12 36 018 Removing/installing electrical machine electronics (EME)

WARNING: High-voltage system - danger to life!
The following points must be strictly observed prior to starting work and during work:

DE-ENERGIZE THE HIGH-VOLTAGE SYSTEM
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.
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 (EME).
For handling of the electrical machine electronics (EME), always install protection connector (part number: 12 5 7 620 458).

IMPORTANT: Read and comply with notes on PROTECTION AGAINST ELECTROSTATIC DAMAGE (ESD PROTECTION) .

Necessary preliminary tasks:

Connection overview of electrical machine electronics (EME):

Potential compensation line to body
High-voltage connection for electrical machine
Signal lead connection
High-voltage connection to high-voltage battery unit
High-voltage connection for convenience charging electronics (KLE)
Connection for earth wire
Coolant connection (feed line)
Battery positive lead connection
Coolant connection (return line)

Fig 1: Overview Of Electrical Machine Electronics (EME) Connections

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Removal:

Release screws (1).

Unfasten screws (2).

Release sheet metal nuts (3).

Unscrew nuts (4).

Remove heat shield.

Fig 2: Identifying Nuts And Screws

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Release screws (1).

Remove heat shield.

Fig 3: Identifying Heat Shield Screws

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Unlock and disconnect signal line (1).

Unclip signal line (1) from the electrical machine electronics (EME).

Release screw (2) from the tension relief and remove cover.

IMPORTANT: Observe notes on UNLOCKING AND DISCONNECTING PLUG CONNECTIONS .

Unlock high-voltage cable (3) and disconnect.

Unclip high-voltage cable (3) from holder for electrical machine electronics (EME).

Remove protective earth connector (part number: 12 52 7 620 458).

Fig 4: Identifying Electrical Machine Electronics Signal Line, Screw And High Voltage Cable

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Release screws (1) from high-voltage cable.

Unscrew nuts (2).

Release screws (3) from holder for high-voltage cable.

Release screw (4) from the potential compensation line.

IMPORTANT: Observe notes on UNLOCKING AND DISCONNECTING PLUG CONNECTIONS .

Fig 5: Identifying Screws And Nuts

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Pull off high-voltage cable.

Release nut (1) from grounding cable.

Remove grounding cable from threaded bolt (grounding cable).

Release nut (2) from grounding cable.

Remove grounding cable from threaded bolt (body).

Unclip grounding cable from the electrical machine electronics (EME).

Fig 6: Identifying Grounding Cable Nuts

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Unlock coolant line (1) and disconnect.

Unlock coolant line (2) and disconnect.

Pull off cover (3) from the positive battery cable and release the nut beneath it.

Unlock high-voltage cable (4) and disconnect.

Fig 7: Identifying Coolant Lines, Cover And High Voltage Cable

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IMPORTANT: The following operation must be carried out using a second person.

Slacken screws (1) from electrical machine electronics (EME) (3).

Secure electrical machine electronics (EME) (3) from falling down using another person.

Release screws (2) from electrical machine electronics (EME) (3).

Feed out electrical machine electronics (EME) (3) carefully and remove.

Fig 8: Identifying Electrical Machine Electronics And Screws

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IMPORTANT: Electrical machine electronics (EME) may not be placed on the aluminium lid (top side).

Installation:

Check diaphragm (1) for damage.

Fig 9: Identifying Diaphragm

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IMPORTANT: The following operation must be carried out using a second person.

Feed electrical machine electronics (EME) (3) carefully into screws (1).

Secure electrical machine electronics (EME) (3) from falling down using another person.

Tighten screws (2) from electrical machine electronics (EME) (3).

Tightening torque 12 36 8AZ .

Tighten screws (1) from electrical machine electronics (EME) (3).

Tightening torque 12 36 8AZ .

Fig 10: Identifying Electrical Machine Electronics And Screws

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IMPORTANT: Observe notes on UNLOCKING AND DISCONNECTING PLUG CONNECTIONS .

Connect and lock high-voltage cable (4).

Tighten nut (3) and connect cover of positive battery cable.

Tightening torque 12 36 7AZ .

Connect coolant line (2) and lock.

Connect and lock coolant line (1).

Fig 11: Identifying Coolant Lines, Cover And High Voltage Cable

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Tighten grounding cable (2) on body.

IMPORTANT:

Observe notes on EARTH BONDING SCREW CONNECTIONS !

Tightening torque 12 36 5AZ .

Tighten grounding cable (1) on the grounding cable (2).

IMPORTANT:

Observe notes on EARTH BONDING SCREW CONNECTIONS !

Tightening torque 12 36 5AZ .

Fig 12: Identifying Grounding Cable Nuts

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Clip in grounding cable to the electrical machine electronics (EME).

IMPORTANT: Observe notes on UNLOCKING AND DISCONNECTING PLUG CONNECTIONS .

Connect high-voltage cable.

Tighten screws (1) of high-voltage cable.

Tightening torque 12 36 1AZ .

Tighten nuts (2) of high-voltage cable.

Tightening torque 12 36 16AZ .

Tighten screws (3) of holder for high-voltage cable.

Tightening torque 12 36 2AZ .

Tighten screw (4) from potential compensation line.

Fig 13: Identifying Screws And Nuts

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IMPORTANT:

Observe notes on EARTH BONDING SCREW CONNECTIONS !

Tightening torque 12 36 3AZ .

Observe notes on UNLOCKING AND DISCONNECTING PLUG CONNECTIONS .

Remove protection connector.

Connect and lock high-voltage cable (3).

Clip in high-voltage cable (3) on holder for electrical machine electronics (EME).

Position cover for the tension relief and tighten screw (2).

Tightening torque 12 36 17AZ .

Connect and lock signal line (1).

Clip in signal line (1) on the electrical machine electronics (EME).

Fig 14: Identifying Electrical Machine Electronics Signal Line, Screw And High Voltage Cable

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Position heat shield.

Tighten down screws (1).

Fig 15: Identifying Heat Shield Screws

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Position heat shield.

Tighten down nuts (4).

Tightening torque 12 36 18AZ .

Tighten sheet metal nuts (3).

Tightening torque 12 36 18AZ .

Tighten down screws (2).

Tightening torque 12 36 18AZ .

Tighten down screws (1).

Tightening torque 12 36 18AZ .

Fig 16: Identifying Nuts And Screws

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Required reworking:

Install COMPLETE EXHAUST SYSTEM
Install UNDERBODY PANELLING, RIGHT
Connect BATTERY EARTH LEAD
Fill and bleed the COOLANT (LOW-TEMPERATURE CIRCUIT)