Volkswagen ID.4: Removing and installing rear motor

• Assembly overview - rear motor
• Removing rear motor
• Securing motor to engine and gearbox support, rear motor
• Installing rear motor

Assembly overview - rear motor

1. Electrical connector

• High voltage

2. Wiring guide
3.  Bolt

• Qty. 6
• 8 Nm

4.  O-ring
5. Retaining clip
6. Coolant hose
7. Clip
8. Clamp
9.  Bolt

• Qty. 2
• Renew after removing
• 8 Nm +90º

10. O-ring

• Renew after removing

11. Union
12. Three-phase current drive - VX54-

• With power and control electronics for electric drive - JX1-
• ⇒ Rep. gr. 93 ; Removing and installing power and control electronics for electric drive
• ⇒ Rep. gr. 10 ; Removing rear motor
• ⇒ Rep. gr. 10 ; Installing rear motor

13.  Coolant pipe

• To remove, remove high-voltage battery ⇒ Rep. gr. 93 ; High-voltage battery unit

14. O-ring
15. Bleeder valve

• Special lubricant for sealing seat ⇒ Electronic parts catalogue (ETKA)
• Renew after removing

16. Bolt

• Qty. 2
• Renew after removing
• 130 Nm +180º

17. Bolt

• Qty. 3
• Renew after removing
• 70 Nm +180º

18. Engine support
19. Bolt

• Renew after removing
• 130 Nm +180º

20. Temperature sensor - G18-

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

21. O-ring

• Renew after removing

22. Coolant hose
23. Retainer

• Contact point for potential equalisation line
• Secured to centre hex stud
• Centre hex stud: 8 Nm +45º

24. Nut

• 8 Nm

25. O-ring
26. Breather line
27. Bolt

• 8 Nm

28. Electrical connector

Removing rear motor

Special tools and workshop equipment required

• Hook - 3282/049-
• Pin - 3282/34-
• Pin - 3282/45-
• bit XZN 16 - T10198-
• engine and gearbox jack - VAS 6931-
• engine bung set - VAS 6122-
•  gearbox support - 3282-

Three-phase current drive - VX54- with power and control electronics for electric drive - JX1- is referred to hereafter as motor.

Removing

DANGER

High voltage can cause fatal injury.

Danger of severe or fatal injuries from electric shock or electric arcs.

• Have a high-voltage technician (HVT) or a high-voltage expert (HVE) de-energise the high-voltage system.

• ⇒ Rep. gr. 93 ; De-energise high-voltage system .

• Remove rear centre underbody cladding -1- ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody cladding; Removing and installing rear centre underbody cladding .
• Remove rear underbody cladding -2- ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody cladding; Removing and installing rear underbody cladding .
• Remove stone deflector for spring control arm -4- ⇒ Running gear, axles, steering; Rep. gr. 42 ; Suspension link, track rod; Removing and installing stone deflector for spring control arm .

• Remove left and right drive shaft ⇒ Running gear, axles, steering; Rep. gr. 42 ; Drive shaft; Removing and installing drive shaft .
• Remove rear left and right wheel housing liner ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing liner; Removing and installing rear wheel housing liner .
• ⇒ Rep. gr. 19 ; Drain coolant .

Note

For the bolt of the gearbox mounting to be renewed it is necessary to remove the charger.

• Remove charging unit 1 for high-voltage battery - AX4- ⇒ Rep. gr. 93 ; Removing and installing charging unit 1 for high-voltage battery [AX4] .

• Open hose clip -arrow-, and pull off coolant hose -1-.
• Disconnect electrical connector -2-.

• Unscrew nut -arrow-, and remove bracket -1- for potential equalisation line.

• Unclip coolant hose -1- as shown -arrow-.

• Unclip gearbox breather line -1- in rear left wheel housing -arrows-.

• On gearbox side, unscrew bolts -arrows- for high-voltage cable duct -1-.

• Place gearbox support - 3282- -D- on engine and gearbox jack - VAS 6931- -E-.
• Position engine and gearbox jack -E- centrally under motor and gearbox -2-.
• Screw in adapters into supports as follows:

1. Pin - 3282/34-
2. Pin - 3282/45- with screwed on nut -1-
3. Hook - 3282/049-

• Align mountings -A- and -B- to mounting points in motor and gearbox.
• Position mounting -C- under power and control electronics for electric drive - JX1- .
• Raise motor with gearbox to relieve load on motor mountings.

• Use bit XZN 16 - T10198- to unscrew bolts -1- for left and right motor mountings through opening -arrow- in longitudinal member.

• Unscrew gearbox mounting bolt -arrow-.

• Lower motor with gearbox approx. 150 mm

• Detach high-voltage cable -1- from power and control electronics for electric drive - JX1- . To do this, unscrew bolts -2- and -3- above the gearbox.
• Open locking bracket -A- on high-voltage connector -4-, and pull off high-voltage connector ⇒ Rep. gr. 93 ; Disconnecting high-voltage connectors .

• Unclip coolant hose -1- above gearbox -arrow A-.
• Lift catch -2- and pull off coolant hose.
• Unclip gearbox breather line -3- -arrow B-, and pull it off gearbox.

NOTICE

Risk of damage to lines and hoses when lowering the motor/ gearbox assembly.

• Make sure that all connections between the motor/gearbox and the vehicle body have been disconnected.
• When lowering, carefully guide motor/gearbox assembly out of motor compartment.

• Lower motor with gearbox.
• Seal any open connections on motor and gearbox with plugs from engine bung set - VAS 6122- .

Securing motor to engine and gearbox support, rear motor

Special tools and workshop equipment required

• Motor bracket - VAS 6095A/1-21-
• engine and gearbox support - VAS 6095A-
• lifting tackle - VAS 501 019-
• retaining plate - VW309A-
• workshop hoist - VAS 6100-

CAUTION

Risk of injury from moving parts.

Body parts could suffer contusions.

• Never reach or step into the hazard zone.

Assembling lifting tackle - VAS 501 019- -A-

• Fit bow - VAS 501 019/1- -1- and bow - VAS 501 019/2- -2- to lifting tackle. Screw in bolts -5-.
• Secure shackle -4- in hole shown in illustration.

• Align bows -1- and -2- with markings -arrows-.
• Tighten bolts -5-.

Securing motor on engine and gearbox support

•  Insert bows -1- and -2- of lifting tackle -A- into holes -arrows B-.
• Screw bolt -3- by hand to stop into hole -arrow C-.
• Attach workshop hoist - VAS 6100- to shackle -4-, and raise motor.

• Mount motor bracket - VAS 6095A/1-21- -A- on retaining plate - VW309A- -B- and tighten bolts.
• Position motor bracket -A- on motor -1-, and tighten bolts.

• Secure motor -1- with motor bracket -A- and support plate -B- to engine and gearbox support - VAS 6095A- -C-.

Installing rear motor

Special tools and workshop equipment required

• bit XZN 16 - T10198-
• engine and gearbox jack - VAS 6931-
• gearbox support - 3282-

Three-phase current drive - VX54- with power and control electronics for electric drive - JX1- is referred to hereafter as motor.

Installing

Important

• Motor and gearbox are secured to gearbox support - 3282- and engine and gearbox jack - VAS 6931- ⇒ Rep. gr. 10 ; Removing rear motor .

• Raise motor with gearbox -1- up to 150 mm before installation position.

• Fit electrical connector -1- above gearbox, and close locking bracket in direction of -arrow A-.
• Tighten bolts -2- and -3-.

• Fit coolant hose -1- above gearbox, and close locking element -2-. Ensure proper engagement by pulling.
• Attach breather line -3-.
• Close clips -arrow A- and -arrow B-.

• Raise motor with gearbox -1- until bolts for motor and gearbox mountings can be started.
• Tighten bolts for engine and gearbox mounting using bit XZN 16 - T10198- .

• Mount bracket -1- for potential equalisation line on gearbox and tighten nut -arrow-.

• Install left and right drive shafts ⇒ Running gear, axles, steering; Rep. gr. 42 ; Drive shaft; Removing and installing drive shaft .

If the power and control electronics for electric drive - JX1- has been renewed:

• Carry out function "power and control electronics for electric drive [JX1], commissioning" ⇒ Rep. gr. 00 ; Access to diagnoses .

Note

At the end of the diagnosis, the function "Calibrate electric drive motor" is carried out automatically.

Continued

If the three-phase current drive - VX54- was renewed:

• Carry out function "Calibrate electric drive motor" ⇒ Rep.

  gr. 93 ; Calibrating electric drive motor [VX54] .

Continued

Further installation is carried out in reverse order of removal, observing the following:

WARNING

High voltage can cause fatal injury.

Danger of severe or fatal injuries from electric shock or electric arcs.

• Have a high-voltage technician (HVT) or a high-voltage expert (HVE) re-energise the high-voltage system.

• ⇒ Rep. gr. 93 ; Re-energise high-voltage system

Tightening torques

• ⇒ Rep. gr. 10 ; Assembly overview - motor
• ⇒ Rep. gr. 93 ; Assembly overview - electric drive motor, rear motor
• ⇒ Rep. gr. 93 ; Assembly overview - charging unit for high-voltage battery
•  ⇒ Running gear, axles, steering; Rep. gr. 42 ; Drive shaft; Assembly overview - drive shaft
• ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody cladding; Assembly overview - underbody cladding