12 35 015 Replacing the starter motor generator (vehicles with range extender W20) (i3 base, i3s)

Special tools required:

2 285 548
2 286 315

Preliminary work needed:

Refer to Mount ENGINE ON ASSEMBLY JIG .

Installation note:

Once disassembled, a torsion splined shaft must not be reused.

Reset adaptation values after replacing the torsion splined shaft.

Risk of damage to engine and starter motor generator during operation.

Release screws (1), remove the engine mounting bracket (2).

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Lever out holding clamps (1).

Remove sound insulation (2).

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Release screws in sequence (1 to 6).

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Screw special tool 2 285 548 into screw points (1, 4 and 5).

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To pull off the starter motor generator, screw the special tool 2 285 548 into bolting points (1, 4 and 5).

Uniformly pull off starter motor generator in 360° steps until the torsion splined shaft releases.

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Check crankshafts and generator gearing for damage and if necessary clean metal residues (shavings) off the tooth flanks.

Replace RADIAL SHAFT SEAL .

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Sealing sleeve (1) with clamping ring

Length compensation spring (2)

Valve seat insert (3)

Installation note:

Always replace sealing sleeve (1) and valve seat insert (3).

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Installation note:

Replace torsion splined shaft (1).

Coat torsion splined shaft (1) at both ends (2) with sufficient motor oil.

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Insert valve seat insert (1) into the starter motor generator with the rounded area downwards.

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Insert length compensation spring (1).

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Grease the O-ring on the starter motor generator (1) with 4.9 grease.

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Push sealing sleeve (2) with clamping ring downwards into the starter motor generator (1).

Insert torsion splined shaft in arrow direction.

During joining, position in such a way that the 5 crowns of the clamping sleeve match the 5 starter motor generator pockets.

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Mount starter motor generator with torsion splined shaft.

During joining, position starter motor generator in such a way that the 5 crowns of the clamping sleeve match the 5 crankshaft pockets.

Align special tool 2 286 315 with notch on housing facing cylinder head and screw in at crankcase until hand-tight.

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Measure distance between both housing halves by means of a caliper gauge (1) 63 mm and re-align the starter motor generator if necessary.

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Screw in mounting bolts 1, 2 and 3 on engine block with 15 Nm.

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Attention!

Risk of damage to starter motor generator!

Join engine and starter motor generator with a torque of 12.5 Nm by means of special tool 2 286 315 to a distance of 5 mm .

Attention!

Connect starter motor generator to the spindle (1) with special tool 2 286 315 with MAXIMUM 7.5 Nm, leaving no gap.

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Insert screws (1) and tighten with 10 Nm.

Remove special tool 2 286 315 .

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Tighten screws in sequence (1 to 6).

Tightening torque: 12 35 9AZ .

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Assemble engine.

Reset adaptation values.