Volkswagen ID.3: Electric drive EIP220, EIA200, EIA210. Engine assy,cylinder block,crankcase

• Assembly overview – front motor, left-hand drive vehicles
• Installing front motor, right-hand drive vehicles
• Installing rear motor
• Securing motor to engine and gearbox support, rear motor
• Removing rear motor
• Assembly overview - rear motor
• Installing front motor, left-hand drive vehicles
• Securing motor to engine and gearbox support, front motor
• Removing front motor, right-hand drive vehicles
• Removing front motor, left-hand drive vehicles
• Assembly overview – front motor, right-hand drive vehicles
• Removing and installing gearbox mountings

Assembly overview – front motor, left-hand drive vehicles

Assembly overview – front motor, left-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 +90°

3 - Bolt for gearbox support

❏ Qty. 3

❏ Renew after removing

❏ 50 Nm +90°

4 - Gearbox support

5 - Gearbox breather line

6 - Bolt for gearbox mounting

❏ Qty. 2

❏ Renew after removing

❏ 50 Nm +90°

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 +180°

17 - Bolt for motor support

❏ Qty. 3

❏ Renew after removing

❏ 50 Nm +90°

18 - Bolt for motor support

❏ Qty. 3

❏ Renew after removing

❏ 50 Nm +90°

19 - Bolt for motor mounting

❏ Renew after removing

❏ 130 Nm +180°

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-

5 - Noise insulation

- Depending on equipment/version

6 - Retaining clip

Installing front motor, right-hand drive vehicles

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.

– Tighten bolt -1- for motor mounting -2-.

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 rear motor

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

Securing motor to engine and gearbox support, rear motor

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-.

Tightening torques

BoltsSpecified torqueBracket -VAS 501 019/1- and bracket -VAS 501 019/2- to lifting tackle -VAS 501 019-25 NmMotor bracket -VAS 6095A/1-21- to retaining plate -VW309A-80 NmMotor bracket -VAS 6095A/1-21- to motor20 Nm

Removing rear motor

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:

A - Pin -3282/34-

B - Pin -3282/45- with screwed on nut -1-

C - 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-.

Assembly overview - 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 +90°

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 +180°

17 - Bolt

❏ Qty. 3

❏ Renew after removing

❏ 70 Nm +180°

18 - Engine support

19 - Bolt

❏ Renew after removing

❏ 130 Nm +180°

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 +45°

24 - Nut

❏ 8 Nm

25 - O-ring

26 - Breather line

27 - Bolt

❏ 8 Nm

28 - Electrical connector

Installing front motor, left-hand drive vehicles

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

Securing 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-.

Tightening torques

BoltsSpecified torqueMotor bracket -VAS 6095A/1-22- to motor20 NmMotor bracket -VAS 6095A/1-22- to retaining plate -VW309A-80 Nm

Removing front motor, right-hand drive vehicles

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.

Removing front motor, left-hand drive vehicles

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.

Assembly overview – front motor, right-hand drive vehicles

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 +90°

3 - Bolt for gearbox support

❏ Qty. 3

❏ Renew after removing

❏ 50 Nm +90°

4 - Gearbox support

5 - Gearbox breather line

6 - Bolt for gearbox mounting

❏ Qty. 2

❏ Renew after removing

❏ 50 Nm +90°

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 - Cover plate

15 - Bolt

❏ Qty. 3

❏ 8 Nm

16 - Bolt for motor support

❏ Qty. 2

❏ Renew after removing

❏ 50 Nm +90°

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 +180°

19 - Bolt for motor support

❏ Qty. 2

❏ Renew after removing

❏ 50 Nm +90°

20 - Bolt for front motor mounting

❏ Renew after removing

❏ 130 Nm +180°

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 and installing gearbox mountings

Removing and installing gearbox mountings

Removing

– → Rep. gr.10; Remove motor (front).

– Remove bolts -arrows- and detach gearbox mounting -1-.

Installing

Installation is carried out in reverse order; note the following:

Tightening torques

♦ → Rep. gr.10; Exploded view - motor (front)

Electric drive EIP220, EIA200, EIA210. Technical dataElectric drive EIP220, EIA200, EIA210. Engine cooling