Install the electrical machine electronics (EME)

Check 

• Place the electrical machine electronics (EME) reversed into the special tool 2 356 938 .
• Check the seals (1) and (2) and the diaphragms (3) for damage.

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  Result 

  » The gaskets or diaphragms are damaged.

  Measure

• Replace the electrical machine electronics (EME).
  • Cleaning the copper connections of the electrical machine electronics (EME) and the connection housing 
• Cleaning copper connections (1) of EME (2) and connection housing (3):
• Do not touch the copper connections (1).
• Clean the copper connections (1) using a non-woven abrasive until the condition as displayed in the illustration is achieved.
• Thoroughly draw off the particles that are produced during the grinding process.

  Do not use compressed air.

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  CONSUMABLE SPECIFICATION
  
  

  Non-woven abrasives  3M-07904

  45176141 (BASF)

  • Replacing the decoupling elements 
  • When replacing the electrical machine electronics (EME): 

  Replace the decoupling elements (1) of the electrical machine electronics (EME) (2).

  Parts:  Isolators

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• Position the electrical machine electronics (EME) (2).
  WARNING: Potential equalization in high-voltage system  .
  Mortal hazard if the potential equalization screw connection is not correct! 

  • Observe the safety requirements for potential equalization screw connection.
  • Clean contact faces and have then checked by a second person.
  • Tighten the screws/nuts for equipotential bonding with torque; have a second person check the torque.
  • Correct execution of this work must be documented by both persons in the vehicle records.

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• Tighten the bolts (1) on the electrical machine electronics (EME) (2).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Electrical machine electronics (EME) to electrical machine
  M8	Tightening torque	19 Nm

  WARNING: Potential equalization in high-voltage system  .
  Mortal hazard if the potential equalization screw connection is not correct! 

  • Observe the safety requirements for potential equalization screw connection.
  • Clean contact faces and have then checked by a second person.
  • Tighten the screws/nuts for equipotential bonding with torque; have a second person check the torque.
  • Correct execution of this work must be documented by both persons in the vehicle records.

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• Tighten the bolts (1) on the electrical machine electronics (EME) (2).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Electrical machine electronics (EME) to electrical machine
  M8	Tightening torque	19 Nm

  NOTE: RISK OF DAMAGE 
  Contaminant or foreign body  .
  Contamination can result in malfunctions, loss of function or leaks  .

  • Adhere to the utmost cleanliness.
  • Protect components from contamination e.g. by covering.
  • Close off line connections with seal plugs.

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• Replace screws (1).

  Parts:  Screws

• Tighten the bolts (1) of the high-voltage cables.
  TIGHTENING TORQUES SPECIFICATION
  
  

  High-voltage cable to electrical machine electronics (EME)
  M8 Replace screws.	Tightening torque	14 Nm

• Connect the connector (2) of the temperature sensor and the rotor position sensor and lock.
• Replace the service cap (2).

  Parts:  service cap

• Check the seal of the service cap (2) for damage, replace the seal if necessary.
• If necessary, attach a new warning sign on the service cap (2).
• Position the service cap (2) and tighten the screws (1).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Service cap to electrical machine
  M6	Tightening torque	10 Nm

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• Insert and position the sound insulation (3).
• Replace the clamps (2).

  Parts:  Clamps

• Secure the clamps (2) on the sound insulation (3).
• Attach the high-voltage cable of the electric A/C compressor (EKK) at the attachment point (1).

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• Replace the clamps (3).

  Parts:  Clamps

• Secure the clamps (3) on the sound insulation.
• Position the line clip and tighten the screw (4).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Line clip to electrical machine electronics (EME)
  M6	Tightening torque	8 Nm

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  WARNING: Potential equalization in high-voltage system  .
  Mortal hazard if the potential equalization screw connection is not correct! 

  • Observe the safety requirements for potential equalization screw connection.
  • Clean contact faces and have then checked by a second person.
  • Tighten the screws/nuts for equipotential bonding with torque; have a second person check the torque.
  • Correct execution of this work must be documented by both persons in the vehicle records.
• Position the potential equalization line and tighten the screw (2).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Potential equalization line to electrical machine electronics (EME)
  M6	Tightening torque	8 Nm

• Connect the coolant hose and close the gripper clamp (1).
  • On vehicles with range extender 
• Connect and lock the coolant line (2).
  WARNING: Potential equalization in high-voltage system  .
  Mortal hazard if the potential equalization screw connection is not correct! 

  • Observe the safety requirements for potential equalization screw connection.
  • Clean contact faces and have then checked by a second person.
  • Tighten the screws/nuts for equipotential bonding with torque; have a second person check the torque.
  • Correct execution of this work must be documented by both persons in the vehicle records.

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• Tighten screw (1) of the potential equalization line.
  TIGHTENING TORQUES SPECIFICATION
  
  

  Potential equalization line to electrical machine electronics (EME)
  M6	Tightening torque	8 Nm

• For SA4U8 alternating current quick charging: 

  Connect and lock the high-voltage cable (6) of the convenience charging electronics (KLE).

• Connect and lock the high-voltage cable (5) of the electric A/C compressor (EKK).
• Attach the wiring harness (4) at the attachment points (arrows).
• Tighten the screw (1) of the ground connection of the wiring harness.
  TIGHTENING TORQUES SPECIFICATION
  
  

  Wiring harness ground connection to electrical machine electronics (EME)
  M6	Tightening torque	8 Nm

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• Connect and lock the signal line (3).
• With SA4U7 direct current quick charging or SA4U8 alternating current quick charging: 

  Insert the high-voltage cable (2) of the convenience charging electronics (KLE) and clip it in at the holders (arrows).

• Connect and lock the connector of the high-voltage cable (2).
• Replace the clamps (1).

  Parts:  Clamps

• Position the sound insulation (2) and secure the clamps (1).

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• Position the sheet metal bracket of the electrical machine electronics (EME) (2) and tighten the screws (1).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Sheet metal bracket on electrical machine electronics
  M6	Tightening torque	8 Nm

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• Position the mounting bracket (3) and tighten the screws (2).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Transmission mounting bracket, left to electrical machine
  M10	Tightening torque	56 Nm

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• Attach the high-voltage cable at the attachment points (1).

Follow-up work 

• Refer to INSTALLING THE DRIVE UNIT COMPLETE WITH THE RANGE EXTENDER .
• Refer to CHECK/TOPPING UP TRANSMISSION OIL IN THE ELECTRIC MACHINE TRANSMISSION .
• Refer to REPLACING THE RADIAL SHAFT SEAL ON THE ELECTRIC MACHINE TRANSMISSION .
• Refer to CHECKING THE GEARING OF THE OUTPUT SHAFT .
• Refer to INSTALLING RIGHT OUTPUT SHAFT .
• Refer to INSTALLING LEFT OUTPUT SHAFT .
• Refer to MOUNTING CONTROL LINK AND CAMBER CONTROL ARM ON THE WHEEL CARRIER .
• Refer to MOUNTING THE TRAILING ARM ON THE WHEEL CARRIER .
• Refer to RELEASING SPRING STRUT SHOCK ABSORBER FROM WHEEL CARRIER .
• Refer to TIGHTENING THE THREADED CONNECTION OF THE TOE LINK, CAMBER LINK, AND TRAILING LINK TO THE NORMAL POSITION .
• Refer to SECURING SPRING STRUT SHOCK ABSORBER ON THE WHEEL CARRIER .
• Refer to INSTALLING THE OUTPUT SHAFT ON THE WHEEL BEARING .
• Refer to GREASE THE WHEEL HUB .
• Refer to INSTALLING RANGE EXTENDER ELECTRICAL MACHINE ELECTRONICS (REME) .
• Refer to INSTALLING THE CONVENIENCE CHARGING ELECTRONICS (KLE) .
• Refer to INSTALLING ENGINE COMPARTMENT FAN .
• Refer to INSTALLING VERTICAL STRUT .
• Refer to INSTALLING INTAKE SILENCER HOUSING .
• Refer to INSTALLING THE COMPLETE EXHAUST SYSTEM .
• Refer to INSTALLING WHEEL ARCH COVER .
• Refer to INSTALLING REAR CROSS-MEMBER .
• Refer to INSTALLING THE HORIZONTAL STRUT ON THE LEFT AND RIGHT .
• Refer to INSTALLING UNDERBODY PROTECTION .
• Refer to INSTALLING SUPPORT FOR THE REAR BUMPER PANEL .
• Refer to INSTALLING REAR BUMPER PANEL .
• Refer to INSTALLING NUMBER PLATE LIGHT .
• Refer to MOUNTING LICENSE PLATE .
• Refer to ON VEHICLES WITH RANGE EXTENDER: INSTALLING THE COVER OF THE ENGINE COMPARTMENT .
• Refer to CLOSING THE LOW-TEMPERATURE COOLANT CIRCUIT OF THE DRIVE .
• Refer to INSTALLING THE REAR LEFT AND RIGHT WHEELS .
• Refer to INSTALLING SERVICE CAP IN TRUNK .
• Refer to INSTALLING LUGGAGE COMPARTMENT FLOOR COVERING .
• Refer to CONNECTING FRONT RIGHT BATTERY GROUND LEAD IN TRUNK .
• Refer to ACTIVATING HIGH-VOLTAGE SYSTEM .
• Refer to FILLING AND VENTING THE LOW-TEMPERATURE COOLANT CIRCUIT .
• Refer to INSTALLING FRONT RIGHT COVER IN TRUNK .
• Refer to CHECKING THE RANGE EXTENDER FOR LEAKS .