Installing Electric Motor

Information 

• Get one or more people to help when installing/removing heavy or difficult-to-reach components. 
• This will prevent or reduce the risk of possible damage. 

1. Only if re-installing the electric motor; 

   Replace sealing ring on front-axle differential -1-  .

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   Sealing ring on front-axle differential

   1. 1.1  Remove old sealing ring on front-axle differential -1-  .
   2. 1.2  Carefully clean running and sealing faces.
   3. 1.3  Install new sealing ring on front-axle differential -1-  using > T40391 - assembly fixture  .
2. Only if re-installing the electric motor; 

   Replace seal -1-  .

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   Seal

   1. 2.1  Remove old seal -1-  correctly and clean the sealing face.
   2. 2.2  Fit new seal -1-  flat on the sealing face.

      Make sure that the seal -1-  is also positioned on the sealing face when the guide sleeves -2-  are fitted.

3. Only if replacing the electric motor; 

   Remove transport lock from new electric motor.

   Information 

   Before  assembling the electric motor and automatic transmission, the upright oval hole on the torque converter must  be positioned (-2-  ) at the connection point marked -x-  of the electric motor.

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   Fastening screws

4. Fit electric motor -1-  on transmission flange.

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   Straight pins

   Information 

   When assembling the electric motor and automatic transmission, make sure that the protective tube -2-  does not damage the sealing ring -1-  and sealing face -3-  .

   The help of another person is required.

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   Sealing ring on protective tube

   1. 4.1  Carefully guide electric motor -1-  using > VAS 6100 - workshop crane  over the straight pins -2-  onto the transmission flange and fit it.
   2. 4.2  Screw in two fastening screws loosely  to secure the electric motor -1-  and prevent it from falling down.
   3. 4.3  > 9700 - Transport eyebolts  must be removed from the electric motor -1-  . 5  Connecting torque converter to electric motor.
   1. 5.1  Screw fastening screw for torque converter into the upright oval hole on the torque converter -2-  .

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      Fastening screw

   2. 5.2  Continue to turn the torque converter at the shaft of the electric motor -1-  by hand until the next connection point on the torque converter is accessible.

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      Shaft of electric motor

   3. 5.3  Screw in the next fastening screw on the torque converter -1-  .

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      Fastening screws on torque converter

   4. 5.4  Repeat the steps until you have fitted all fastening screws securing torque converter -1-  to electric motor.
   5. 5.5  Tighten all fastening screws on the torque converter -1-  to > Tightening torque 62 Nm (46 ftlb.)  .

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      Fastening screws on torque converter

      Information 

      All fastening screws for the electric motor must be replaced.

5. Secure electric motor to automatic transmission.
   Fig 1: Electric Motor Screws Tightening Sequence

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   Screws for electric motor

   1. 6.1  Tighten fastening screws in the following sequence -1, 5, 3-  to > Initial tightening 12 Nm (9 ftlb.)  .
   2. 6.2  Tighten fastening screws in the following sequence -1, 2, 3, 4, 6-  to > Final tightening 24 Nm (18 ftlb.)  .
   3. 6.3  Tighten fastening screws in the following sequence -6, 7, 8, 9, 10, 11, 12, 13-  to > Final tightening 24 Nm (18 ftlb.) 
6. Clip in cap -1-  .

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   Cap

   Information 

   The fastening screws for the transmission housing cover must be replaced.

   The transmission housing cover must  be replaced.

   Before installing the new  transmission housing cover, the sealing face must be cleaned.

7. Secure high-voltage line from power electronics to electric motor -2-  at the electric motor.

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   High-voltage line from power electronics to electric motor

   1. 8.1  Check high-voltage line from power electronics to electric motor -2-  for damage and replace damaged high-voltage line if necessary.
   2. 8.2  Fit high-voltage line from power electronics to electric motor -2-  at the electric motor and tighten fastening screws -3-  to > Tightening torque 7 Nm (5 ftlb.)  .
   3. 8.3  Tighten fastening screws -1-  to > Tightening torque 21 Nm (15 ftlb.)  until secure.
8. Install cover for high-voltage connection for electric motor -1-  .

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   Cover for high-voltage connection for electric motor

   1. 9.1  The transmission housing cover at the high-voltage connection for the electric motor -1- must  be replaced.
   2. 9.2  Fit transmission housing cover at high-voltage connection for electric motor -1-  .
   3. 9.3  Tighten fastening screws -2-  to > Tightening torque 4 Nm (3 ftlb.)  until secure.
   4. 9.4  Tighten fastening screw -3-  to > Tightening torque 9 Nm (6.5 ftlb.)  .
9. Fit coolant hoses -2-  at the electric motor and secure spring band clamps -1-  using > VAS 6890 - spring band clamps pliers  .

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   Coolant hoses

10. Secure coolant supply hose -2-  with line bracket -1-  to the electric motor.

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    Coolant supply hose

11. Fit heat shield -2-  and tighten fastening screws -1-  to > Tightening torque 12 Nm (9 ftlb.)  .

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    Heat shield