side walls should be at least 120 mm in the XXL transport box -a- .

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High voltage system - general information - Edition 05.2022

•

Minimum distance between batteries -b- must be at least 200 mm.

– Check that between the High-voltage battery 1 -AX2- and the upper edge of the transport box has at least 120 mm of space for abysurrounding oforthe hollow glassingranulate.

Protected copyright. Copyinglayer for private commercial purposes, part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability

respect to the correctness of information so in this document.

Copyright by ŠKODA AUTO A. S. – Pour with in the hollow glass granulate that the free spaces and the entire transport box are filled to the top.

NOTICE ♦ Make sure that the surrounding rubber seals are not dam‐ aged. ♦ If the lid closes with difficulty, turn the lid 180 ° if necessa‐ ry.

– Place the lid on the transport box and close tightly with the circumferential tension locks, re-tighten the locks if necessa‐ ry.

– Place the warning label for hazardous substances and apply on both long sides of the transport box.

♦ Hazardous goods class “9A” ♦ Lettering “UN 3480” ♦ “This side up” ♦ Lettering “Lithium-ion high-voltage batteries damaged / de‐ fective” 6. High-voltage battery

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High voltage system - general information - Edition 05.2022 Advice on transport preparation and hazardous goods labelling (Europe)

1-

“Protect from moisture”

2-

“Caution fragile”

3-

“This side up”

4-

“Limitation of the mass of the stack load”

5-

Hazardous goods label: hazardous goods class “9A”, brand size at least 100x100 mm

6-

Lettering “UN 3480” Text height at least 12 mm Note

Logistics information can be found at: https: //eportal.skoda.vwg/b2bpub‐ lish/content/b2b/skoda/cs/aftersales/gp/programme/bezpe_nost‐ ni-listy--aktualni-/li-ion-baterie/p_eprava- li-ion-baterie.html

6.4.3

Packaging critical high-voltage batter‐ ies with status “Warning”, Citigo-e iV

DANGER Danger to life due to high voltage.

Death or severe injury from electric shock.

– Wear arc-proof clothing.

– Wear an insulated helmet with face shield.

– Wear protective gloves.

– Wear safety shoes.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

♦ Only after prior instruction (for the respective certified trans‐ port box), at least one responsible high voltage expert (HVE). ♦ In addition, hazardous goods instruction is required for per‐ sons who are involved in the transport of hazardous goods according to 1.3 ADR. ♦ Both lithium-ion high-voltage batteries and lithium-ion highvoltage battery modules may only be packed if they are

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High voltage system - general information - Edition 05.2022 prepared for transport! See transport regulations D / BAM / GGVSEB. This guide describes the packaging processes for critical highvoltage batteries classified with the status “Warning”.

To determine whether and to what extent a lithium-ion high-volt‐ age battery poses an increased hazard potential, it must be classified ⇒ h6.1 igh-voltage battery”, page 26 .

Process according to a central concept for Europe Part 1 1. - High-voltage battery classified as critical.

2. - Quarantine critical high-voltage battery ⇒ c4 oncept”, page 17 . Fasten foil thermometer to the High-voltage battery 1 -AX2so that a possible temperature change inside the battery is recognizable.

3. - High voltage expert (HVE) contacts the service provider and coordinates the delivery date for the transport container (after prior consultation with the importer).

4. - High-voltage battery shows no reaction for at least 5 days, especially no temperature increase.

5. - Commissioning service providers.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

Part 2

6. - Delivery of the transport container including hollow glass granulate.

7. - After prior training, packaging of the high-voltage battery by high-voltage experts (HVE).

8. - Info to importer about provision for removal.

9. - Removal of the packaged high-voltage battery.

10. - Invoice to importer.

Transport box

Note ♦ In the illustration, e.g. the Lion Guard transport box. ♦ Service providers' transport boxes may vary.

A special transport box is required to ship lithium-ion high-volt‐ age batteries classified as critical for the Superb III iV, Octavia IV iV and Citigo-e iV models.

The boxes are currently available in 2 sizes: M and XL.

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High voltage system - general information - Edition 05.2022 Description Transport container size M enables the shipment of one HV battery of the following models: ♦ Superb III iV ♦ Octavia IV iV ♦ Individual modules of the HV battery or several modules Transport container size XL enables the shipment of HV batter‐ ies of the following models: ♦ Citigo-e IV ♦ Superb III iV ♦ Octavia IV iV ♦ Individual modules of the HV battery or several modules Packaging Special tools and workshop equipment required ♦ Workshop crane, e.g. -VAS 6100-

♦ High-voltage tool set -VAS 6762Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

♦ Foil thermometer (irreversible) Temperature range: at least 40 to 60 ° C

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High voltage system - general information - Edition 05.2022 ♦ Warning sign: Warning of dangers from batteries -VAS 6786-

♦ Warning sign: Warning of dangerous electrical voltage -VAS 6649-

♦ Cut-off -VAS 6884♦ Personal protective equipment (PPE) Procedure – Secure all contacts of the High-voltage battery 1 -AX2against external short circuit.

– Close all openings for equipment, except for electrolyte.

– Remove build-up of hazardous substances as well as the electrolyte on the outside of the High-voltage battery 1 AX2-.

Apply foil thermometers -1- on High-voltage battery 1 -AX2-.

– Stick at least 13 foil thermometers -1- on High-voltage bat‐ tery 1 -AX2-.

NOTICE

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

Damage to the high-voltage battery is possible.

Protect the high-voltage battery from heat and direct sunlight.

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High voltage system - general information - Edition 05.2022 – Document the values in writing or by photo immediately after sticking and before shipping.

– Observe High-voltage battery 1 -AX2- for at least 5 days before transportation.

– Record the temperature of the High-voltage battery 1 -AX2and the ambient temperature.

If there is an increase in temperature during this time, wait for the reaction before another observation is carried out for at least 5 days.

– Repeat this process until no further reactions are observed.

– Open the latches of the transport box.

– Remove the lid of the transport box and take out the bag with the hollow glass granulate.

The amount of hollow glass granulate is sufficient.

– Visual inspection of the all-round rubber seal -1- as well as the relief valves -2- for external damage.

– Pour the hollow glass granulate into the bottom of the trans‐ port box up to a layer thickness of at least 200 mm.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

– Record High-voltage battery 1 -AX2- as in chapter ⇒ t6.3.1 he high-voltage battery, Citigo-e iV”, page 34 .

– Put High-voltage battery 1 -AX2- in transport box.

Distance -a- of the High-voltage battery 1 -AX2- to the side walls should be at least 120 mm.

60 Rep. gr.93 - Electric drive systems

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High voltage system - general information - Edition 05.2022

– Check that between the High-voltage battery 1 -AX2- and the upper edge of the transport box has at least 120 mm of space for a surrounding layer of the hollow glass granulate.

– Pour in the hollow glass granulate so that the free spaces and the entire transport box are filled to the top.

NOTICE ♦ Make sure that the surrounding rubber seals are not dam‐ aged. ♦ If the lid closes with difficulty, turn the lid 180 ° if necessa‐ ry.

– Place the lid on the transport box and close tightly with the circumferential tension locks, re-tighten the locks if necessa‐ ry.

– Place the warning label for hazardous substances and apply on both long sides of the transport box.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

♦ Hazardous goods class “9A” ♦ Lettering “UN 3480” ♦ “This side up” ♦ Lettering “Lithium-ion high-voltage batteries damaged / de‐ fective”

6. High-voltage battery

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High voltage system - general information - Edition 05.2022 Advice on transport preparation and hazardous goods labelling (Europe)

1-

“Protect from moisture”

2-

“Caution fragile”

3-

“This side up”

4-

“Limitation of the mass of the stack load”

5-

Hazardous goods label: hazardous goods class “9A”, brand size at least 100x100 mm

6-

Lettering “UN 3480” Text height at least 12 mm

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

Note

Logistics information can be found at: https: //eportal.skoda.vwg/b2bpub‐ lish/content/b2b/skoda/cs/aftersales/gp/programme/bezpe_nost‐ ni-listy--aktualni-/li-ion-baterie/p_eprava- li-ion-baterie.html

6.5

Additional information on opening and bonding high-voltage batteries

Only valid for Citigo-e iV Special tools and workshop equipment required ♦ Double cartridge gun -VAS 5237-

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High voltage system - general information - Edition 05.2022 ♦ Electric knife, e.g. -V.A.G 1561A- or -V.A.G 1561B-

♦ Repair set for high-voltage battery -VAS 6900-

♦ Cutting blade 27 mm -VAS 6900/1♦ Scraper knife, 25 mm -VAS 6900/2♦ One-handed clamps -VAS 6900/4♦ High-voltage tool set -VAS 6762Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

♦ Disassembly wedge -3409-

♦ Commercially-available vacuum cleaner with plastic nozzle

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High voltage system - general information - Edition 05.2022 ♦ 2-K windscreen adhesive set 1) ♦ Cleaning solution 1) ♦ Applicator 1) ♦ Glass / finish primer 1) ♦ Activator 1) ♦ Corrosion protection wax 1) ♦ Sandpaper / sanding fleece (grain 120-240) ♦ Lint-free cleaning rag Note

The part numbers of the materials can be found in the ⇒ Elec‐ tronic catalogue of original parts (ETKA).

1) Processing instructions according to the manufacturer's instructions are de‐ scribed in the package insert.

Opening DANGER Danger to life due to high voltage.

Death or severe injury from electric shock.

– Have the high-voltage system switched off by a suitably qualified person ⇒ /1.2 personnel qualification”, page 6 .

– Wear arc-proof clothing.

– Wear an insulated helmet with face shield.

– Wear protective gloves.

– Wear safety shoes.

DANGER

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

Danger to life due to voltage AC ≥ 30 V and DC ≥ 60 V. Severe physical injury or death from electric shock or arcing. ♦ For the following work, a second person with the ap‐ propriate qualifications (minimum qualification: electrically trained person EIP and mechanic) must be present as a supervisor. ♦ If necessary, the second person can support the high-volt‐ age expert HVE within the scope of their qualification. ♦ Observe country-specific requirements and laws.

– Unscrew screws -1-.

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High voltage system - general information - Edition 05.2022

– Remove the nuts -1- from the charging connection -2-.

– Unclip the charging port -arrows-.

– Turn charging port -1- in -Arrow direction-.

– Remove the fuse -2- by prying it off at the sides and pulling it outwards.

– Disconnect the 2 cables ⇒ Electrical system - general infor‐ mation; Rep. gr. 97; Cables.

– Unscrew screws -Arrows-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

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– Pry off stop buffers on the right and left.

– Fold up the shielding -arrows- 90°.

– Attach the cutting blade 27 mm -VAS 6900/1- to the electric knife e.g. -V.A.G 1561A- or -V.A.G 1561B-.

– Set the speed on the electric knife e.g. -V.A.G 1561A- or -V.A.G 1561B- to 4.

Note

Wear protective shoes, safety goggles and ear protection!

– Hold the electric knife with both hands.

– Cut open glued seam in the back left beginning with an elec‐ tric knife e.g. -V.A.G 1561A- or -V.A.G 1561B- and cutting knife 27 mm -VAS 6900/1-.

– Cut and break off corners of the battery top shellCopying in thefor private or commercial purposes, in part or in whole, is not permitted Protected by copyright. places where the cutting knife 27unless mmauthorised -VAS 6900/1doesA. not by ŠKODA AUTO S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S. reach the adhesive seam.

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High voltage system - general information - Edition 05.2022 Due to the design of the blade, the electric knife e.g. -V.A.G 1561A- or -V.A.G 1561B- is angled at approx. 45 ° upwards.

Always guide the electric knife gently upwards along the top shell of the high-voltage battery.

Note ♦ Spacers are located at regular intervals on the top shell of

the high-voltage battery.

♦ Spacers must not be cut so that they do not slip into the

bottom shell.

♦ Damage to the high-voltage battery bottom shell must be

avoided.

Overview of spacers on the high-voltage battery top shell

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

1-

Spacers in the screw connections

2-

Spacers in the adhesive seam

– Pull out electric knife e.g. -V.A.G 1561A- or -V.A.G 1561Bfrom adhesive seam in the area of the spacers -Arrows-.

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– Push the electric knife e.g. -V.A.G 1561A- or -V.A.G 1561Bdeeper into the adhesive seam after the spacers -Arrows-.

Position of the disassembly wedges -3409- on high-voltage bat‐ tery

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

– Use the disassembly wedges -3409- at the specified points -Arrows- during the slicing, by a second mechanic.

NOTICE Only pry up the high-voltage battery top shell with disassem‐ bly wedges -3409- at the specified positions, otherwise me‐ chanical and electrical components, in particular the battery modules, can be damaged.

– Pry up high-voltage battery top shell.

– Lift the top part of the battery down with a second mechanic in the direction of the -arrow-, touching it with both hands at the front and rear -arrows-.

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Bonding – Check the high-voltage battery top cover for any damage to avoid leaks after bonding.

Note

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

Ideally, the high-voltage battery top shell is checked immediate‐ ly after receipt of the goods.

Prepare the high-voltage battery top cover for bonding

Position of the spacers on the high-voltage battery top shell -Arrows-.

To ensure better adhesion of the glass / lacquer primer, lightly roughen the top shell in the area of the adhesive surface with sandpaper / sanding fleece (grain size 120 - 240).

Clean top shell of grinding dust and other contaminants using a vacuum cleaner, lint-free cleaning cloth and cleaning solution.

Do not touch the adhesive surface afterwards.

6. High-voltage battery

69

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High voltage system - general information - Edition 05.2022 Note ♦ Because the effect of glass / lacquer primer decreases

great;y after 24 hours, the bonding should ideally be carried out within 2 hours after its application. This also avoids po‐ tential contamination.

♦ Applying the glass / lacquer primer by means of applicator

may only be done in one direction (no back and forth).

– Stroke adhesive surface with glass / lacquer primer.

– Let glass / lacquer primer dry damp places.

2)

. There must be no more

2) Processing instructions according to the manufacturer's instructions are de‐ scribed in the package insert.

Prepare the high-voltage battery lower shell for bonding Note ♦ Only carry out this process step shortly before bonding,

since the adhesion of the adhesive to the freshly cut glued seam is increased.

♦ After the adhesive Protected bead has been Copying cut down, it must no lon‐ by copyright. for private or commercial purposes, in part or in whole, is not permitted

unless authorised by ŠKODA AUTOsweat, A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability ger be touched or contaminated (grease, etc.). with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

♦ In order to avoid damage to the battery bottom shell and to

ensure that the new adhesive bead adheres, the height of the old adhesive bead must not be less than 1 mm.

Have the specific height of the adhesive seam checked by a second mechanic while cutting down.

•

Be sure to keep scraper 25 mm -VAS 6900/2- straight while cutting.

– Cut the adhesive bead on the lower part of the battery housing with the electric knife e.g. -V.A.G 1561A- or -V.A.G 1561B- and the scraper 25 mm -VAS 6900/2- back to 1 ... 2 mm. Under no circumstances remove the material complete‐ ly.

If the glued seam -arrow- is cut too much or the paint surface damaged, the adhesive seam must be completely removed at this point and a paint build-up carried out.

– Vacuum the lower part of the battery housing with a vacuum cleaner that has a plastic nozzle until the sealing material and dirt has been completely removed.

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High voltage system - general information - Edition 05.2022 Note

Since accidental contact with the adhesive bead must be avoi‐ ded during installation of the high-voltage battery top shell, it is advisable to test this step beforehand.

NOTICE Danger of damaging the paint by using an activator.

– Apply activator to the cut adhesive seam.

Note ♦ Let activator dry before you start bonding 3). There must be

no more damp places.

♦ Because the effect of activator decreases greatly after 24

hours, the bonding should ideally be carried out within 2 hours after its application. This also avoids potential contam‐ ination.

3) Processing instructions according to the manufacturer's instructions are de‐ scribed in the package insert.

Preparatory work before bonding ♦ Open one-handed clamp -VAS 6900/4- and distribute around the high-voltage battery. ♦ Prepare screws for high-voltage battery top cover. ♦ Have the necessary tools ready. ♦ Prepare adhesive cartridges of the 2-K window adhesive set by removing the metal bottom. copyright.

Copying ♦ If several cartridge sets are required,Protected all of by them must alsofor private or commercial purposes, in part or in whole, is not permitted authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability be prepared in advance in order notunless towith unnecessarily pro‐ respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S. long the bonding process.

♦ Use cartridges of the 2-K window adhesive set with the con‐ nection adapter in double cartridge gun -VAS 5237-. ♦ Press double cartridge gun -VAS 5237- carefully until both components (black and white) can be seen. ♦ Screw the green mixing tip onto the connector so that the opening points vertically downwards. ♦ Then pull a max. 10 cm bead of glue to ensure that both components mix.

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High voltage system - general information - Edition 05.2022 Glue in the high-voltage battery 1 -AX2Note ♦ Use disposable gloves during the bonding process. ♦ Prepare a suitable object (e.g. spatula) to repair the glued

seam afterwards.

♦ In order to shorten the time for applying the adhesive bead,

it is advisable for two people to apply the adhesive bead in parallel.

♦ The bead of glue must not be applied too quickly, otherwise

it will become too thin and not high enough.

– Apply glue bead -1- to the high-voltage battery lower shell, paying attention to using the correct speed.

Applying too slowly will result in the ridge of the glue bead -1being wavy and can be pushed outwards when the high-voltage battery top shell is put on.

When attaching the compressed air glue gun again, make sure that there are no gaps that are too large -arrow- between the adhesive beads -1- and -2- because they have to be connected to each other afterwards.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

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High voltage system - general information - Edition 05.2022

– Check the glue bead afterwards.

– If necessary, replace the tip of the adhesive bead with a clean object.

– Straighten wavy sections and connect gaps.

Note ♦ Put on the high-voltage battery top cover within 10 minutes,

otherwise the adhesion of the applied adhesive will be im‐ paired.

♦ When removing the high-voltage battery top shell, be careful

not to accidentally come into contact with the adhesive bead.

♦ Refitting can lead to leaks. by copyright. Copying for private commercial in part – Install Protected the high-voltage battery top orcover withpurposes, the help ofor3in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability mechanics. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

– Place screws in the holes.

– Press the high-voltage battery top cover all round and evenly by hand.

– Position one-handed clamp -VAS 6900/4- immediately at the marked places -Arrows- and tighten slightly.

6. High-voltage battery

73

Citigo-e iV 2020 ➤, Enyaq 2021 ➤, Enyaq Coupe 2021 ➤, Octavia IV 2020 ➤, Superb ...

High voltage system - general information - Edition 05.2022

NOTICE ♦ If the clamp is incorrectly attached, fine cracks can occur in the top shell, which can lead to leakage. ♦ Do not over-tighten one-handed clamp -VAS 6900/4-, oth‐ erwise the high-voltage battery upper shell may deform or the adhesive seam may be pressed out.

– Let the adhesive seam dry for at least 2 hours.

– Remove one-handed clamp -VAS 6900/4-.

– Carry out leak test High-voltage battery 1 -AX2- ⇒ Rep. gr. 93; High-voltage battery unit.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

74 Rep. gr.93 - Electric drive systems

Service

Workshop Manual

Citigo 2012 ➤, Citigo-e iV 2020 ➤, Enyaq 2021 ➤, Fabia 2000 ➤, Fabia II 2007 ➤, Fabia II 2009 ➤, Fabia II 2011 ➤, Fabia III 2015 ➤, Fabia IV 2022 ➤, Kamiq 2019 ➤, Karoq 2018 ➤, Karoq 2020 ➤, Kodiaq 2017 ➤, Kodiaq 2019 ➤, Kushaq 2021 ➤, Octavia 1997 ➤, Octavia II 2004 ➤, Octavia II 2010 ➤, Octavia III 2013 ➤, Octavia III 2014 ➤, Octavia IV 2020 ➤, Octavia IV 2021 ➤, Rapid 2011 ➤, Rapid NH 2013 ➤, Rapid NH 2014 ➤, Roomster 2006 ➤, Scala 2019 ➤, Slavia 2022 ➤, Superb 2002 ➤, Superb II 2008 ➤, Superb III 2015 ➤, Yeti 2010 ➤, Yeti 2011 ➤

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

Paint - general information Edition 10.2021

Service Department. Technical Information

Service List of Workshop Manual Repair Groups

Repair Group 00 - Technical data

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2022 ŠKODA AUTO a. s.

D4B8064A3AF

Citigo 2012 ➤, Citigo-e iV 2020 ➤, Enyaq 2021 ➤, Fabia 2000 ➤, Fabia II 2007 ➤, ...

Paint - general information - Edition 10.2021

Contents 00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety measures when painting vehicles that use natural gas . . . . . . . . . . . . . . . . . . . . . .

Safety measures when painting vehicles that use electric drive . . . . . . . . . . . . . . . . . . . .

General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Structure of original paintwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Structure of customer service paintwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Varnish construction Matte effect varnishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Different paintwork structure for engine compartment and inside of front flap . . . . . . . . . .

Work instructions for underseal and anti-chip coating . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Work instruction for disc lug area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pretreating the adhesive surface when replacing laser-brazed roofs . . . . . . . . . . . . . . . .

Corrosion protection measure, mudguard in the contact area of the wheel arch liner with foam block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.9 Instructions for repairing fold corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.10 Corrosion protection of body, surface and welded parts . . . . . . . . . . . . . . . . . . . . . . . . . .

2.11 Radiation protection for the side edge or the rear doors in the wheel arch area . . . . . . . .

2.12 Painting the parking aid transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.13 Adaptive cruise control (ACC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.14 Bumper cover painting instructions in the lane change assistant control unit area . . . . . .

2.15 Painting new bumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.16 Photo documentation of the reported paint damage according to the ŠKODA standard to create the DISS paint report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted 3 Original products . . . A.. .S..ŠKODA . . . . AUTO . . . .A.. S. . .does . . .not. .guarantee . . . . . or. .accept . . . any . . .liability ..................... unless authorised by ŠKODA AUTO with respect to the correctness of information in this document.

Copyright by ŠKODA AUTO A. S. 3.1 Paint products for customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Filler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 Corrosion prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 Underseal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6 Protection against stone chipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7 Underbody sealing wax . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8 Sealant materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9 Cleaning agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10 SprayMax system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Workshop equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Dust-retention cloths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Repairing rims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Generally applicable standards regarding rim repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Measures taken for rim repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 Types of damage that are not permitted in respect of repairs . . . . . . . . . . . . . . . . . . . . . .

5.4 Rim repair instructions - step by step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5 Colours approved for repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

1 1.1 1.2 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8

1 1 2 3 3 4 7 8 9 10 12 15 17 19 20 21 23 23 24 26 30 30 30 42 47 52 63 71 76 84 89 131 131 142 145 145 145 146 147 152

Contents

i

Citigo 2012 ➤, Citigo-e iV 2020 ➤, Enyaq 2021 ➤, Fabia 2000 ➤, Fabia II 2007 ➤, ...

Paint - general information - Edition 10.2021

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

ii Contents

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Citigo 2012 ➤, Citigo-e iV 2020 ➤, Enyaq 2021 ➤, Fabia 2000 ➤, Fabia II 2007 ➤, ...

Paint - general information - Edition 10.2021

00 –

Technical data

1

Safety instructions

(SRL001889; Edition 10.2021) ⇒ m1.1 easures when painting vehicles that use natural gas”, page 1 ⇒ m1.2 easures when painting vehicles that use electric drive”, page 2

1.1

Safety measures when painting vehi‐ cles that use natural gas DANGER!

Danger of death if drying temperatures are too high! High temperatures increase the pressure in the natural gas or LPG fuel tank. If the pressure is too high, a natural gas or LPG tank may explode and cause death or serious injuries.

High temperatures trigger the thermal fuse of the shut-off valve on natural gas fuel tanks. A pressure increase as a result of high temperature triggers the pressure relief valve in LPG fuel tanks. Gas escapes from the natural gas or LPG fuel tank and may ignite, in particular in the presence of sparks, and cause explosive flames. This can cause death or serious injuries. ♦ The vehicle may be placed in the heated drying oven with a maximum of 3/4 filling level of the natural gas fuel tank. ♦ As part of a refinishing process in the drying oven or its preheating zone, object temperatures (natural gas fuel containers or components carrying gas) of a maxi‐ mum of 65 ° C may be achieved. This corresponds to a residence time of the vehicle of 1 hour at 80°C room temperature in a drying oven. ♦ When using infrared heaters to dry painted sections outside of the drying oven, care must be taken not to expose the natural gas fuel containers or gas-carrying components to the infrared heater directly. The lining of the natural gas fuel tank is sufficient heat protection from direct heat radiation.

The safety instructions for working on vehicles with an LPG or natural gas system must be followed.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted

unless authorised by ŠKODA A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability ⇒ Engine; 00 technical data; safetyAUTO instructions with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

Removing and installing the fuel tank.

⇒ Engine; Rep. gr. 20; fuel supply, operation Additional information ♦ ⇒ Self-study programme No. 73; LPG system in ŠKODA vehicles ♦ ⇒ Self-study programme No. 102; CNG system in ŠKODA AUTO vehicles

1. Safety instructions

1

Citigo 2012 ➤, Citigo-e iV 2020 ➤, Enyaq 2021 ➤, Fabia 2000 ➤, Fabia II 2007 ➤, ...

Paint - general information - Edition 10.2021

1.2

Safety measures when painting vehi‐ cles that use electric drive Caution

Risk of damage to battery cells if the drying temperatures are too high! ♦ At a drying temperature of 80°C, observe the maximum drying time of 30 minutes. ♦ At a drying temperature of +60 °C, observe the maxi‐ mum drying time of 45 minutes. ♦ For infrared drying, protect all high-voltage components from direct infrared radiation.

Observe safety instructions when working on vehicles with elec‐ tric drive. ⇒ Engine; 00 technical data; safety instructions

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

2 Rep. gr.00 - Technical data

Citigo 2012 ➤, Citigo-e iV 2020 ➤, Enyaq 2021 ➤, Fabia 2000 ➤, Fabia II 2007 ➤, ...

Paint - general information - Edition 10.2021

2

General Instructions

⇒ o2.1 f original paintwork”, page 3 ⇒ o2.2 f customer service paintwork”, page 4 ⇒ c2.3 onstruction Matte effect varnishing”, page 7 ⇒ p2.4 aintwork structure for engine compartment and inside of front flap”, page 8 ⇒ i2.5 nstructions for underseal and anti-chip coating”, page 9 ⇒ i2.6 nstruction for disc lug area”, page 10 ⇒ t2.7 he adhesive surface when replacing laser-brazed roofs”, page 12 ⇒ p2.8 rotection measure, mudguard in the contact area of the wheel arch liner with foam block”, page 15 ⇒ f2.9 or repairing fold corrosion”, page 17 ⇒ p2.10 rotection of body, surface and welded parts”, page 19 ⇒ p2.11 rotection for the side edge or the rear doors in the wheel arch area”, page 20 ⇒ t2.12 he parking aid transmitter”, page 21 ⇒ c2.13 ruise control (ACC)”, page 23 ⇒ c2.14 over painting instructions in the lane change assistant control unit area”, page 23 ⇒ d2.16 ocumentation of the reported paint damage according to the ŠKODA standard to create the DISS paint report”, page 26

2.1

Structure of original paintwork

Structure of solid paint, water-based

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Layer thickness: approx. 80-130 µm 1-

Steel sheet

2-

Zinc phosphating

3-

Electrophoretic coating

4-

Water-based filler

5-

Water-based paint

6-

1K burning clear coat (except Citigo and vehicles painted in Russia and Ukraine - 2K clear coat)

2. General Instructions

3

Citigo 2012 ➤, Citigo-e iV 2020 ➤, Enyaq 2021 ➤, Fabia 2000 ➤, Fabia II 2007 ➤, ...

Paint - general information - Edition 10.2021 Structure of metallic and pearl colour paint, water-based

Layer thickness: approx. 80-130 µm 1-

Steel sheet

2-

Zinc phosphating

3-

Electrophoretic coating

4-

Water-based unlessfiller authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability

5-

Water-based metallic/pearl colour

6-

1K burning clear coat (except Citigo and vehicles painted in Russia and Ukraine - 2K clear coat)

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Note ♦ The approximate layer thickness may vary depending on

tone and indicates differences depending on position, as well as vertical and horizontal surfaces.

♦ The values may be exceeded for some vehicles in two or

more coats are applied. However, this does not need to be communicated.

2.2

Structure of customer service paint‐ work

Galvanized sheets on both sides Note ♦ Ensure that: ♦ all sheets edges are adequately deburred for body repairs. ♦ inner surfaces not to be painted have a complete zinc CDP

layer.

♦ that welded interior surfaces and sanding-through points are

reworked with e.g. 2K wash primer -LHV 043 000 A2- or -LLS MAX 230 M1- and then with 2K HS performance fillers.

Applying filler Filler compounds are now essential for bodywork and in the paint shop to restore contour. When applying filler, the different substrate requirements must be observed.

Product information ♦ ⇒ 3.2 , page 30

4 Rep. gr.00 - Technical data

Citigo 2012 ➤, Citigo-e iV 2020 ➤, Enyaq 2021 ➤, Fabia 2000 ➤, Fabia II 2007 ➤, ...

Paint - general information - Edition 10.2021 Primer The primer is the most important part of the anti-corrosion sys‐ tem, because is prevents water and oxygen reaching the metal surface. Original spare parts are normally coated with a black or yellow CDP. Note ♦ Sanded-through areas and weld seams must be re-coated

with corrosion protection as soon as possible.

♦ The CDP primer is not resistant to UV or acid. Spare parts

must therefore also be painted from the inside.

♦ After repairing corrosion and in general for any bare metallic

substrate, you must insulate with e.g. 2K wash primer -LHV 043 000 A2- or -LLS MAX 230 M1-, then fill with 2K HS performance filler.

Product information ♦ ⇒ p3.3 revention”, page 42 Filler ♦ The filler makes sure that the entire coating system adheres well to the body part to be painted. ♦ The filler serves as the substrate for the top coat, levels out unevenness in areas that have already been worked and determines the quality of the top coat. The filler protects the body against chipping and also acts as a barrier/substrate insulation, which is essential for corrosion protection.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.

2. General Instructions

5

Citigo 2012 ➤, Citigo-e iV 2020 ➤, Enyaq 2021 ➤, Fabia 2000 ➤, Fabia II 2007 ➤, ...

Paint - general information - Edition 10.2021 PVC seam sealing and underseal Note ♦ For repair, the joint seal must be restored to its original thick‐

ness.

♦ To avoid damage and failures, the seal welds in the area of

the assembly-specific add-on parts must be coated smooth‐ ly.

♦ Water drain holes must be left clear. ♦ All threaded bolts and weld nuts with M-thread and all other

bolts and contact surfaces for assembly must be fully func‐ tional all along the seal.

♦ The sealant material must not be applied to bare sheet met‐

al, but only on to filled substrates.

♦ To prevent water ingress into the flanges, the sheet fold is

sealed with pasty, solvent-free PVC at critical points of the body. A layer of PVC with varying thickness is also sprayed onto accurately defined areas of the underbody and in the wheelhousings as protection against chipping and for sound absorption.

♦ Before sealing/applying underseal, the surface must always

be thoroughly primed and filled.

♦ After repairing corrosion and in general for any bare metallic

substrate, you must insulate with 2K wash primer e.g. -LHV 043 000 A2- or -LLS MAX 230 M1- then fill with 2K HS performance filler.

♦ The specific layer thicknesses for the underseal must be

observed.

Product information ♦ ⇒ 3.5 , page 52 ♦ ⇒ a3.6 gainst stone chipping”, page 63 ♦ ⇒ m3.8 aterials”, page 76 Base coat The base coat is primarily decorative.

The paints provide different coverage depending on pigment content. The manufacturer's instructions must be followed.

Clear coat The clear coat is primarily decorative. The clear coat protects the top coat/base coat against ultraviolet radiation and environ‐ mental pollution, such as acid in bird droppings.

Wax preservation/cavity preservation Wax preservation/cavity preservation plays an essential role in corrosion protection. Depending on application, there are vari‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted ous materials available for customer service. Theseunless materials authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S. provide excellent protection because they have the following properties: ♦ They are hydrophobic (water-repellent). ♦ They have good adhesion. ♦ No corrosion creep.

6 Rep. gr.00 - Technical data

Citigo 2012 ➤, Citigo-e iV 2020 ➤, Enyaq 2021 ➤, Fabia 2000 ➤, Fabia II 2007 ➤, ...

Paint - general information - Edition 10.2021 ♦ Water vapour permeates through them at a rate approx.

1500 times lower than a layer of paint of the same thickness.

Product information ♦ ⇒ 3.4 , page 47 ♦ ⇒ s3.7 ealing wax”, page 71

2.3

Varnish construction Matte effect var‐ nishing Note

Applies to Kushaq India and Rapid India models Technology Paintwork with a matt effect on vehicles is usually only paint‐ work with a matt clearcoat. It can be applied either directly to the basecoat or to an existing clearcoat.

If the application is too dry, there is a risk of clouding due to uneven ventilation or due to spray mist that has not been absorbed. Larger areas should therefore be painted early in the morning. The order may have to be postponed for a few days.

Colour determination basecoat Due to the matt structure of the clearcoat, the colour tones and the effect pigments of the basecoat cannot be clearly assigned.

It is therefore advisable to prepare sample sheets in advance in two to three variants of the basecoat.

Colour determination of matt clearcoat The use of a gloss level meter is recommended.

Despite the gloss level measurement, three different degrees of matting should also be applied.

Application

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In order to achieve a homogeneous matting effect, the following tips are recommended: Note ♦ In order to achieve the determined degree of matting, the

clearcoat must be mixed with a scale or according to the supplier's instructions.

♦ The spray distance to the object is slightly larger compared

to the standard application in order to utilize the full atomiza‐ tion of the spray mist.

♦ In addition, it is advantageous to apply the two coats of paint

in a cross-coat to horizontal replacement parts (to avoid streaking).

♦ Care must be taken to ensure that the spray lines overlap

evenly and that a sufficiently wet spray film is applied.

♦ If possible, full painting should be divided into sections,

which means that the vehicle body is painted separately from the add-on parts in order to avoid overlapping zones and spray mist.

♦ It should be noted that the matting can change over time.

2. General Instructions

7

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