Electric Drive Motor Leak Test, Rear Motor

WARNING: This page is about a different car, the 2022 Volkswagen ID.4 and 2021 Volkswagen ID.4. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Sealing Element: T10634
Leakage Test Set: VAS 691 005/15
Leak-Tight Connector (Replacement Part): T10607/4
Pressure and Vacuum Pump: VAS 671 005
Digital Pressure Sensor: V.A.G 1397B
Cooling System Tester - Test Adapter: VAS 691 005/4
Sealing Cap: VAS 691 005/11-2
Cooling System Tester - Directional Valve: VAS 691 005/1

The Electric Drive Power and Control Electronics -JX1- will be called the power electronics in the information that follows.

Condition

The Three-Phase Current Drive -VX54- with Electric Drive Power and Control Electronics -JX1- must be secured on the engine and transmission holder.
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 Pressure and Vacuum Pump: VAS 671 005 -D- with the pressure side to the Cooling System Tester - Directional Valve: VAS 691 005/1 -B-.

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-- 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 Cooling System Tester - Cap: 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 connection adapter -E-.

-- Create a pressure of 1000 mbar using the pressure and vacuum pump -D-.

-- Monitor the pressure sensor -C- for one minute.

Condition

The pressure must not reduce.

Tip

Because of the high measuring exactness of the pressure sensor, the pressure displayed can vary.

Step 2: Checking the motor and the transmission 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-.

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-- Position the Leak-Tight Connector: T10634 -L- as shown on the power electronics -1-.

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-- Position the center sealant plate in front of the breather valve -arrow-.

-- Install the spindle -2- hand-tight.

-- Insert the Cap: VAS 691 005/15-1 -F- into the left input shaft flange.

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-- Install the clamping nut -1- hand-tight.

-- Engage the safety cord -2- to the motor.

-- Insert the Cap: VAS 691 005/15-1 -G- into the right input shaft flange.

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-- Install the clamping nut -1- hand-tight.

-- Engage the safety cord -2- to the motor.

-- Press in the locking mechanism -arrow- and place the Cooling System Tester - Cap: VAS 691 005/15-3 -E- onto the transmission ventilation.

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-- Release of the locking mechanism -arrow- and check the retainer by pulling against it.

-- Carefully pry out the breather valve -1- using a small screwdriver -arrow-.

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-- Install the Test Adapter: VAS 691 005/15-2 -A- on the motor.

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Condition

The compressed air connection -1- must be flush with the hole for the breather valve -arrow-.

-- Install the knurled bolts -2- hand-tight.

-- Hand-tighten the compressed air connection -1- centrally against the hole for the breather valve.

-- Connect the distribution piece -B- with the pressure sensor -C- and the pressure and vacuum pump -D- on the connection adapter -E-.

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-- Open all shut-off valves -arrows-.

-- Switch on the pressure sensor -C-. Select the unit "mbar" and relative pressure measurement "rEL".

-- Create a pressure of 200 mbar (2.9 psi) using the pressure and vacuum pump -D-.

-- When the pressure is reached, close the shut-off valve -arrow- at the distribution piece -B-.

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-- Monitor the pressure sensor for five minutes.

Condition

The pressure must not reduce by more than 2 mbar (0.03 psi).

-- If the pressure falls by more than 2 mbar (0.03 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 connection adapter -E-.

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Tip

The pressure in the transmission must not be released! It is necessary for the leak test on the motor side.

Checking for leaks on the motor side:

-- Connect the distribution piece -B- with the pressure sensor -C- and the pressure and vacuum pump -D- to the Test Adapter: VAS 691 005/15-2 -A-.

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-- 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 a pressure of 200 mbar (2.9 psi) using the pressure and vacuum pump -D-.

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-- When the pressure is reached, close the shut-off valve -arrow- at the distribution piece -B-.

-- Monitor the pressure sensor -C- for five minutes.

Condition

The pressure must not reduce by more than 2 mbar (0.03 psi).

-- If the pressure falls by more than 2 mbar (0.03 psi), localize the leak using a commercially available leak detection spray.

-- Remove the pressure and vacuum pump -D- after the leak test.

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-- First release the pressure on the motor-side by opening the shut-off valve -arrow 1- Afterward, open the shut-off valve -arrow 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-.

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Special lubricant. Refer to the Parts Information.

Step 3: Checking for leaks at the coolant side of the motor

-- Close the coolant connection -1- at the bottom on the power electronics using the Sealing Cap: VAS 691 005/11-2 -H-.

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-- Secure the closure using a hose clamp -arrow-.

-- Connect the Test Adapter: VAS 691 005/4 -I- to the coolant connector -2-.

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-- Connect the distribution piece -B- with the pressure sensor -C- and the pressure and vacuum pump -D- on the test adapter -E-.

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-- Open all shut-off valves -arrows- at the distribution piece -B-.

-- Create a pressure of 1000 mbar using the pressure and vacuum pump -D-.

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-- When the pressure is reached, close the shut-off valve -arrow-.

-- Monitor the pressure sensor -C- for five minutes.

Condition

The pressure must not reduce by more than 1 mbar (0.01 psi).

-- If the pressure falls by more than 1 mbar (0.01 psi), localize the leak using a commercially available leak detection spray.

Condition

If leaks are located and sealed, repeat the leak test.
If leaks are detected, remove all tools.