12 36 000 Removing and installing (replacing) electronics box power module

Special tools required:

17 2 050

WARNING: High-voltage system - danger to life!

WARNING: The following points must be strictly observed prior to starting work:

DE-ENERGIZE THE HIGH-VOLTAGE SYSTEM
Observe SAFETY INFORMATION for working with hybrid cars.

Necessary preliminary tasks:

Unclip line from crash element (4) at attachment points (1).

Unfasten screws (2).

Tightening torque 12 36 3AZ .

Unclip line from crash element (4) at attachment points (3).

Feed out crash element (4) towards front.

UNLOCK PLUG CONNECTION (5) AND DISCONNECT.

UNFASTEN PLUG CONNECTION (6) AND DISCONNECT.

Fig 1: Removing Line From Crash Element At Attachment Points

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UNLOCK PLUG CONNECTION (1) AND DISCONNECT.

Detach line from attachment points (2).

Detach high voltage line from attachment points (3).

If necessary, detach cable strap (4) from grounding cable on power electronic box holder.

Release screw (5) from earthing cable.

Tightening torque 12 36 4AZ .

Fig 2: Identifying Plug Connection, Attachment Points, Cable Strap And Screw

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Detach line at attachment point (1).

Open clamps (2) with special tool 17 2 050 and pull off coolant hoses.

Fig 3: Identifying Line Attachment Point And Clamps

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Release screws (1).

Tightening torque 12 36 2AZ .

Fig 4: Identifying Power Electronic Box Screws

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Release screws (1).

Tightening torque 12 36 5AZ .

Remove cover (2).

Installation note:

Clean sealing surface of lid (2).

Check the gasket of the power electronic box. If damaged, seal must be replaced.

Fig 5: Identifying Sealing Surface Of Lid And Screw

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Release screws (1).

Tightening torque 12 36 6AZ .

IMPORTANT: Carefully remove screws (1) from power electronics box. After being screwed down, the power electronics box must not have any loose screws remaining in it.

Unfasten screws (2).

Fig 6: Removing Screws From Power Electronics Box

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Tightening torque 12 36 7AZ .

Pull high-voltage cables (3) a little towards rear from guides of electronics box power module.

Installation:

During installation, make sure that high-voltage cables (3) are correctly seated in electronics box power module.

IMPORTANT: Conduct this operation with the assistance of a second person
Feed out electronics box power module (2) towards front.

Installation note:

Carefully feed in high-voltage cables (1).

Fig 7: Removing Electronics Box Power Module

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FILLING AND VENTING COOLING SYSTEM WITH VACUUM FILLING UNIT

Replacement:

Carry out VEHICLE PROGRAMMING/ENCODING .