12 36 516 Removing and installing/replacing range extender electrical machine electronics (REME)

WARNING: High-voltage system - danger to life
Compliance with the following points is mandatory before beginning work:

De-energize the HIGH-VOLTAGE SYSTEM .
Observe SAFETY INFORMATION for working with electric vehicles.
Observe NOTES ON EARTH BONDING SCREW CONNECTIONS .

Necessary preliminary tasks:

REMOVAL:

Release screws (1) from heat shield (2).

Feed out heat shield (2) and remove.

Fig 1: Identifying Heat Shield And Screws

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Fig 2: Identifying High-Voltage Safety Connector, Plug Connection, Signal Connector, Screws And Clamps

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Unlock and disconnect high-voltage safety connector (1).

Release screws (2) and disconnect high-voltage plug connection (3).

Unlocking and disconnect signal connector (4).

Detach high-voltage cables from clamps (5).

IMPORTANT: Observe notes on UNLOCKING AND DISCONNECTING PLUG CONNECTIONS on electric vehicles.

Unlock and disconnect connector (6) from high-voltage cable.

Release screw (1) from equipotential bonding line (2).

Unfasten and detach the coolant hoses (3).

Fig 3: Identifying Equipotential Bonding Line, Coolant Hoses And Screw

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Release screws (1).

Slacken nut (2).

Feed out range extender electrical machine electronics (3).

NOTE: Drain residual coolant from range extender electrical machine electronics (3) into coolant collecting vessel.

Fig 4: Identifying Range Extender Electrical Machine Electronics, Nut And Screws

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INSTALLATION:

Feed in range extender electrical machine electronics (3).

Tighten screws (1) and nuts (2).

Tightening torque 12 36 8AZ .

Fig 5: Identifying Range Extender Electrical Machine Electronics, Nut And Screws

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Connect and lock coolant hoses (3).

Tighten equipotential bonding line (2) with screw (1).

IMPORTANT: Observe NOTES ON EARTH BONDING SCREW CONNECTIONS !
Tightening torque 12 36 9AZ .

Fig 6: Identifying Equipotential Bonding Line, Coolant Hoses And Screw

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Fig 7: Identifying High-Voltage Safety Connector, Plug Connection, Signal Connector, Screws And Clamps

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IMPORTANT: Observe notes on UNLOCKING AND DISCONNECTING PLUG CONNECTIONS on electric vehicles.

Connect connector (6) of high-voltage cable and lock.

Attach high-voltage cables to holder (5).

Connect and lock connector (4) of signal line.

Connect connector (3) of high-voltage cable to range extender electrical machine electronics and tighten screws (2).

Tightening torque 12 36 10AZ .

Connect and lock high-voltage safety connector (1).

Feed in heat shield (2).

Tighten down screws (1).

Tightening torque 12 36 11AZ .

Fig 8: Identifying Heat Shield And Screws

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Required reworking:

Fill and bleed COOLING SYSTEM .

Replacement:

Carry out VEHICLE PROGRAMMING/ENCODING .