Electric Drive Power And Control Electronics, Removing And Installing, AWD: Installing

-- Close the openings at the three-phase current drive -1- using Cover: T10643/2 -A- and Cover: T10643/1 -B-.

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Clean the sealing surfaces:

CAUTION:

Risk of injury due to chemical cleaning solutions. Chemical cleaning solutions can be extremely flammable and cause eye and skin irritation.

- Wear protective eyewear, safety gloves and respirators.

- Pay attention to the safety data sheet and operating instructions of the chemical.

-- Remove the sealant with commercially available, chemical sealant remover and commercially available plastic scraper.

-- Remove the sealant residue with a commercially available brass brush.

-- Carefully clean the opening for the connecting piece on the three-phase current drive -arrow-.

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-- Coat the new connecting piece -2- with lithium grease and insert in the power electronics -1-.

Lithium lubricating grease. Refer to Parts Information.

-- Remove the Cover: T10643/2 -A- and Cover: T10643/1 -B-.

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-- Clean the three-phase current drive sealing surfaces -arrow- and the power electronics using Clean with Cleaning Solution "D 291 091 A1".

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Tip

The cleaning solution "D 291 091 A1" acts as an activator before application of the sealant and is decisive for a functional sealant bond.

Condition

Allow the sealing surfaces to dry for 10 minutes.

Applying sealant for three-phase current drive:

Sealant. Refer to the Parts Information.

-- Cut free the tube nozzle on the front mark so that the diameter is 3 mm.

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-- Apply the sealant -arrow- to the clean sealing surface on the three-phase current drive, as shown.

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Condition

Sealant bead thickness: approximately 2 through 3 mm
Within 5 minutes of applying the sealant, install the power electronics and tighten the screws.

-- Position the power electronics -1- on the three-phase current drive. At the same time pay attention to the connector.

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-- Install the bolts -arrows- evenly hand-tight in a diagonal sequence.

-- Tighten the bolts -arrows-.

Prepare the Anti-Rotation: T10614 for tightening the bolts for the busbars:

-- Loosen the bolts -C- for the holding plates -B- one turn.

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Condition

The holding plates -B- must be movable.

-- Install the anti-rotation protector -A- hand tight to the three-phase current drive, as shown, using the bolts from the cover -arrows-.

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-- In order to tighten the bolts of the busbars, press the holding plates -B- to the left and fasten the bolts -C- hand-tight.

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-- Tighten the bolts -arrows- for the busbars -1-.

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-- Remove the bolts -arrows- and remove the anti-rotation protector -A-.

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Install cover:

-- Clean the three-phase current drive sealing surfaces -arrow- and the cover using Clean with Cleaning Solution "D 291 091 A1".

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Tip

The Cleaning Solution "D 291 091 A1" is used to activate the surface before application of the sealant and is decisive for a functional sealant bond.

Condition

Allow the sealing surfaces to dry for 10 minutes.

-- Apply the sealant -arrow- to the clean sealing surface on the three-phase current drive, as shown.

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Sealant. Refer to the Parts Information.

Condition

Sealant bead thickness: approximately 2 through 3 mm
Within 5 minutes of applying the sealant, install the cover and tighten the screws.

-- Attach the double bolts -1- and the bolts -arrows- and tighten. Tightening sequence. Refer to Overview - Electric Drive Power and Control Electronics JX1 or Overview - Electric Drive Power and Control Electronics JX1 .

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-- Perform the leak test. Refer to Electric Drive Motor Leak Test, Rear Motor .

Further installation is performed in reverse order of removal, while noting the following:

If the Electric Drive Power and Control Electronics -JX1- was replaced:

-- Perform the necessary Function/Functions using the Vehicle Diagnostic Tester. Refer to Diagnostic Entries .

Continuation

-- Replacing the seal -1-.

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-- Replace the alignment pin -2-.

-- Remove the coolant connecting piece -3- from the three-phase current drive.

-- Carefully clean the opening for the coolant connecting piece on the three-phase current drive and on the power electronics.

-- Coat the new coolant connecting piece -3- with lithium lubricating grease and insert in the three-phase current drive.

Lithium lubricating grease. Refer to Parts Information.

-- Position the power electronics -1- on the three-phase current drive. At the same time pay attention to the alignment pin and the coolant connecting piece -arrows-.

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-- Install the bolts -arrows- evenly hand-tight in a diagonal sequence.

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-- Tighten the bolts -arrows- to the required tightening specification.

-- Tighten the bolts -1- for the busbars.

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-- Position the new cover -1- and tighten the bolts -arrows- evenly in a diagonal sequence.

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Further installation is performed in reverse order of removal, while noting the following:

If the Electric Drive Power and Control Electronics 2 -JX4- was replaced:

-- Perform the necessary Function/Functions using the Vehicle Diagnostic Tester. Refer to Diagnostic Entries .

Continuation