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

Clearing sealing surfaces and replacing seals

-- Remove the connecting piece -1-.

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-- Clean the contact surfaces -arrows- and remove the remainder of the wax.

-- Remove the bolt -1-.

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-- Use a commercially available vacuum cleaner to clean the threaded hole.

-- Remove the connector housing -2-.

-- Remove the thermal compound -3-.

-- Insert the Cover :T10662/1  -A- and Cover :T10662/2  -B- in the three-phase current drive -1-.

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-- Clean the sealing surfaces on the three-phase current drive and on the cover.

-- 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-.

-- Suction off the installation area for the power electronics and all threaded holes.

-- Carefully check the sealing surfaces and remove loose adhesions.

-- Position the thermal compound -3- as shown.

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-- Install the connector housing -2- and tighten the screw -1-.

-- Carefully clean the openings for the three-phase current drive -1- and -2- on the three-phase current drive.

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-- Connect the connecting piece all the way in the three-phase current drive.

-- Pry out the breather valve -3- with a socket 12 mm from the three-phase current drive.

Tip

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

Removing and installing the power electronics from puller 

Remove the power electronics from the puller:

-- Place down the puller with the power electronics onto a protection mat for ESD Work Surface :VAS 6613  . At the same time do not bend the busbars.

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-- Turn the locking mechanism -1- and -2- and -3- on the Guide Frame :T10668/3-1  -B- in the "open" position -arrows-.

-- Remove the puller from the power electronics.

Install the power electronics on the puller:

Condition

• Remove the power electronics only with the puller out of the packaging
• The locking mechanism -1-, -2- and -3- must be located in the "open" position -arrows-.

-- Position the puller -B- on the power electronics.

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-- Turn the locking mechanism -1-. -2- and -3- in "closed" position.

Power electronics, installing

-- Position the Guide Frame :T10668/2-1  -A- and install the bolts -arrows-.

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Condition

• The guide frames must still be able to be moved

-- Position the Guide Frame :T10668/1-1  -B- over the guide rods on the guide frame -A-.

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-- Introduce the retainers -C- in the mounts from the three-phase current drive.

-- Tighten the bolts -arrows- for the guide frame hand-tight.

-- Remove the locating pins -B-.

-- Position the puller -B- with the power electronics on the guide frame -A-.

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-- Turn the wing nuts -1- on the knurled bolt -2- all the way upward.

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-- Insert the knurled bolts -2- in the motor housing.

-- Tighten the wing nuts -1- until the puller is positioned evenly on the guide frame.

-- Insert the bolts -arrows- and nuts -1- through the openings in the puller -A- and install all the way.

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-- Tighten the bolts -arrows- and nuts -1- using the Torque Screwdriver :VAS 275 003/2-1  and Torque Wrench :V.A.G 1783  .

Tightening sequence. Refer to OVERVIEW - REAR ELECTRIC DRIVE POWER AND CONTROL ELECTRONICS  .

-- Turn the knurled bolt -2- all the way upward and push in the wing nuts -1- downward.

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-- Turn the locking mechanism -1-. -2- and -3- in "open" position.

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-- Remove the puller -B-.

-- Remove the guide frame.

-- Insert the protective cap -1-.

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Condition

• At the same time do not touch the power electronics circuit board.

-- Install the bolts -1- all the way on the busbars -2-.

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Prepare the Anti-Rotation Protector :T10687  -A- to tighten the bolts for the busbars:

-- Loosen all bolts -B- for the retaining plates -C- one turn.

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Condition

• The holding plates -C- 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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-- To tighten the bolts for the bolts, tun the retaining plate -C- on the anti-rotation protector -A- to the left and tighten the bolts -B- hand-tight.

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-- Tighten the bolts -1- for the busbars through the openings in the anti-rotation protector -A-.

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

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-- Connect the connector -1-.

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Power Electronics Cover Installing: 

-- Coat the cleaning cloth with cleaning solution "D 291 091 A1" and wipe the sealing surfaces on the three-phase current drive -arrow- and cover.

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Tip

The cleaning solution activates the surfaces before applying sealant and is pivotal for the successful seal bonding.

Condition

• Allow the sealing surfaces to dry for 10 minutes
• Do not touch the sealing surfaces after cleaning

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

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

Condition

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

-- Position the cover -2- vertically and horizontally and install the internal multi-point bolt -1-.

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-- Install the bolts -arrows-.

-- Tighten the internal multi-point bolts -1- and bolts -arrows-.

Tightening sequence. Refer to OVERVIEW - REAR ELECTRIC DRIVE POWER AND CONTROL ELECTRONICS  .

Busbars cover installing:

-- Clean the three-phase current drive sealing surfaces -arrow- and the cover using 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
• Do not touch the sealing surfaces after cleaning

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

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

Condition

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

-- Position the cover -2- and install the internal multi-point bolt -1-.

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-- Install the bolts -arrows-.

-- Tighten the internal multi-point bolts -1- and bolts -arrows-.

Tightening sequence. Refer to Overview - Rear Electric Drive Motor  .

-- Install the right coolant pipe. Refer to COOLANT PIPE, REMOVING AND INSTALLING, RIGHT SIDE OF THE MOTOR .

-- Perform the leak test. Refer to ELECTRIC DRIVE MOTOR LEAK TEST, REAR  .

-- Apply the wax -arrow- as shown between the connector mount -1- and housing.

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Wax. Refer to the Electronic Parts Information (ETKA).

Condition

• The gap must be filled
• No wax may enter the connector

-- Refer to Rear Motor, Installing .

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