Front Electric Drive Motor, Leak Test
Special tools and workshop equipment required
- Adapter :VAS 691 005/11-1
- Adapter :VAS 691 005/15-3
- Leak-Tight Connector (Replacement Part) :T10607/4
- Leak-Tight Connector :T10633
- Digital Pressure Sensor :V.A.G 1397B
- Cooling System Tester :V.A.G 1274B
- Adapter :VAS 691 005/16-1
- Sealing Cap :VAS 691 005/11-2
- Sealing Cap :VAS 691 005/ 16-2
- Cooling System Tester - Directional Valve :VAS 691 005/1
The Electric Drive Power and Control Electronics 2 -JX4- will be called the power electronics in the information that follows.
Condition
- Sealants must dry for at least 15 minutes before the leak test is performed.
Perform the following steps one after another.
Step 1: Checking the tools in use for leaks
-- Connect the Cooling System Tester :V.A.G 1274B -D- on the Cooling System Tester - Directional Valve :VAS 691 005/1 -B-.
-- Connect the Digital Pressure Sensor :V.A.G 1397B -C- on the distribution piece -B-.
-- Open all shut-off valves -arrows- at the distribution piece -B-.
-- Connect the distribution piece -B- on the Leakage Test Set - Adapter :VAS 691 005/15-3 -E-.
-- Switch on the pressure sensor -C-. Select the unit "mbar" and relative pressure measurement "rEL".
-- Close the shut-off valve -arrow- at the adapter -E-.
-- Create pressure using the cooling system tester -D-.
Test pressure:
- 2000 mbar
-- When the pressure is reached, close the shut-off valve -arrow- at the distribution piece -B-.
Wait until the pressure stabilized.
-- Monitor the pressure sensor -C- for one minute.
Permitted pressure decrease:
- 0 mbar (0 psi)
Tip
Because of the high measuring exactness of the pressure sensor, the pressure displayed can vary.
Step 2: Checking the transmission side for leaks
-- Seal the connections on the power electronics -1- using the Leak-Tight Connector (Replacement Part) :T10607/4 -J- and Leak-Tight Connector :T10633 -K-.
-- Insert the Cap :VAS 691 005/16-2 -F- into the left input shaft flange.
-- Install the clamping nut -1- hand-tight.
-- Engage the safety cord -2- to the motor.
-- Insert the Cap :VAS 691 005/ 16- 2 -G- into the right input shaft flange.
-- Install the clamping nut -1- hand-tight.
-- Engage the safety cord -2- to the motor.
-- Press in the locking mechanism -arrow- and place the Adapter :VAS 691 005/15-3 -E- onto the transmission ventilation.
-- Release the locking mechanism -arrow- and check the retainer by pulling against it.
-- If already installed, carefully pry out the breather valve -1- using a small screwdriver -arrow-.
-- Install the Test Adapter :VAS 691 005/16- 1 -A- on the motor.
-- Tighten the knurled bolt -1- hand-tight.
-- Hand-tighten the compressed air connection -2- centrally against the hole for the breather valve.
-- Connect the distribution piece -B- with the pressure sensor -C- and the pressure and cooling system tester -D- on the connection adapter -E-.
-- Open all shut-off valves -arrows-.
-- Switch on the pressure sensor -C-. Select the unit "mbar" and relative pressure measurement "rEL".
-- Create pressure using the cooling system tester -D-.
Test pressure:
- 400 mbar (5.8 psi)
-- When the pressure is reached, close the shut-off valve -arrow- at the distribution piece -B-.
Wait until the pressure stabilized.
-- Monitor the pressure sensor for five minutes.
Permitted pressure decrease:
- 4 mbar (0.06 psi)
-- If the pressure falls by more than 4 mbar (0.06 psi), localize the leak using a commercially available leak detection spray.
-- If the transmission side is without leaks, close the shut-off valve -arrow- at the adapter -E-.
Tip
The pressure in the transmission must not be released! It is necessary for the leak test on the motor side.
Step 3: Checking for leaks at the motor-side
-- Connect the distribution piece -B- with the pressure sensor -C- and the pressure and cooling system tester -D- on the test adapter -A-.
-- Open all shut-off valves -arrows- at the distribution piece -B-.
-- Switch on the pressure sensor -C-. Select the unit "mbar" and relative pressure measurement "rEL".
-- Create pressure using the cooling system tester -D-.
Test pressure:
- 200 mbar (2.9 psi)
-- When the pressure is reached, close the shut-off valve -arrow- at the distribution piece -B-.
Wait until the pressure stabilized.
-- Monitor the pressure sensor -C- for five minutes.
Permitted pressure decrease:
- 4 mbar (0.06 psi)
-- If the pressure falls by more than 4 mbar (0.06 psi), localize the leak using a commercially available leak detection spray.
-- After the leak test remove the cooling system tester -D-.
-- First release the pressure on the motor-side by opening the shut-off valve -1- Afterward, open the shut-off valve -2-.
-- Remove all tools.
-- Apply a thin layer of special lubricant onto the breather valve seal at the gear carrier -arrow- and install a new breather valve -1-.
Special lubricant. Refer to the Electronic Parts Information (ETKA).
Step 4: Checking for leaks at the coolant side of the motor
-- Close the coolant connection -1- using the Sealing Cap :VAS 691 005/11-2 -H-.
-- Connect the Adapter :VAS 691 005/ 11-1 -I- to the coolant connector -2-.
-- Secure the cap and the adapter using a hose clamps -arrows-.
-- Connect the distribution piece -B- with the pressure sensor -C- and the pressure and cooling system tester -D- on the test adapter -I-.
-- Open all shut-off valves -arrows- at the distribution piece -B-.
-- Create pressure using the cooling system tester -D-.
Test pressure:
- 2000 mbar
-- When the pressure is reached, close the shut-off valve -arrow-.
Wait until the pressure stabilized.
-- Monitor the pressure sensor -C- for five minutes.
Permitted pressure decrease:
- 4 mbar (0.06 psi)
-- If the pressure falls by more than 4 mbar (0.06 psi), localize the leak using a commercially available leak detection spray.
Condition
- If leaks are located and sealed, repeat the leak test
- If no leaks are detected, remove all tools