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.
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.
CONSUMABLE SPECIFICATIONNon-woven abrasives
3M-0790445176141 (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
- 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.
- 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.
- 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.
- 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 - 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).
- 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 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.
- 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 - 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).
- 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 - 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 - 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 .