Volkswagen ID.3: Electric drive EIP220, EIA200, EIA210. Engine cooling

• Removing and installing coolant temperature sender 2 for high-voltage battery G899
• Removing and installing coolant pump for low-temperature circuit [V468]
• Removing and installing mixing valve for high-voltage battery pre-heating, rear-wheel drive
• Removing and installing mixing valve for high-voltage battery pre-heating, all-wheel drive
• Removing and installing mixing valve 2 for high-voltage battery pre-heating V696
• Removing and installing temperature sensor [G18]
• Removing and installing coolant temperature sender 1 for high-voltage battery G898
• Assembly overview - radiator/radiator fan
• Assembly overview – radiator cowl and radiator fan
• Removing and installing radiator module
• Dismantling and assembling radiator module
• Removing and installing radiator cowl with radiator fan
• Removing and installing radiator fan [VX57]
• Removing and installing coolant pump for high-voltage battery [V590], all-wheel drive
• Removing and installing coolant pump for high-voltage battery [V590], rear-wheel drive
• Connection diagram - coolant hoses, rear-wheel drive
• Assembly overview – cooling system, all-wheel drive
• Connection diagram - coolant hoses, four-wheel drive
• Connection diagram - coolant hoses, rear-wheel drive
• Connection diagram - coolant hoses, four-wheel drive
• 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
• Checking cooling system for leaks
• Exploded view - coolant temperature senders
• Removing and installing coolant expansion tank
• Checking filling quality
• Draining coolant
• Filling cooling system
• Assembly overview - electric coolant pump
• Assembly overview - coolant valves
• Removing and installing control motor for radiator roller blind [V711]

Removing and installing coolant temperature sender 2 for high-voltage battery G899

Removing and installing coolant temperature sender 2 for high-voltage battery G899

Coolant temperature sender 2 for high-voltage battery - G899- is referred to as coolant temperature sender below.

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.

– Open filler cap on coolant expansion tank -arrow- briefly to release pressure in cooling system and then tighten cap again.

– Remove underbody trim (front) → General body repairs, exterior; Rep. gr.66; Underbody trim; Removing and installing underbody trim (front).

– Unplug electrical connector -1-.

– Remove bolt -arrow-.

– Pull coolant temperature sender -2- out and insert new coolant temperature sender -2- immediately.

Installing

– Tighten bolt -arrow-.

– Plug in electrical connector -1-.

– Install underbody trim (front) → General body repairs, exterior; Rep. gr.66; Underbody trim; Removing and installing underbody trim (front).

– Fill up coolant and check filling quality → Rep. gr.19; Checking filling quality.

Tightening torques

♦ → Rep. gr.19; Exploded view - coolant temperature senders

♦ → General body repairs, exterior; Rep. gr.66; Underbody trim; Exploded view - underbody trim

Removing and installing coolant pump for low-temperature circuit [V468]

Removing and installing coolant pump for low-temperature circuit [V468]

Coolant pump for low-temperature circuit -V468- will henceforth be referred to as “coolant pump”.

Removing

– Remove front underbody cladding → General body repairs, exterior; Rep. gr.66; Underbody cladding; Removing and installing front underbody cladding.

– → Rep. gr.19; Drain coolant.

– Unscrew bolts -1-.

– Pull electrical wires -arrow- off bracket.

– Pull coolant pump in direction of -arrow-, and disconnect electrical connector -1-.

– Loosen clips -2- and pull off coolant hoses.

Installing

Install in reverse order of removal, observing the following:

– Fit coolant hoses, and make sure that installation markings are properly aligned.

Important

● Installation markings -arrows- on coolant hoses -1- and -2- must face vertically upwards.

– → Rep. gr.19; Fill cooling system.

Tightening torques

♦ → Rep. gr.19; Assembly overview – electric coolant pump

Removing and installing mixing valve for high-voltage battery pre-heating, rear-wheel drive

Removing and installing mixing valve for high-voltage battery pre-heating, rear-wheel drive

The mixing valve for high-voltage battery pre-heating -V683- will henceforth be referred to as “mixing valve”.

Removing

– Remove front underbody cladding → General body repairs, exterior; Rep. gr.66; Underbody cladding; Removing and installing front underbody cladding.

– → Rep. gr.19; Drain coolant.

– Remove cable holder -arrow-.

– Unscrew bolts -1-.

– Disconnect electrical connector -1-.

– Pull out retaining clip -arrow-, and pull plug-in connector -2- off high-voltage battery 1 -AX2-.

– Pull mixing valve in direction of -arrow-, and disconnect electrical connector -1-.

– Unclip electrical wire -2- from retainer -3-.

– Loosen clamps -4-, and pull off coolant hoses.

– Remove mixing valve with bracket -3-.

– Unscrew nuts -arrows-.

– Loosen clamp -1-, and pull coolant hose off mixing valve -2-.

Installing

Install in reverse order of removal, observing the following:

– Observe installation markings on mixing valve and coolant hoses.

– → Rep. gr.19; Fill cooling system.

Tightening torques

♦ → Rep. gr.19; Assembly overview – coolant valves

Removing and installing mixing valve for high-voltage battery pre-heating, all-wheel drive

Removing and installing mixing valve for high-voltage battery pre-heating, all-wheel drive

Removing

The mixing valve for high-voltage battery pre-heating -V683- will henceforth be referred to as “mixing valve”.

– Remove front underbody cladding → General body repairs, exterior; Rep. gr.66; Underbody cladding; Removing and installing front underbody cladding.

– → Rep. gr.19; Drain coolant.

– Disconnect electrical connector -1-.

– Pull out securing clip -arrow-, and pull off plug-in connector -2-.

– Detach cable holder -1-.

– Open hose retainer -2-, and move aside coolant hose -3-.

– Unscrew bolts -arrows-.

– Push coolant pump bracket -4- upwards.

– Pull off electrical connector -1-.

– Pull out securing clip -arrow-, and pull off plug-in connector -2-.

– Open hose clips -arrows-, and pull off coolant hoses -1-, -6- and -7-.

– Pull mixing valve holder -8- downwards, and disconnect electrical connector -3-.

– Unclip electrical wire -5- from holder.

– Unscrew nuts -2-, and remove mixing valve.

Installing

Install in reverse order of removal, observing the following:

– Observe installation markings on mixing valve and coolant hoses.

– → Rep. gr.19; Fill cooling system.

Tightening torques

♦ → Rep. gr.19; Assembly overview – coolant valves

♦ → General body repairs, exterior; Rep. gr.66; Underbody cladding; Assembly overview – underbody cladding

Removing and installing mixing valve 2 for high-voltage battery pre-heating V696

Removing and installing mixing valve 2 for high-voltage battery pre-heating V696

Mixing valve 2 for high-voltage battery pre-heating -V696- is referred to as mixing valve below.

Removing

– Remove mixing valve for high-voltage battery pre-heating -V683- → Rep. gr.19; Removing and installing mixing valve for high-voltage battery pre-heating V683.

– Pull bracket -8- downwards and unplug electrical connector -4-.

– Unfasten clip -3- and detach coolant hose -4-.

– Swivel bracket -1- in direction of -arrow A-, release retaining clip -2- and move coolant hose clear.

– Remove bolts -arrows B- and detach bracket -1-.

– Release clips -arrows- and detach coolant hoses -1- and -3-.

Installing

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

– Note installation markings on mixing valve and coolant hoses.

– → Rep. gr.19; Fill cooling system.

Tightening torques

♦ → Rep. gr.19; Assembly overview - coolant valves

Removing and installing temperature sensor [G18]

Removing and installing temperature sensor [G18]

Removing

– → Rep. gr.19; Draining coolant

– Remove rear right wheel → Running gear, axles, steering; Rep. gr.44; Wheels, tyres; Removing wheel.

– Disconnect connector -1-.

– Pull out retaining clip -arrow-, and remove temperature sensor -G18- -2-.

Installing

Install in reverse order of removal, observing the following:

– Renew O-ring for temperature sensor.

– → Rep. gr.19; Fill cooling system.

Tightening torques

♦ → Running gear, axles, steering; Rep. gr.44; Wheels, tyres; Specified torques for wheel bolts

Removing and installing coolant temperature sender 1 for high-voltage battery G898

Removing and installing coolant temperature sender 1 for high-voltage battery G898

Coolant temperature sender 1 for high-voltage battery -G898- is referred to as coolant temperature sender below.

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.

– Open filler cap on coolant expansion tank -arrow- briefly to release pressure in cooling system and then tighten cap again.

– Remove underbody trim (front) → General body repairs, exterior; Rep. gr.66; Underbody trim; Removing and installing underbody trim (front).

– Unplug electrical connector -1-.

– Remove bolt -arrow-.

– Pull coolant temperature sender -2- out and insert new coolant temperature sender -2- immediately.

Installing

– Tighten bolt -arrow-.

– Plug in electrical connector -1-.

– Install underbody trim (front) → General body repairs, exterior; Rep. gr.66; Underbody trim; Removing and installing underbody trim (front).

– Fill up coolant and check filling quality → Rep. gr.19; Checking filling quality.

Tightening torques

♦ → Rep. gr.19; Exploded view - coolant temperature senders

♦ → General body repairs, exterior; Rep. gr.66; Underbody trim; Exploded view - underbody trim

Assembly overview - radiator/radiator fan

Assembly overview - radiator/radiator fan

1 - Front air duct

2 - Radiator

❏ → Rep. gr.19; Removing and installing radiator module

3 - Cooler blind

❏ → Rep. gr.19; Dismantling and assembling radiator module

4 - Condenser/gas cooler

❏ Depending on equipment/version

❏ → Heating, air conditioning system; Rep. gr.87; Refrigerant circuit; Assembly overview – condenser/gas cooler

5 - Rear air duct

6 - Radiator cowl with radiator fan - VX57-

❏ With radiator fan control unit - J293-

❏ With radiator fan - V7-

❏ → Rep. gr.19; Assembly overview – radiator cowl and radiator fan

❏ → Rep. gr.19; Removing and installing radiator cowl with radiator fan

7 - Bolt

❏ Qty. 2

❏ 2 Nm

8 - Control motor for radiator roller blind -V711-

❏ → Rep. gr.19; Removing and installing control motor for radiator roller blind [V711]

Assembly overview – radiator cowl and radiator fan

Assembly overview – radiator cowl and radiator fan

1 - Bolt

❏ Qty. 3

❏ 6 Nm

2 - Radiator cowl

❏ → Rep. gr.19; Removing and installing radiator cowl with radiator fan

3 - Radiator fan -VX57-

❏ With radiator fan control unit -J293-

❏ With radiator fan -V7-

❏ → Rep. gr.19; Removing and installing radiator fan VX57

Removing and installing radiator module

Removing and installing radiator module

Removing

– Remove front underbody cladding → General body repairs, exterior; Rep. gr.66; Underbody cladding; Removing and installing front underbody cladding.

– Move impact bar into service position → General body repairs, exterior; Rep. gr.63; Front bumper; Moving bumper carrier to and back from service position.

CAUTION

Risk of injury as the radiator fan(s) may start up automatically.

– When working in the vicinity of the radiator, keep a safe distance from the radiator fan.

– Do not reach into the radiator fan when unplugging the electrical connector.

– Unplug electrical connector for radiator fan -VX57- -arrow-.

– → Rep. gr.19; Drain coolant.

– Pull out securing clip -arrow- and disconnect coolant hose -1- from radiator (bottom left).

– Pull out securing clip -arrow- and disconnect coolant hose from radiator (top right).

– Disconnect refrigerant lines from condenser/gas cooler → Heating, air conditioning; Rep. gr.87; Refrigerant circuit; Detaching and attaching refrigerant lines at condenser/gas cooler.

– Pull catches for radiator mounting (bottom) -arrow- out of retaining plates -1- on both sides and detach retaining plates.

Important

● A second person is required for the following steps.

– Lift radiator module out of radiator mountings.

Installing

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

– Connect refrigerant lines to condenser/gas cooler → Heating, air conditioning; Rep. gr.87; Refrigerant circuit; Detaching and attaching refrigerant lines at condenser/gas cooler.

– Reset service position of impact bar → General body repairs, exterior; Rep. gr.63; Front bumper; Moving bumper carrier to and back from service position.

Tightening torques

♦ → Rep. gr.19; Assembly overview - radiators/radiator fans

Dismantling and assembling radiator module

Dismantling and assembling radiator module

Dismantling radiator module

– Remove radiator module → Rep. gr.19; Removing and installing radiator module.

– Press in retaining tabs -1- for radiator cowl on left and right in direction of -arrow A-.

– Pull radiator cowl -2- in direction of -arrow B- off radiator.

– Disconnect air ducts -1- and -2-. To do this, release fasteners -arrows-.

– In addition, release bottom fasteners -3-. Pull apart air ducts -1- and -2-.

Important

● To be able to remove the condenser/gas cooler, the radiator roller blind -2- must first be pulled approx. 15 mm out of the fastener.

NOTICE

Risk of damage to the material shaft of radiator roller blind.

– Only pull or push on the outer frame of the radiator roller blind.

– Press in retaining tabs -1- for radiator roller blind -2- on left and right in direction of -arrow A-.

– Grasp radiator roller blind -2- on outer side, and pull it approx. 15 mm upwards out of fastener in direction of -arrow B-.

– Remove condenser/gas cooler -2- by pressing in retaining tabs -1- for condenser/gas cooler on left and right in direction of -arrow A-.

– Pull condenser/gas cooler -2- upwards off radiator in direction of -arrow B-.

– Take radiator blind off radiator.

Assembling radiator module

– Bring radiator blind -1- into installation position on radiator -2- -arrows-. Do not engage the radiator roller blind yet!

– Install condenser/gas cooler -2-, and engage it. Ensure proper engagement by pulling.

NOTICE

Risk of damage to the material shaft of radiator roller blind.

– Only pull or push on the outer frame of the radiator roller blind.

– Apply pressure to outside of frame, and press radiator roller blind -1- into fastener.

– Position air ducts -1- and -2- on radiator, and engage them with each other -arrows-.

– Make sure that the lower fastener -3- is securely seated.

– Position radiator cowl on radiator, and engage it.

– Install radiator module → Rep. gr.19; Removing and installing radiator module.

If the control motor for radiator roller blind -V711- has been renewed:

– Carry out function “Adapt control motor for radiator roller blind” using → Vehicle diagnostic tester → Rep. gr.00; Access to diagnoses.

Continued

If the control motor for radiator roller blind -V711- has been renewed:

– Carry out function “Renew control motor for radiator roller blind” using → Vehicle diagnostic tester → Rep. gr.00; Access to diagnoses.

Removing and installing radiator cowl with radiator fan

Removing and installing radiator cowl with radiator fan

Removing

– Move bumper carrier to service position → General body repairs, exterior; Rep. gr.63; Front bumper; Moving bumper carrier to and back from service position.

CAUTION

Risk of injury as the radiator fan(s) may start up automatically.

– When working in the vicinity of the radiator, keep a safe distance from the radiator fan.

– Do not reach into the radiator fan when unplugging the electrical connector.

– Disconnect electrical connector of radiator fan -VX57- -arrow-.

For reasons of clarity, the following work procedures are shown with the radiator module removed.

– Press in retaining tabs -1- for radiator cowl -2- on left and right in direction of -arrow A-.

– Pull radiator cowl -2- upwards off radiator in direction of -arrow B-.

– Tilt radiator cowl -2-, and remove it upwards.

Installing

Install in reverse order of removal, observing the following:

– Position radiator cowl on radiator, and engage it.

– Move bumper carrier back from service position → General body repairs, exterior; Rep. gr.63; Front bumper; Moving bumper carrier to and back from service position.

Removing and installing radiator fan [VX57]

Removing and installing radiator fan [VX57]

Removing

– Remove radiator cowl with radiator fan -VX57- → Rep. gr.19; Removing and installing radiator cowl with radiator fan.

– Detach electrical wire -1- from radiator cowl.

– Unscrew bolts -arrows-.

– Remove radiator fan -VX57- -2- from radiator cowl.

Installing

Install in reverse order of removal, observing the following:

Tightening torques

♦ → Rep. gr.19; Assembly overview – radiator cowl and radiator fan

Removing and installing coolant pump for high-voltage battery [V590], all-wheel drive

Removing and installing coolant pump for high-voltage battery [V590], all-wheel drive

Removing

Coolant pump for high-voltage battery -V590- will henceforth be referred to as “coolant pump”.

Vehicles without heat pump:

– Remove mixing valve for high-voltage battery pre-heating -V683- and bracket → Rep. gr.19; Removing and installing mixing valve for high-voltage battery pre-heating [V683].

All vehicles (continued)

Vehicles with heat pump:

– Remove bracket for mixing valve 2 for high-voltage battery pre-heating -V696- → Rep. gr.19; Removing and installing mixing valve 2 for high-voltage battery pre-heating [V696].

All vehicles (continued)

– Disconnect electrical connector -1-.

– Pull out securing clip -arrow-, and pull off plug-in connector -2-.

– Pull coolant pump downwards slightly -arrow-, and disconnect electrical connector -1-.

– Open hose clip -2-, and pull off coolant hose.

Installing

Install in reverse order of removal, observing the following:

– Fit coolant hoses, and make sure that installation markings are properly aligned.

Important

● Installation markings -arrows- on coolant hoses -1- and -2- must face vertically upwards.

– → Rep. gr.19; Fill cooling system.

Tightening torques

♦ → Rep. gr.19; Assembly overview – electric coolant pump

Removing and installing coolant pump for high-voltage battery [V590], rear-wheel drive

Removing and installing coolant pump for high-voltage battery [V590], rear-wheel drive

Special tools and workshop equipment required

♦ hose clamps, up to 25 mm -3094-

Coolant pump for high-voltage battery -V590- will henceforth be referred to as “coolant pump”.

Removing

– Remove front underbody cladding → General body repairs, exterior; Rep. gr.66; Underbody cladding; Removing and installing front underbody cladding.

– Unscrew bolts -1-.

– Open clip -2-.

– Clamp off coolant hoses before and after coolant pump using hose clamps, up to 25 mm -3094- -A-.

– Pull coolant pump in direction of -arrow-, and disconnect electrical connector -1-.

– Open clamps -2- and -3-, and pull off coolant hoses.

Installing

Install in reverse order of removal, observing the following:

– Fit coolant hoses, and make sure that installation markings are properly aligned.

Important

● Installation markings -arrows- on coolant hoses -1- and -2- must face vertically upwards.

– → Rep. gr.19; Fill cooling system.

Tightening torques

♦ → Rep. gr.19; Assembly overview – electric coolant pump

Connection diagram - coolant hoses, rear-wheel drive

Connection diagram - coolant hoses, rear-wheel drive

1 - Charging unit 1 for high-voltage 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 high-voltage battery pre-heating -V683-

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

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

8 - Voltage converter -A19-

9 - PTC heater element 3 -Z132-

10 - Radiator

11 - Heat exchanger for high-voltage battery

12 - Thermostat

13 - Coolant expansion tank

Assembly overview – cooling system, all-wheel drive

Assembly overview – cooling system, all-wheel drive

A - Assembly overview – cooling system, front right

❏ → Anchor

B - Assembly overview – cooling system, rear

❏ → Anchor

C - Assembly overview – cooling system, front left

❏ → Anchor

A - 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 °C

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

B - Assembly overview – cooling system, rear

1 - Voltage converter -A19-

❏ → Rep. gr.93; Removing and installing voltage converter [A19]

2 - Charging unit 1 for high-voltage battery -AX4-

❏ With control unit for high-voltage battery charger -J1050-

❏ → Rep. gr.93; Removing and installing charging unit 1 for high-voltage 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

C - Assembly overview – cooling system, front left

1 - Hose clamp

2 - 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]

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 high-voltage 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 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]

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

Connection diagram - coolant hoses, four-wheel drive

Connection diagram - coolant hoses, four-wheel drive

1 - Voltage converter -A19-

2 - Charging unit 1 for high-voltage 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 high-voltage battery pre-heating -V696-

7 - Mixing valve for high-voltage 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 high-voltage battery

13 - Thermostat

14 - Coolant expansion tank

15 - Coolant pump for high-voltage battery -V590-

Connection diagram - coolant hoses, rear-wheel drive

Connection diagram - coolant hoses, rear-wheel drive

1 - Charging unit 1 for high-voltage 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 high-voltage battery pre-heating -V683-

6 - Coolant pump for high-voltage battery -V590-

7 - PTC heater element 3 -Z132-

8 - Voltage converter -A19-

9 - Radiator

10 - Heat exchanger for high-voltage battery

11 - Thermostat

12 - Coolant expansion tank

Connection diagram - coolant hoses, four-wheel drive

Connection diagram - coolant hoses, four-wheel drive

1 - Voltage converter -A19-

2 - Charging unit 1 for high-voltage 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 - Coolant pump for high-voltage battery -V590-

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

8 - Mixing valve for high-voltage 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 high-voltage battery

13 - Thermostat

14 - Coolant expansion tank

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

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 high-voltage battery -AX4-

❏ With control unit for high-voltage battery charger -J1050-

❏ → Rep. gr.93; Removing and installing charging unit 1 for high-voltage 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

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 high-voltage battery -AX4-

❏ With control unit for high-voltage battery charger -J1050-

❏ → Rep. gr.93; Removing and installing charging unit 1 for high-voltage 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

Assembly overview – cooling system, rear-wheel drive

A - Assembly overview – cooling system, front right

❏ → Anchor

B - Assembly overview – cooling system, rear

❏ → Anchor

C - Assembly overview – cooling system, front left

❏ → Anchor

A - 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 °C

14 - Bracket for coolant manifold

15 - Spreader rivet

16 - Coolant manifold

❏ Coolant hose and coolant pipe are marked with numbers

❏ Note allocation

B - 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 high-voltage battery -AX4-

❏ With control unit for high-voltage battery charger -J1050-

❏ → Rep. gr.93; Removing and installing charging unit 1 for high-voltage 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

C - 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

Checking cooling system for leaks

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 → Anchor.

– Check cooling system for leaks → Anchor.

– Check pressure relief valve in filler cap → Anchor.

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.

Exploded view - coolant temperature senders

Exploded view - coolant temperature senders

Exploded view - bolted coolant temperature sender

1 - Connection

2 - Bolt

❏ 8 Nm

3 - Coolant temperature sender

❏ Coolant temperature sender 1 for high-voltage battery -G898- in coolant supply

❏ Coolant temperature sender 2 for high-voltage battery -G899- in coolant return

❏ → Rep. gr.19; Removing and installing coolant temperature sender 1 for high-voltage battery G898

❏ → Rep. gr.19; Removing and installing coolant temperature sender 2 for high-voltage battery G899

4 - Support ring

5 - O-ring

❏ Renew after removing

Exploded view - inserted coolant temperature sender

1 - Connection

2 - Temperature sensor -G18-

❏ → Rep. gr.19; Removing and installing temperature sensor G18

3 - O-ring

❏ Renew after removing

4 - Retaining clip

Removing and installing coolant expansion tank

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.

Checking filling quality

Checking filling quality

Special tools and workshop equipment required

♦ adapter -VAS 691 005/5-

♦ cooling system tester -V.A.G 1274B-

Note

It is necessary to make sure that there is no air in the cooling system. If there is any air in the cooling system, the coolant level will drop far below the permissible level in the course of time. Overheating of the motor is also possible.

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 sealing cap of coolant expansion tank -arrow-.

– Check coolant level. It must be approx. 10 mm above the max. marking or be at the max. marking -1-. If necessary, top up with coolant.

– Fit cooling system tester -V.A.G 1274B- -3- with adapter -VAS 691 005/5- -1- onto coolant expansion tank -2-.

– Build up pressure of 1.5 bar using hand pump of cooling system tester.

– Observe coolant level in expansion tank.

If the coolant level in the coolant expansion tank has dropped more than 20 mm, this is an indication of an air bubble in the cooling system.

– Carry out function “Bleed cooling system” using → Vehicle diagnostic tester → Rep. gr.00; Access to diagnoses.

– Repeat filling quality check.

If the coolant level in the coolant expansion tank has dropped less than 20 mm, the cooling system has been filled correctly.

Continued

– Release pressure at hand pump of cooling system tester -3-.

– Detach adapter -1- from coolant expansion tank.

Draining coolant

Draining coolant

Special tools and workshop equipment required

♦ cooling system service unit -VAS 531 011-

♦ hose clamp up to 40 mm -3093-

NOTICE

Risk of damage to high-voltage components due to overheating.

– Do not perform high-voltage charging if coolant has been drained.

– Indicate this on the vehicle accordingly.

Procedure

Important

● Observe operating manual of cooling system service unit -VAS 531 011-.

– Make sure that the “DRAIN” container of the cooling system service unit is sufficiently empty to accept 12 litres of coolant.

Note

12 litres of coolant correspond to the total capacity of the cooling system. Due to the complexity of the cooling system, its total capacity cannot be discharged.

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 filler cap -arrow- for coolant expansion tank.

– Screw adapter from cooling system service unit onto coolant expansion tank.

– Connect service hose.

Important

● Do not disconnect service hose from cooling system service unit.

– Remove rear centre underbody cladding → General body repairs, exterior; Rep. gr.66; Underbody cladding; Removing and installing rear centre underbody cladding.

– Position cooling system service unit under coupling point to collect coolant.

– In main menu select “Vehicle maintenance” and “Drain system”.

– Start “Draining procedure”.

– Open clip -arrow- on power and control electronics for electric drive -JX1-, and pull off coolant hose -1-.

– Drain coolant into drip tray of cooling system service unit.

– Clamp off coolant hose -1- using hose clamp up to 40 mm -3093-.

– Attach commercially available coolant hose to connection -1- on motor.

– Hold commercially available coolant hose into funnel of cooling system service unit while draining coolant.

– Select “Drain system” procedure.

– Follow instructions on display, and blow out coolant until only small amounts are dripping out or until only air flows out.

– If necessary, start “Drain system” procedure again.

– Disconnect commercially available coolant hose from coolant hose connection -1- on motor.

– Remove hose clamp on coolant hose -1-.

– Hold coolant hose -1- in funnel of cooling system service unit while draining coolant.

– Start “Drain system” procedure again.

– Follow instructions on display, and blow out coolant until only small amounts are dripping out or until only air flows out.

– If necessary, start “Drain system” procedure again.

– Assemble cooling system.

Filling cooling system

Filling cooling system

Special tools and workshop equipment required

♦ cooling system service unit -VAS 531 011-

Filling cooling system

Important

● Observe operating manual of cooling system service unit -VAS 531 011-.

– Fill “NEW” container of cooling system service unit -VAS 531 011- with sufficient coolant mixed in proper ratio → Safety information and repair notes; Rep. gr.00; Repair notes; Replacement parts, servicing materials and consumables.

– Make sure that all coolant hoses are connected.

– Connect cooling system service unit.

– From the main menu, select “Vehicle maintenance”.

– In the menu, select “Pressure test”, and carry out hydraulic leak test.

♦ Test duration => 120 s

♦ Max. delta P => 40 mbar

♦ Test pressure => 2000 mbar

♦ Observe messages on display.

♦ The result will be displayed, after the test is completed.

– In the menu, select “Vacuum phase”, and carry out hydraulic leak test.

♦ Time => 240 s

♦ Specified pressure => 40 mbar

♦ Max. delta P => 30 mbar

♦ Test duration => 120 s

♦ Observe messages on display.

♦ The result will be displayed, after the test is completed.

♦ Repeat procedure if necessary.

– In the menu, select “Charge system”, and start filling.

♦ Filling quantity => Enter mass of 12000 g which corresponds to 12 litres.

♦ When the charging procedure is completed, the display shows the amount of filled coolant.

♦ When the charging procedure is completed, the service unit automatically starts cleaning the hoses.

♦ Follow the instructions on the display, and do not interrupt the process.

♦ The result will be displayed, after the test is completed.

♦ Repeat procedure if necessary.

– From the main menu, select “Vehicle maintenance”.

– In the menu, select “Bleed system”, and carry out bleeding procedure.

♦ Test pressure => 1800 mbar

– Carry out function “Bleed cooling system” using → Vehicle diagnostic tester → Rep. gr.00; Access to diagnoses.

Important

● Carry out this function 2 times in succession.

– Remove adapter with service hose from coolant expansion tank.

– Fill or extract coolant as necessary.

Important

● Coolant level must be 10 mm above max. marking -1-.

Note

This excess amount of coolant is necessary since the coolant level may decrease automatically as the vehicle is operated.

– → Rep. gr.19; Check filling quality.

Assembly overview - electric coolant pump

Assembly overview - electric coolant pump

1 - Coolant hose

2 - Clip

3 - Coolant pump for low-temperature circuit -V468-

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

4 - Electrical connector

5 - Rubber mounting

6 - Bolt

❏ Qty. 2

❏ 8 Nm

7 - Bracket

8 - Bracket

9 - Bolt

❏ Qty. 2

❏ 8 Nm

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

❏ → Rep. gr.19; Removing and installing coolant temperature sender 2 for high-voltage battery [G899]

11 - Coolant hose

12 - Coolant hose

13 - Clip

14 - Coolant pump for high-voltage battery -V590-

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

15 - Rubber mounting

16 - Electrical connector

Assembly overview - coolant valves

Assembly overview - coolant valves

1 - Mixing valve 2 for high-voltage battery pre-heating -V696-

❏ Depending on equipment/installation period

❏ → Rep. gr.19; Removing and installing mixing valve 2 for high-voltage battery pre-heating [V696]

2 - Clip

3 - Coolant hose

4 - Mixing valve for high-voltage battery pre-heating -V683-

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

5 - Electrical connector

6 - Nut

❏ Qty. 2

❏ 8 Nm

7 - Coolant temperature sender 1 for high-voltage battery -G898-

❏ → Rep. gr.19; Removing and installing coolant temperature sender 1 for high-voltage battery [G898]

8 - Coolant hose

9 - Bolt

❏ Qty. 2

❏ 8 Nm

10 - Bracket

11 - Bolt

❏ Qty. 2

❏ 8 Nm

12 - Coolant hose

13 - Clip

Removing and installing control motor for radiator roller blind [V711]

Removing and installing control motor for radiator roller blind [V711]

Removing

The control motor for radiator roller blind - V711- will henceforth be referred to as “control motor”.

– Remove lock carrier → General body repairs, exterior; Rep. gr.50; Lock carrier; Removing and installing lock carrier.

– Disconnect electrical connector -2-.

– Unscrew bolts -arrows-.

– Remove control motor -1-.

Installing

– Fit control motor -1- in position. If the drive pin of the control motor does not fit into the material shaft, turn the material shaft slightly.

– Tighten control motor -arrows-.

– Connect electrical connector -2-.

– Install lock carrier → General body repairs, exterior; Rep. gr.50; Lock carrier; Removing and installing lock carrier.

If the control motor for radiator roller blind -V711- has been renewed:

– Carry out function “Renew control motor for radiator roller blind” using → Vehicle diagnostic tester → Rep. gr.00; Access to diagnoses.

Continued

Tightening torques

♦ → Rep. gr.19; Assembly overview - radiator, radiator fan

Electric drive EIP220, EIA200, EIA210. Engine assy,cylinder block,crankcaseElectric drive. High-voltage components, charging unit and voltage converter