Electric Drive Power And Control Electronics, Front, Removing And Installing: Notes

Special tools and workshop equipment required 

• Cover :T10661/1 
• Cover :T10661/2 
• Brass Wire Brush :VAS 294 025 
• Scraper :VAS 294 027 

The Electric Drive Power and Control Electronics 2 -JX4- will be called the power electronics in the information that follows.

The Three-Phase Current Drive 2 -VX97- will be called the three-phase current drive in the information that follows.

Power electronics, removing

-- Refer to FRONT MOTOR, REMOVING, LHD .

-- Refer to MOTOR, SECURING TO ENGINE AND TRANSMISSION HOLDER, FRONT MOTOR .

-- Remove the bolts -arrows- for the cap -1-.

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-- Pry out the cap -1- at the shown locations -arrows-.

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-- Remove the bolts -1- for the busbars.

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-- Disconnect the connector -arrow-.

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-- Remove the bolts -arrows- for the power electronics -1-.

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-- Pry off the power electronics -1- from the three-phase current drive.

Clean the sealing surfaces:

-- Close the openings at the three-phase current drive -1- using Cover :T10661/2  -A- and Cover :T10661/1  -B-.

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-- Remove the sealant with commercially available, chemical sealant remover and Scraper :VAS 294 027  .

-- Remove the sealant residue using the Brass Wire Brush :VAS 294 025  .

-- Clean the sealing surfaces and covers -A- and -B- using a commercially available vacuum cleaner.

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-- Remove the three-phase current drive covers -1-.

Power electronics, installing

-- Thoroughly clean the openings for the connecting piece -arrows- to the power electronics -1- and the three-phase current drive -3-.

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

Lithium lubricating grease. Refer to Electronic Parts Information (ETKA).

-- Clean the sealing surfaces -arrow- of the three-phase current drive and the power electronics using cleaning solution "D 291 091 A1".

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Tip

The Cleaning Solution "D 291 091 A1" acts as an activator for 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

Applying sealant for power electronics:

For sealant, refer to the Electronic Parts Information (ETKA).

-- 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 bolts

-- Position the power electronics -1- on the three-phase current drive. At the same time, pay attention to the alignment sleeves and the 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-.

-- Connect the connector -arrow-.

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

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-- Clean the sealing surface -arrow- of the three-phase current drive using cleaning solution "D 291 091 A1".

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Tip

The Cleaning Solution "D 291 091 A1" acts as an activator for 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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Condition

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

Condition

• The cover -1- must be installed without bleeder valve

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

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Tip

After assembly the leak test is performed through the bleeder valve opening.

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

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 .