For gen2 35,8kWh pack.boekel wrote: ↑Tue Apr 13, 2021 5:32 pm Hi all, I'm a bit late to the party... but I've taken apart quite some of the gen1 and gen2 e-golf batteries..
there is no need to cut the pack open! I only cut the tabs where bolts are, to get access to the glue.
with a 'long box cutter' style knife you can cut the glue and then pry the cover open a bit (some wooden blocks to keep tension on the glue) and cut the rest of the glue. 30-45 minutes maximum.
when removing gen2 cover I do cut a little bit of the front so the charge connector comes free easily.
wiring: just unwrap all orange wiring, they are 90% the same pinout but different length.
most 'master' modules (module with CMU) connect to 8s of other modules, some connect to less and have some special wiring to keep CMU working.
comms wiring is 'daisy chain style' but not really daisy chained (only the enable signal I believe)
contactor assembly I don't know much about, I just take them apart... they differ between the years btw.
I have traced all the black and orange harnesses, pinouts and wire colours last year, and with Alibro's help, now completed the schematics, but I have only handwritten/drawn notes in Finnish.
Comms wire, Black.
enable is a loop from BMS to modules to BMS
CAN wires go daisychained from BMS to modules in different order than enable and end on last BMS slave.
12v and GND goes with CAN to half pack, daisychained from module to another, but split in the middle to go to two different sides of pack.
Orange harness actually has 5 different types.
Amount x 4S/2S modules starting from
the slave BMS module.
3x444
2x442
1x422
1x4422
1x42222
+1 wire to BMS from most positive module.
Others just need proper group to work.
I have a draft ready Image of all of it, that I will "computerize" later.