Removing and installing electric drive motor: Audi A8 D4 (CHJA)

🧭 Before you start

Have a qualified technician de-energise and lock the high-voltage system, then remove the high-voltage wires and the gearbox. Remove the left flange shaft, connection box and coolant line connection, cap all openings, turn the gearbox and lift the motor out vertically. On refit, clean the housing, grease and check the oil seal, renew the input shaft O-ring and lower the motor gently onto the splines. Reinstall the gearbox, connect the high-voltage wires by their coding and re-energise the system.

Fits: Audi A8 D4 (4H, 2010–2017)

• Renewed: if necessary

Don't miss

• Only a qualified high-voltage technician may de-energise and confirm the system is dead before work starts.
• Screw the eye-head bolt in no deeper than 8 mm, or the damper module is damaged.
• Lower the motor slowly; if splines drop into engagement the lugs and bearings can be damaged.
• Do not let the rotor position sender or high-voltage connection knock the gearbox housing.
• Renew the input shaft O-ring and pack the oil seal half-full with sealing grease.
• Join the round high-voltage connectors only according to their colour and mechanical coding.

Written for this job from the workshop steps below · TorqFix editorial.

🔧 Engine codes this applies to

📋 Procedure

1. ⚠ Working on vehicles with high-voltage wiring:Do not support yourself or tools on high-voltage wiring or associated components --> this can damage the insulation. High-voltage wiring must not be excessively bent or kinked --> this can damage the insulation. The round high-voltage connectors are colour-coded with an external coloured ring and are provided with mechanical coding or guide lugs. It is important to observe this coding when joining up the round high-voltage connectors, otherwise the connectors can be damaged. — De-energise high-voltage system. [Note: De-energising high-voltage system:Connect vehicle diagnostic testerSelect Guided Fault Finding modeUsing the Go to button, select the following menu options in succession:Selecting function/componentBodyElectrical systemSelf-diagnosis-compatible systems8C - Hybrid battery management -J8408C - Hybrid battery management, functions51 - De-energise high-voltage system (Rep. gr. 93)]
2. ⚠ High voltage can cause fatal injuryDanger of severe or fatal injuries from electric shock The high-voltage system may only be de-energised by a suitably qualified person (Audi high-voltage technician). It must be definitely confirmed that the high-voltage system is de-energised. The system may only be de-energised using the vehicle diagnostic tester via "“Guided Fault Finding”". The qualified person (Audi high-voltage technician) confirms that the system is de-energised and uses the locking cap T40262 to ensure that the system cannot be re-energised. The ignition key and the maintenance connector for high-voltage system TW are then stored in a safe place by the qualified person.The qualified person (Audi high-voltage technician) marks the vehicle by attaching the appropriate warning signs. — First remove high-voltage wires on electric drive motor V141.
3. Remove gearbox 37Removing and installing gearbox; Removing gearbox.
4. Secure gearbox to engine and gearbox supportVAS 609537Securing to engine and gearbox support.
5. Remove flange shaft (left-side) Gearbox39Differential; Removing and installing flange shaft (left-side).

6. Remove bolt (2) and detach connection box housing (1) for high-voltage wires from gearbox.
7. Remove bolt (2) and lever connection for coolant lines (1) off gearbox housing.
8. Fit protective caps on high-voltage connections (1) and coolant line connections (2) on electric drive motor V141. [Note: For clarity, the illustration shows an electric drive motor V141 which has been removed from the vehicle. Protective cap (3) for gearbox connection can only be fitted after electric drive motor V141 has been removed.]
9. Rotate gearbox so that electric drive motor V141 is pointing vertically upwards.
10. Assemble eye-head bolt3368 with adapter VW 771/40 and washer (M8) (1).
11. ⚠ Risk of damaging damper module in electric drive motor V141If the eye-head bolt3368 with adapter VW 771/40 is screwed in deeper than 8 mm, the damper module in the electric drive motor V141 will be damaged.The electric drive motor V141 must be renewed if the damper module in the electric drive motor V141 is damaged. — Attach eye-head bolt3368 with adapter VW 771/40 and washer (M8) (1) at top of electric drive motor V141.
12. Unscrew bolt (3) at drive motor rotor position sender 1G713.
13. Remove bolts (2) on electric drive motor V141(1).
14. Carefully lift electric drive motor V141 vertically out of gearbox using workshop hoistVAS 6100.
15. ⚠ Risk of damage to electric drive motor V141The drive motor rotor position sender 1G713 and the high-voltage connection with protective cap (1) must not be allowed to knock against the gearbox housing when the motor is being lifted out. — Make sure that no coolant is allowed to enter the opening for the input shaft; cover the opening if necessary.
16. Make sure that all protective caps are fitted.
17. Carefully set down electric drive motor V141.
18. Check that the red warning label on the housing cover of the high-voltage connections is present and take care not to damage it.
19. Installation is carried out in reverse sequence; note the following:
20. Thoroughly clean area of gearbox housing leading to differential (arrow A), and oil seal (arrow B). [Note: If oil seal between differential and gearbox housing (arrow B) is damaged, it must be renewed Gearbox39Final drive; Exploded view - final drive.]
21. Pack space between sealing lip and dust lip half-full with sealing greaseG 052 128 A1.
22. Renew O-ring (arrow) on input shaft.
23. Check oil seal for electric drive motor V141 for damage and renew if necessary .
24. Check hub of electric drive motor V141.
25. Assemble eye-head bolt3368 with adapter VW 771/40 and washer (M8) (1).
26. ⚠ Risk of damaging damper module in electric drive motor V141If the eye-head bolt3368 with adapter VW 771/40 is screwed in deeper than 8 mm, the damper module in the electric drive motor V141 will be damaged.The electric drive motor V141 must be renewed if the damper module in the electric drive motor V141 is damaged. — Attach eye-head bolt3368 with adapter VW 771/40 and washer (M8) (1) at top of electric drive motor V141.
27. Lift electric drive motor V141 out of transport pallet using workshop hoistVAS 6100.
28. Detach base plate (3) and support (2) for torsion damper from electric drive motor V141(1).
29. Continue with instructions for installing a previously removed electric drive motor V141.
30. Remove protective cap on gearbox connection (3).
31. ⚠ Risk of damage to electric drive motor V141The drive motor rotor position sender 1G713 and the high-voltage connection with protective cap (1) must not be allowed to knock against the gearbox housing when the motor is being lowered into the gearbox. — Using workshop hoistVAS 6100, lower electric drive motor V141 vertically into gearbox housing until four lugs on electric drive motor V141 rest against contact surfaces in gearbox housing. Align axial bores in lugs and gearbox housing.
32. ⚠ Risk of damage to electric drive motor V141When guiding the electric drive motor V141 onto the gearbox input shaft and the hollow oil pump shaft, the splines on the shafts may be directly opposite each other, so that the motor cannot be fully located at the first attempt.If the electric drive motor V141 is lowered further it can then drop down suddenly as the splines come into engagement, thus allowing the lugs to impact against the surfaces in the gearbox housing.This must be avoided, otherwise the lugs and the roller bearings can be damaged. — Install flange shaft (left-side) Gearbox39Differential; Removing and installing flange shaft (left-side).
33. Install gearbox 37Removing and installing gearbox; Installing gearbox.
34. ⚠ Working on vehicles with high-voltage wiring:Do not support yourself or tools on high-voltage wiring or associated components --> this can damage the insulation. High-voltage wiring must not be excessively bent or kinked --> this can damage the insulation. The round high-voltage connectors are colour-coded with an external coloured ring and are provided with mechanical coding or guide lugs. It is important to observe this coding when joining up the round high-voltage connectors, otherwise the connectors can be damaged. — Check that the red warning label on the housing cover of the high-voltage connections is present and take care not to damage it.
35. Connect high-voltage wires according to their coding .
36. Re-energise high-voltage system. [Note: Re-energising high-voltage system:Connect vehicle diagnostic testerSelect Guided Fault Finding modeUsing the Go to button, select the following menu options in succession:Selecting function/componentBodyElectrical systemSelf-diagnosis-compatible systems8C - Hybrid battery management -J8408C - Hybrid battery management, functions51 - Re-energise high-voltage system (Rep. gr. 93)]

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