Volkswagen ID.4: Cooling system/coolant

• Connection diagram - coolant hoses, refrigerant R744
• Connection diagram - coolant hoses, refrigerant R1234yf
• Overview of fitting locations - cooling system, rear-wheel drive
• Overview of fitting locations - cooling system, all-wheel drive
• Assembly overview - cooling system, rear-wheel drive
• Assembly overview - cooling system, all-wheel drive
• Checking cooling system for leaks
• Removing and installing coolant expansion tank

Connection diagram - coolant hoses, refrigerant R744

Connection diagram - coolant hoses, rear-wheel drive

1. Charging unit 1 for highvoltage battery - AX4-

• With control unit for high-voltage battery charging unit - J1050-

2. Three-phase current drive - VX54-

• With power and control electronics for electric drive - JX1-

3. High-voltage battery 1 - AX2-
4.  Coolant pump for low-temperature circuit - V468-
5.  Mixing valve for highvoltage battery pre-heating - V683-
6. Mixing valve 2 for highvoltage battery pre-heating - V696-
7. Coolant pump for highvoltage battery - V590-
8. Voltage converter - A19-
9. PTC heater element 3 - Z132-
10. Radiator
11. Heat exchanger for highvoltage battery
12. Thermostat
13. Coolant expansion tank

Connection diagram - coolant hoses, four-wheel drive

1. Voltage converter - A19-
2. Charging unit 1 for highvoltage battery - AX4-

• With control unit for high-voltage battery charging unit - J1050-

3. Three-phase current drive - VX54-

• With power and control electronics for electric drive - JX1-

4. Coolant hose

• Equipment version depending on vehicle version

5. High-voltage battery 1 - AX2-
6. Mixing valve 2 for highvoltage battery pre-heating - V696-
7. Mixing valve for highvoltage battery pre-heating - V683-
8. Coolant pump for low-temperature circuit - V468-
9. Power and control electronics 2 for electric drive - JX4-
10. PTC heater element 3 - Z132-
11. Radiator
12. Heat exchanger for highvoltage battery
13. Thermostat
14. Coolant expansion tank
15. Coolant pump for high-voltage battery - V590-

Connection diagram - coolant hoses, refrigerant R1234yf

Connection diagram - coolant hoses, rear-wheel drive

1. Charging unit 1 for highvoltage battery - AX4-

• With control unit for high-voltage battery charging unit - J1050-

2. Three-phase current drive - VX54-

• With power and control electronics for electric drive - JX1-

3. High-voltage battery 1 - AX2-
4. Coolant pump for low-temperature circuit - V468-
5. Mixing valve for highvoltage battery pre-heating - V683-
6. Coolant pump for highvoltage battery - V590-
7. PTC heater element 3 - Z132-
8. Voltage converter - A19-
9. Radiator
10. Heat exchanger for highvoltage battery
11. Thermostat
12. Coolant expansion tank

Connection diagram - coolant hoses, four-wheel drive

1. Voltage converter - A19-
2. Charging unit 1 for highvoltage battery - AX4-

• With control unit for high-voltage battery charging unit - J1050-

3. Three-phase current drive - VX54-

• With power and control electronics for electric drive - JX1-

4. Coolant hose
5. Equipment version depending on vehicle version

• High-voltage battery 1 - AX2-

6. Coolant pump for highvoltage battery - V590-
7. Coolant pump for low-temperature circuit - V468-
8. Mixing valve for highvoltage battery pre-heating - V683-
9. Power and control electronics 2 for electric drive - JX4-
10. PTC heater element 3 - Z132-
11. Radiator
12. Heat exchanger for highvoltage battery
13. Thermostat
14. Coolant expansion tank

Overview of fitting locations - cooling system, rear-wheel drive

1. Three-phase current drive - VX54-

• ⇒ Rep. gr. 10 ; Assembly overview - rear motor
• ⇒ Rep. gr. 10 ; Removing rear motor
• ⇒ Rep. gr. 10 ; Installing rear motor

2. Temperature sensor - G18-

• At top of charging unit 1 for high-voltage battery - AX4- in hose connection
• ⇒ Rep. gr. 19 ; Removing and installing temperature sensor [G18]

3. Charging unit 1 for highvoltage battery - AX4-

• With control unit for high-voltage battery charger - J1050-
• ⇒ Rep. gr. 93 ; Removing and installing charging unit 1 for highvoltage battery AX4

4. Power and control electronics for electric drive - JX1-

• ⇒ Rep. gr. 93 ; Removing and installing power and control electronics for electric drive at rear

5. Mixing valve for high-voltage battery pre-heating - V683-

• ⇒ Rep. gr. 19 ; Removing and installing mixing valve for high-voltage battery pre-heating [V683]

6. Mixing valve 2 for high-voltage battery pre-heating - V696-

• Depending on equipment/version
• ⇒ Rep. gr. 19 ; Removing and installing mixing valve 2 for high-voltage battery pre-heating [V696]

7. Coolant temperature sender 2 for high-voltage battery - G899-

• Battery outlet (return)
• ⇒ Rep. gr. 19 ; Removing and installing coolant temperature sender 2 for high-voltage battery [G899]

8. Coolant temperature sender 1 for high-voltage battery - G898-

• Battery inlet (supply)
• ⇒ Rep. gr. 19 ; Removing and installing coolant temperature sender 1 for high-voltage battery [G898]

9. Coolant pump for low-temperature circuit - V468-

• ⇒ Rep. gr. 19 ; Removing and installing coolant pump for low-temperature circuit [V468]

10. Voltage converter - A19-

• ⇒ Rep. gr. 93 ; Removing and installing voltage converter [A19]

11. PTC heater element 3 - Z132-

• ⇒ Heating, air conditioning; Rep. gr. 87 ; Coolant circuit; Removing and installing PTC heater element 3 [Z132]

12. Radiator module

•  ⇒ Rep. gr. 19 ; Removing and installing radiator module

13. Heat exchanger for high-voltage battery

• ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit; Removing and installing heat exchanger for high-voltage battery

14. Coolant expansion tank

• With coolant temperature display sender - G32-
• ⇒ Rep. gr. 19 ; Removing and installing coolant expansion tank

15. Thermostat

•  ⇒ Rep. gr. 19 ; Assembly overview - cooling system, rear-wheel drive

16. Coolant pump for high-voltage battery - V590-

• ⇒ Rep. gr. 19 ; Removing and installing coolant pump for high-voltage battery [V590]

Overview of fitting locations - cooling system, all-wheel drive

1. Power and control electronics for electric drive - JX1-

• ⇒ Rep. gr. 93 ; Removing and installing power and control electronics for electric drive at rear

2. Temperature sensor - G18-

• At top of charging unit 1 for high-voltage battery - AX4- in hose connection
• ⇒ Rep. gr. 19 ; Removing and installing temperature sensor [G18]

3. Voltage converter - A19-

• ⇒ Rep. gr. 93 ; Removing and installing voltage converter [A19]

4. Charging unit 1 for highvoltage battery - AX4-

• With control unit for high-voltage battery charger - J1050-
• ⇒ Rep. gr. 93 ; Removing and installing charging unit 1 for highvoltage battery AX4

5. Three-phase current drive - VX54-

• ⇒ Rep. gr. 10 ; Assembly overview - rear motor
• ⇒ Rep. gr. 10 ; Removing rear motor
• ⇒ Rep. gr. 10 ; Installing rear motor

6. Power and control electronics 2 for electric drive - JX4-

• ⇒ Rep. gr. 93 ; Removing and installing power and control electronics for electric drive, front

7.  Coolant pump for high-voltage battery - V590-

• ⇒ Rep. gr. 19 ; Removing and installing coolant pump for high-voltage battery [V590]

8. Mixing valve for high-voltage battery pre-heating - V683-

• ⇒ Rep. gr. 19 ; Removing and installing mixing valve for high-voltage battery pre-heating [V683]

9. Mixing valve 2 for high-voltage battery pre-heating - V696-

• Depending on equipment/version
• ⇒ Rep. gr. 19 ; Removing and installing mixing valve 2 for high-voltage battery pre-heating [V696]

10. Coolant temperature sender 2 for high-voltage battery - G899-

• Battery outlet (return)
• ⇒ Rep. gr. 19 ; Removing and installing coolant temperature sender 2 for high-voltage battery [G899]

11. Coolant temperature sender 1 for high-voltage battery - G898-

• Battery inlet (supply)
• ⇒ Rep. gr. 19 ; Removing and installing coolant temperature sender 1 for high-voltage battery [G898]

12. Coolant pump for low-temperature circuit - V468-

• ⇒ Rep. gr. 19 ; Removing and installing coolant pump for low-temperature circuit [V468]

13. Three-phase current drive 2 - VX97-

• ⇒ Rep. gr. 10 ; Assembly overview - front motor
• ⇒ Rep. gr. 10 ; Removing front motor
• ⇒ Rep. gr. 10 ; Installing front motor

14. PTC heater element 3 - Z132-

• ⇒ Heating, air conditioning; Rep. gr. 87 ; Coolant circuit; Removing and installing PTC heater element 3 [Z132]

15. Radiator module

• ⇒ Rep. gr. 19 ; Removing and installing radiator module

16. Heat exchanger for high-voltage battery

• ⇒ Heating, air conditioning; Rep. gr. 87 ; Refrigerant circuit; Removing and installing heat exchanger for high-voltage battery

17. Coolant expansion tank

• With coolant temperature display sender - G32-
• ⇒ Rep. gr. 19 ; Removing and installing coolant expansion tank

18. Thermostat

•  ⇒ Rep. gr. 19 ; Assembly overview - cooling system, all-wheel drive

19. Heat pump valve unit

• Depending on equipment/version
• ⇒ Heating, air conditioning; Rep. gr. 87 ; Heat pump valve unit; Removing and installing heat pump valve unit

Assembly overview - cooling system, rear-wheel drive

1. Assembly overview - cooling system, front right
2.  Assembly overview - cooling system, rear
3. Assembly overview - cooling system, front left

 

1. Assembly overview - cooling system, front right

1. Voltage converter - A19-

• ⇒ Rep. gr. 93 ; Removing and installing voltage converter [A19]

2. Hose clamp
3. Bolt

• Specified torque ⇒ Rep. gr. 93 ; Assembly overview - voltage converter

4. Coolant hose
5. Coolant hose
6. O-ring
7. Retaining clip
8. Hose clamp
9. Coolant hose
10. Retaining clip

• Qty. 2

11. Hose clamp
12. Coolant expansion tank

• With coolant temperature display sender - G32-
• ⇒ Rep. gr. 19 ; Removing and installing coolant expansion tank

13. Thermostat

• Starts to open at 15 ºC

14. Bracket for coolant manifold
15. Spreader rivet
16. Coolant manifold

• Coolant hose and coolant pipe are marked with numbers
• Note allocation

2. Assembly overview - cooling system, rear

1. Rear right coolant pipe
2. Coolant hose
3. Hose clamp
4. Temperature sensor - G18-

• ⇒ Rep. gr. 19 ; Removing and installing temperature sensor [G18]

5. O-ring

• Renew after removing

6. Retaining clip
7. O-ring
8. Retaining clip
9. Charging unit 1 for highvoltage battery - AX4-

• With control unit for high-voltage battery charger - J1050-
• ⇒ Rep. gr. 93 ; Removing and installing charging unit 1 for highvoltage battery AX4

10. Power and control electronics for electric drive - JX1-

• With three-phase current drive - VX54-
• ⇒ Rep. gr. 93 ; Removing and installing power and control electronics for electric drive at rear

11. Coolant hose
12. Retaining clip
13. Hose clamp
14. Coolant pipe

• Return line

15. Coolant pipe

• Supply line

3. Assembly overview - cooling system, front left

1. Hose clamp
2. Coolant hose

• Coolant hose and coolant pipe are marked with numbers
• Note allocation

3. Retaining clip
4. Coolant pipe

• Return line

5. Coolant pipe

• Supply line

6. Coolant hose

• Marking -V- = supply

7. Coolant pump for low-temperature circuit - V468-

• ⇒ Rep. gr. 19 ; Assembly overview - electric coolant pump
• ⇒ Rep. gr. 19 ; Removing and installing coolant pump for low-temperature circuit [V468]

8. Bolt

• Qty. 4
• 8 Nm

9. Coolant hose

• Marking -R- = return

10. Coolant temperature sender 2 for high-voltage battery - G899-

• ⇒ Rep. gr. 19 ; Assembly overview - coolant temperature sender
• ⇒ Rep. gr. 19 ; Removing and installing coolant temperature sender 2 for high-voltage battery [G899]

11. O-ring
12. Retaining clip
13. Coolant temperature sender 1 for high-voltage battery - G898-

• ⇒ Rep. gr. 19 ; Assembly overview - coolant temperature sender
• ⇒ Rep. gr. 19 ; Removing and installing coolant temperature sender 1 for high-voltage battery [G898]

14. Coolant hose
15. Coolant hose
16.  Hose clamp
17. Retaining clip
18.  Bolt

• 8 Nm

19. Mixing valve for high-voltage battery pre-heating - V683-

• ⇒ Rep. gr. 19 ; Assembly overview - coolant valves
• ⇒ Rep. gr. 19 ; Removing and installing mixing valve for high-voltage battery pre-heating [V683]

20. Mixing valve 2 for high-voltage battery pre-heating - V696- ❑ Depending on equipment/version

• Rep. gr. 19 ; Assembly overview - coolant valves
• ⇒ Rep. gr. 19 ; Removing and installing mixing valve 2 for high-voltage battery [V696] pre-heating, heat pump

21. Bracket for mixing valve
22. Bolt

• Specified torque ⇒ Rep. gr. 93 ; Assembly overview - voltage converter

23. Voltage converter - A19-

• ⇒ Rep. gr. 93 ; Assembly overview - voltage converter
• ⇒ Rep. gr. 93 ; Removing and installing voltage converter [A19]

24. Retaining clip
25. Coolant pump for high-voltage battery - V590-

• ⇒ Rep. gr. 19 ; Assembly overview - electric coolant pump
• ⇒ Rep. gr. 19 ; Removing and installing coolant pump for high-voltage battery [V590]

26. Spreader rivet

Assembly overview - cooling system, all-wheel drive

1. Assembly overview - cooling system, front right
2.  Assembly overview - cooling system, rear
3. Assembly overview - cooling system, front left

1. Assembly overview - cooling system, front right

1. Coolant hose
2. Retaining clip
3. O-ring
4. Retaining clip
5. Hose clamp
6. Thermostat

• Starts to open at 15 ºC

7. Coolant hose
8. Hose clamp
9. Coolant expansion tank

• With coolant temperature display sender - G32-
• ⇒ Rep. gr. 19 ; Removing and installing coolant expansion tank

10. Coolant manifold

• Coolant hose and coolant pipe are marked with numbers
• Note allocation

11. Spreader rivet
12. Three-phase current drive 2 - VX97-

• With power and control electronics 2 for electric drive - JX4-
• ⇒ Rep. gr. 10 ; Assembly overview - front motor
• ⇒ Rep. gr. 10 ; Removing front motor
• ⇒ Rep. gr. 10 ; Installing front motor
• ⇒ Rep. gr. 93 ; Removing and installing power and control electronics for electric drive, front

2. Assembly overview - cooling system, rear

1. Voltage converter - A19-

• ⇒ Rep. gr. 93 ; Removing and installing voltage converter [A19]

2. Charging unit 1 for highvoltage battery - AX4-

• With control unit for high-voltage battery charger - J1050-
• ⇒ Rep. gr. 93 ; Removing and installing charging unit 1 for highvoltage battery AX4

3. Power and control electronics for electric drive - JX1-

• With three-phase current drive - VX54-
• ⇒ Rep. gr. 93 ; Removing and installing power and control electronics for electric drive at rear

4. O-ring
5. Retaining clip
6. Coolant hose
7. Retaining clip
8. Hose clamp
9. Coolant pipe

• Return line

10. Coolant connection

• ⇒ Rep. gr. 10 ; Assembly overview - motor

11. Retaining clip
12. Temperature sensor - G18-

• ⇒ Rep. gr. 19 ; Removing and installing temperature sensor [G18]

13. O-ring

• Renew after removing

14. Coolant hose
15. Coolant pipe

• Supply line

16. Coolant hose

3. Assembly overview - cooling system, front left

1. Hose clamp
2. Coolant pump for highvoltage battery - V590-

• ⇒ Rep. gr. 19 ; Assembly overview - electric coolant pump
• ⇒ Rep. gr. 19 ; Removing and installing coolant pump for highvoltage battery [V590]

3. Coolant temperature sender 2 for high-voltage battery - G899-

• ⇒ Rep. gr. 19 ; Assembly overview - coolant temperature sender
• ⇒ Rep. gr. 19 ; Removing and installing coolant temperature sender 2 for highvoltage battery [G899]

4. Retaining clip
5. O-ring
6.  Bolt

• Qty. 2
• 8 Nm

7. Retaining clip
8. Coolant hose

• Marking -R- = return

9. Mixing valve for highvoltage battery pre-heating - V683-

• ⇒ Rep. gr. 19 ; Assembly overview - coolant valves
• ⇒ Rep. gr. 19 ; Removing and installing mixing valve for high-voltage battery pre-heating [V683]

10. Bolt

• Qty. 3
• 8 Nm

11. Coolant pipe

• Return line

12. Coolant temperature sender 1 for high-voltage battery - G898-

• ⇒ Rep. gr. 19 ; Assembly overview - coolant temperature sender
• ⇒ Rep. gr. 19 ; Removing and installing coolant temperature sender 1 for high-voltage battery [G898]

13. Coolant pipe

• Supply line

14. Coolant hose
15. Coolant hose

• Marking -V- = supply

16. Bolt

• Qty. 2
• 8 Nm

17. Coolant pump for low-temperature circuit - V468-

• ⇒ Rep. gr. 19 ; Assembly overview - electric coolant pump
• ⇒ Rep. gr. 19 ; Removing and installing coolant pump for low-temperature circuit [V468]

18.  Coolant pipe
19. PTC heater element 3 - Z132-

• ⇒ Heating, air conditioning; Rep. gr. 87 ; Coolant circuit; Removing and installing PTC heater element 3 [Z132]

20. Coolant hose
21. Coolant hose
22.  Coolant hose
23. Mixing valve holder
24. Mixing valve 2 for high-voltage battery pre-heating - V696-

• Depending on equipment/version
• ⇒ Rep. gr. 19 ; Assembly overview - coolant valves
• ⇒ Rep. gr. 19 ; Removing and installing mixing valve 2 for high-voltage battery pre-heating [V696]

25. Retaining clip
26. Coolant hose
27. Three-phase current drive 2 - VX97-

• With power and control electronics 2 for electric drive - JX4-
• ⇒ Rep. gr. 10 ; Assembly overview - front motor
• ⇒ Rep. gr. 10 ; Removing front motor
• ⇒ Rep. gr. 10 ; Installing front motor
• ⇒ Rep. gr. 93 ; Removing and installing power and control electronics for electric drive, front

Checking cooling system for leaks

Special tools and workshop equipment required

• Cooling system tester - V.A.G 1274B-
• adapter - VAS 691 005/5-
• adapter for cooling system tester - V.A.G 1274/9-
• cooling system tester - V.A.G 1274B-

• Check cooling system tester - V.A.G 1274B- for leaks
• Check cooling system for leaks
• Check pressure relief valve in filler cap

Checking cooling system tester - V.A.G 1274B- for leaks

• Operate hand pump several times to build up pressure of 3.0 bar.
• Observe pressure on pressure gauge of cooling system tester for 30 seconds.

If pressure is not built up or pressure drops again, cooling system tester must not be used.

Checking cooling system for leaks

Important

• Cooling system tester - V.A.G 1274B- checked for leaks.

CAUTION

The cooling system may be under pressure. Risk of scalding due to hot steam and hot coolant Danger of scalding skin and other parts of the body

• Put on protective gloves.
• Put on safety goggles.
• Cover filler cap on expansion tank with a suitable cloth and open carefully to release pressure.

• Open cap -arrow-.

• Screw adapter - VAS 691 005/5- -1- onto coolant expansion tank -2-.
• Connect cooling system tester - V.A.G 1274B- -3- to adapter -1-.
• Operate hand pump several times to build up pressure of 1.5 bar.

Important

• The pressure cannot drop by more than 0.2 bar within 10 minutes.
• If pressure drops by more than 0.2 bar, locate leaks and rectify faults.

Note

A pressure drop of 0.2 bar within 10 minutes is caused by the coolant cooling down. Once the coolant temperature is the same as the ambient temperature there should be no pressure loss.

Important

• If leaks were found and rectified, leak test must be repeated.
• Release pressure on cooling system tester and remove from coolant expansion tank.
• Screw on cap.

Checking pressure relief valve in cap

Important

• Cooling system tester - V.A.G 1274B- checked for leaks.

CAUTION

The cooling system may be under pressure. Risk of scalding due to hot steam and hot coolant Danger of scalding skin and other parts of the body

• Put on protective gloves.
• Put on safety goggles.
• Cover filler cap on expansion tank with a suitable cloth and open carefully to release pressure.

• Open cap -arrow-.

• Connect cooling system tester - V.A.G 1274B- -1- and adapter for cooling system tester - V.A.G 1274/9- -2- to cap -3-.
• Actuate hand pump -1- several times to generate pressure.

Important

• Blue cap: pressure relief valve must open at pressure of 1.4 to 1.6 bar.
• Black cap: pressure relief valve must open at pressure of 1.6 to 1.8 bar.
• Renew filler cap -3-, if pressure relief valve does not open as described.

Removing and installing coolant expansion tank

Special tools and workshop equipment required

• hose clamps for hoses up to 25 mm - 3094-

Removing

CAUTION

The cooling system may be under pressure. Risk of scalding due to hot steam and hot coolant Danger of scalding skin and other parts of the body

• Put on protective gloves.
• Put on safety goggles.
• Cover filler cap on expansion tank with a suitable cloth and open carefully to release pressure.

• In order to release pressure from the cooling system, open filler cap of the coolant expansion tank -arrow- briefly, then close it again.

• Disconnect electrical connector -1- of coolant shortage indicator sender - G32- .
• Pull electrical wire -3- off coolant expansion tank -2-.
• Push locking element -arrow- forwards and swing coolant expansion tank -2- out of mounting.

• Clamp off coolant hoses -1- and -2- using hose clamps for hoses up to 25 mm - 3094- .
• Open hose clip and pull off coolant hose -1-.
• Seal connection on coolant expansion tank using a plug.
• Turn coolant expansion tank over.
• Open hose clip and pull off coolant hose -2-.
• Drain coolant expansion tank.

Installing

Install in reverse order of removal, observing the following:

• Fit coolant hoses, and secure them with hose clips. Observe installation markings when doing this.
• Remove hose clamps.
• Insert coolant expansion tank in receiver and engage.
• Replenish coolant and check filling quality ⇒ Rep. gr. 19 ; Checking filling quality .