Volkswagen ID.4: Removing and installing front motor

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

Assembly overview - front motor

Assembly overview - front motor, left-hand drive vehicles

1. hree-phase current drive 2 - VX97-

• With electric drive motor

2. V717-

• With drive motor 2 temperature sender - G1146-
• With drive motor 2 rotor position sender 1 - G1147-
• With power and control electronics 2 for electric drive - JX4-
• ⇒ Rep. gr. 93 ; Removing and installing power and control electronics for electric drive
• ⇒ Rep. gr. 10 ; Removing front motor
• ⇒ Rep. gr. 10 ; Installing front motor

3. Bolt for gearbox mounting

• Renew after removing
• 70 Nm +90º

4. Bolt for gearbox support

• Qty. 3
• Renew after removing
• 50 Nm +90º

4. Gearbox support
5. Gearbox breather line
6. Bolt for gearbox mounting

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

7. Gearbox mounting

• ⇒ Rep. gr. 10 ; Removing and installing gearbox mounting

8. High-voltage connector for power and control electronics 2 for electric drive - JX4-
9. High-voltage cable duct
10. Bolt for cable guide

• Qty. 3
• 8 Nm

11. Bolt for potential equalisation line

• 8 Nm

12. Electrical connector for power and control electronics 2 for electric drive - JX4-
13. Potential equalisation line
14. Engine support
15. Front motor mounting

• ⇒ Running gear, axles, steering; Rep. gr. 40 ; Subframe; Renewing front motor mounting

16. Bolt for motor mounting

• Renew after removing
• 130 Nm +180º

17. Bolt for motor support

• Qty. 3
• Renew after removing
• 50 Nm +90º

18. Bolt for motor support

• Qty. 3
• Renew after removing
• 50 Nm +90º

19. Bolt for motor mounting

• Renew after removing
• 130 Nm +180º

20. Front motor mounting

• ⇒ Running gear, axles, steering; Rep. gr. 40 ; Subframe; Renewing front motor mounting

21. Engine support

Assembly overview - noise insulation, motor

1. Retaining clip
2.  Clip/bolt

• Depending on equipment/version
• Bolt with washer
• Qty. 2
• 5 Nm

3. Clip

• Qty. 2

4. Three-phase current drive 2 - VX97-

• Noise insulation
• Depending on equipment/version

6. Retaining clip

Assembly overview - front motor, right-hand drive vehicles

1. Three-phase current drive 2 - VX97-

• With electric drive motor

2. V717-

• With drive motor 2 temperature sender - G1146-
• With drive motor 2 rotor position sender 1 - G1147-
• With power and control electronics 2 for electric drive - JX4-
• ⇒ Rep. gr. 93 ; Removing and installing power and control electronics for electric drive
• ⇒ Rep. gr. 10 ; Removing front motor
• ⇒ Rep. gr. 10 ; Installing front motor

2. Bolt for gearbox mounting

• Renew after removing
• 70 Nm +90º

3. Bolt for gearbox support

• Qty. 3
• Renew after removing
•  50 Nm +90º

4. Gearbox support
5. Gearbox breather line
6. Bolt for gearbox mounting

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

7.  Gearbox mounting

• ⇒ Rep. gr. 10 ; Removing and installing gearbox mounting

8. High-voltage connector for power and control electronics 2 for electric drive - JX4-
9. High-voltage cable duct
10. Bolt for cable guide

• Qty. 3
• 8 Nm

11. Bolt for potential equalisation line

• 8 Nm

12. Electrical connector for power and control electronics 2 for electric drive - JX4-

• Potential equalisation line

14. Cover plate
15. Bolt

• Qty. 3
• 8 Nm

16. Bolt for motor support

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

17. Front motor mounting

• ⇒ Running gear, axles, steering; Rep. gr. 40 ; Subframe; Renewing front motor mounting

18. Bolt for front motor mounting

• Renew after removing
• 130 Nm +180º

19. Bolt for motor support

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

20. Bolt for front motor mounting

• Renew after removing
• 130 Nm +180º

21. Front motor mounting

•  ⇒ Running gear, axles, steering; Rep. gr. 40 ; Subframe; Renewing front motor mounting

22. Engine support

Assembly overview - noise insulation, motor

1. Retaining clip
2.  Clip/bolt

• Depending on equipment/version
• Bolt with washer
• Qty. 2
• 5 Nm

3. Clip

• Qty. 2

4. Three-phase current drive 2 - VX97-
5. Noise insulation

• Depending on equipment/version

6. Retaining clip

Removing front motor

Removing front motor, left-hand drive vehicles

Special tools and workshop equipment required

• engine bung set - VAS 6122-
• lifting tackle - VAS 501 021-
• workshop hoist - VAS 6100-

Three-phase current drive 2 - VX97- with power and control electronics 2 for electric drive - JX4- will henceforth be referred to as "motor".

Removing

Important

• Once the drive shafts have been removed, the drive shaft flange must be sealed with a suitable plug from engine bung set - VAS 6122- .
• Make sure that no gear oil leaks out.
• Remove subframe together with motor ⇒ Running gear, axles, steering; Rep. gr. 40 ; Subframe; Removing and installing subframe with motor .

• Insert bracket -A- of lifting tackle - VAS 501 021- into holes -arrows B-.
• Screw bolt -1- to stop into hole -arrow C-.
• Secure shackle -2- in centre hole.

• Attach workshop hoist - VAS 6100- to shackle -arrow-.
• Use workshop hoist to take up weight of motor -1-.
• Unscrew bolts -2-, -3- and -4-.
• Use workshop hoist to raise motor -1-.

• For further repairs, ⇒ Rep. gr. 10 ; Secure motor to engine and gearbox support, front motor .

Removing front motor, right-hand drive vehicles

Special tools and workshop equipment required

• engine bung set - VAS 6122-
• lifting tackle - VAS 501 021-
• workshop hoist - VAS 6100

Three-phase current drive 2 - VX97- with power and control electronics 2 for electric drive - JX4- will henceforth be referred to as "motor".

Removing

Important

• Once the drive shafts have been removed, the drive shaft flange must be sealed with a suitable plug from engine bung set - VAS 6122- .
• Make sure that no gear oil leaks out.
• Remove subframe together with motor ⇒ Running gear, axles, steering; Rep. gr. 40 ; Subframe; Removing and installing subframe with motor .

• Loosen bolts -1- and -2-, and unscrew them by 20 mm -a-.

• Unscrew bolt -1- for motor mounting -2-.

• Raise motor -1- 10 mm in direction of -arrow B- using assembly lever -A-, and pull it towards rear in direction of -arrow C-.

• Insert bracket -A- of lifting tackle - VAS 501 021- into holes -arrows B-.
• Screw bolt -1- to stop into hole -arrow C-.
• Secure shackle -2- in centre hole.

• Attach workshop hoist - VAS 6100- to shackle -arrow-.
• Use workshop hoist to take up weight of motor -1-.
• Unscrew bolts -2- and -3-.
• Use workshop hoist to raise motor -1-.

• For further repairs, ⇒ Rep. gr. 10 ; Secure motor to engine and gearbox support, front motor .

Securing motor to engine and gearbox support, front motor

Special tools and workshop equipment required

• Motor bracket - VAS 6095A/1-22-
• engine and gearbox jack - VAS 6095A-
• lifting tackle - VAS 501 021-
• retaining plate - VW309A-
• workshop hoist - VAS 6100-

The three-phase current drive 2 - VX97- along with the power and control electronics 2 for electric drive - JX4- will henceforth be referred to as "motor".

• Insert bracket of lifting tackle - VAS 501 021- -A- into holes -arrows B-.
• Screw bolt -1- to stop into hole -arrow C- by hand.
• Secure shackle -2- in centre hole.
• Attach workshop hoist - VAS 6100- to shackle -2-, and raise motor.

• Unscrew and remove bolts -arrows- and remove motor support -1-.

• Mount motor bracket - VAS 6095A/1-22- -A- on motor -1- and tighten bolts -arrows-.

• Insert retaining plate - VW309A- -B- into engine and gearbox jack - VAS 6095A- -C-.
• Mount motor bracket - VAS 6095A/1-22- -A- on retaining plate - VW309A- -B- and tighten bolts -arrows-.

Installing front motor

Installing front motor, left-hand drive vehicles

Special tools and workshop equipment required

• lifting tackle - VAS 501 021-
• workshop hoist - VAS 6100-

Three-phase current drive 2 - VX97- with power and control electronics 2 for electric drive - JX4- will henceforth be referred to as "motor".

Installing

• Insert bracket -A- into holes -arrows B-.
• Screw bolt -1- to stop into hole -arrow C-.
• Secure shackle -2- in centre hole.
• Attach workshop hoist - VAS 6100- to shackle -2-.

• Use workshop hoist to position motor -1- on subframe.
• Align motor support with gearbox mounting, and screw in bolts -3- and -4- until stop.
• Tighten bolt -2-.
• Tighten bolts -3- and -4-.
• Detach lifting tackle - VAS 501 021- -arrow

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

• Install subframe together with motor ⇒ Running gear, axles, steering; Rep. gr. 40 ; Subframe; Removing and installing subframe with motor .

Tightening torques

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

Installing front motor, right-hand drive vehicles

Special tools and workshop equipment required

• lifting tackle - VAS 501 021-
• workshop hoist - VAS 6100-

Three-phase current drive 2 - VX97- with power and control electronics 2 for electric drive - JX4- will henceforth be referred to as "motor".

Installing

• Insert bracket -A- into holes -arrows B-.
• Screw bolt -1- to stop into hole -arrow C-.
• Secure shackle -2- in centre hole.
• Attach workshop hoist - VAS 6100- to shackle -2-.

• Use workshop hoist to position motor -1- on subframe in such a way that a distance of -a- = 20 mm remains between motor support and gearbox mounting.
• Align motor support and gearbox mounting with each other.
• Screw in bolts -2- and -3- until bolt heads make contact with gearbox mounting.
• Detach lifting tackle - VAS 501 021- -arrow-.

• Raise motor -1- 10 mm in direction of -arrow B- using assembly lever -A-, and pull it against gearbox mounting in direction of -arrow C-.

• Screw in bolts -1- and -2- entirely, and tighten them.

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

• Install subframe together with motor ⇒ Running gear, axles, steering; Rep. gr. 40 ; Subframe; Removing and installing subframe with motor .

Tightening torques

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