12 36 018 Removing/installing electrical machine electronics
Special tools required:
The following points must be strictly observed prior to starting work and during work:
- Observe SAFETY INFORMATION for working with electric vehicles.
- Observe NOTES ON EARTH BONDING SCREW CONNECTIONS .
- The workbay required for the repair of the drive unit must be clean (free of grease, dirt and debris), dry (no leaking fluid) and free of flying sparks. Therefore, avoid close vicinity to areas intended for cleaning of vehicles and to workbays intended for repair work relating to the body. Use movable walls and high-voltage barrier tapes for separation, if needed.
- It is absolutely essential to remove all small parts/screws that fell into the electrical machine.
- Perform a visual inspection for contamination and damage of the housing, connections and gaskets or sealing surfaces of the electrical machine and electrical machine electronics.
- Replacement: Remove electrical machine electronics immediately before removing the packaging.
- For handling of the electrical machine electronics, always install protection connector (part number: 12 5 7 620 458).
Attention!
Read and comply with notes on protection against electrostatic damage (ESD PROTECTION ).
Necessary preliminary tasks:
- Remove complete drive unit. See REMOVING COMPLETE DRIVE UNIT or REMOVING COMPLETE DRIVE UNIT (RANGE EXTENDER) .
Connection overview of electrical machine electronics (EME):
Removal:
Detach high-voltage cable from attachment points (1).
Release screws (2) and remove engine mounting bracket (3).
Loosen the screws (1) and remove the sheet metal bracket from the electrical machine electronics (2).
Pry out clamps (1) and remove sound insulation (2).
Release screw (1) of wiring harness ground connection.
Only with rapid charging equipment (SA4U7 and/or SA4U8): Disconnect high-voltage cable (2) for convenience charging electronics. Unclip and unthread the high-voltage cable (2).
Disconnect signal line (3).
Detach wiring harness (4) from attachment points.
Disconnect high-voltage cable (5) for electric A/C compressor.
Only with alternating current rapid charging equipment (SA4U8): Disconnect high-voltage cable (6) for convenience charging electronics.
Attention!
Observe notes on UNLOCKING AND DISCONNECTING PLUG CONNECTIONS on electric vehicles.
Open clamp (1) and detach coolant hose.
Release screw (2) and remove equipotential bonding line.
Pry off clamps (3) from sound insulation.
Release screw (4) and remove holder.
Detach and remove high-voltage cable for electric A/C compressor on attachment point (1).
Pry off clamps (2) of sound insulation (3).
Feed out and remove sound insulation (3).
Release screws (1) and remove service cap (2).
Release screws (1) from high-voltage cables.
Attention!
Do not leave screws/small parts in the electrical machine.
It is essential to adhere to conditions of absolute cleanliness. After the electrical machine electronics is disassembled, the connection face of the electrical machine must be covered.
Disconnect plug connections (2).
Release screws (1) from electrical machine electronics (2).
Release screws (1) from electrical machine electronics (2).
Carefully place electrical machine electronics (1) in special tool 2 356 938 .
Installation:
Attention!
Check gaskets (1, 2) and diaphragm (3) for damage.
- Place electrical machine electronics inverted in special tool 2 356 938
.NOTE: High-voltage connections must not be damaged.
- Check gasket (1) for damage. If damaged, the electrical machine electronics must be replaced.
- Check gasket (2) for damage. If damaged, the electrical machine electronics must be replaced.
- Check diaphragm (3) for damage. If damaged, the electrical machine electronics must be replaced.
Tighten screws (1) on electrical machine electronics (2).
Attention!
Observe NOTES ON EARTH BONDING SCREW CONNECTIONS !
Tightening torque 12 36 7AZ .
Tighten screws (1) on electrical machine electronics (2).
Attention!
Observe NOTES ON EARTH BONDING SCREW CONNECTIONS !
Tightening torque 12 36 7AZ .
Tighten down screws (1) on high-voltage cables.
Attention!
Do not leave screws/small parts in the electrical machine.
It is essential to adhere to conditions of absolute cleanliness.
Replace screws.
Observe NOTES ON SAFETY SCREW CONNECTIONS .
Tightening torque 12 35 3AZ .
Connect and lock connectors (2) of temperature sensor and rotor position sensor.
Attention!
Replace service cap (2).
Check gasket of new service cap (2) for damage and contamination.
Attach new label on service cap (2) if necessary.
Tighten screws (1) on service cap (2).
Tightening torque 12 35 2AZ .
Feed in and position sound insulation (3).
Connect clamps (2) of sound insulation (3).
Attention!
Replace clamps.
Attach high-voltage cable for electric A/C compressor to attachment point (1).
Connect clamps (3) of sound insulation.
Attention!
Replace clamps.
Tighten screw (4) on holder.
Tightening torque 12 36 6AZ .
Tighten equipotential bonding line with screw (2).
Attention!
Observe NOTES ON EARTH BONDING SCREW CONNECTIONS !
Tightening torque 12 36 5AZ .
Connect coolant hose and close clamp (1).
Attention!
One retaining lug may be too thin.
The sound insulation (1) has been secured with only one clamp (2).
The right-hand retaining lug (3) does not feature a clamp. The sound insulation (1) has been secured using window glass adhesive in this area.
For electrical machine electronics where the retaining lug is too thin only (see above):
Fold sound insulation (1) upwards.
Clean the adhesive area of the electrical machine electronics using R2 SOLVENT CLEANER .
Apply WINDOW GLASS ADHESIVE (2) to the electrical machine electronics as shown.
- Height: 4 mm to 6 mm
- Width: 6 mm to 8 mm
Securely press on the sound insulation (1) to the electrical machine electronics in the adhesive area.
Connect the left-hand clamp to the electrical machine electronics retaining lug.
Attention!
Observe notes on UNLOCKING AND DISCONNECTING PLUG CONNECTIONS on electric vehicles.
Only with rapid charging equipment (SA4U7 and/or SA4U8): Connect connector (6) of high-voltage cable to convenience charging electronics and lock.
Connect connector (5) of high-voltage cable to electric A/C compressor and lock.
Attach wiring harness (4) to attachment points.
Tighten screw (1) on wiring harness ground connection.
Tightening torque 12 36 4AZ .
Connect connector (3) of signal line and lock.
Only with rapid charging equipment (SA4U8): Mount and clip in the high-voltage cable (2). Connect connector (2) of high-voltage cable to convenience charging electronics and lock.
Position sound insulation (2) and connect clamps (1).
Attention!
Replace clamps (1).
Position the sheet metal bracket on the electrical machine electronics (2) and tighten the screws (1).
Tightening torque 61 12 6AZ .
Tighten screws (2) on engine mounting bracket (3).
Tightening torque 27 00 5AZ .
Attach high-voltage cable to attachment points (1).