Electric Drive Output And Control Electronics, Removing And Installing, RWD: Installing
-- Close the openings at the three-phase current drive -1- using Cover: T10643/2 -A- and Cover: T10643/1 -B-.
Clean the sealing surfaces:
Risk of injury due to chemical cleaning solutions. Chemical cleaning solutions can be extremely flammable and cause eye and skin irritation.
- Wear protective eyewear, safety gloves and respirators.
- Pay attention to the safety data sheet and operating instructions of the chemical.
-- Remove the sealant with commercially available, chemical sealant remover and commercially available plastic scraper.
-- Remove the sealant residue with a commercially available brass brush.
-- Carefully clean the opening for the connecting piece on the three-phase current drive -arrow-.
-- Coat the new connecting piece -2- with lithium grease and insert in the power electronics -1-.
Lithium lubricating grease. Refer to Parts Information.
-- Remove the Cover: T10643/2 -A- and Cover: T10643/1 -B-.
-- Clean the three-phase current drive sealing surfaces -arrow- and the power electronics using Clean with Cleaning Solution "D 291 091 A1".
Tip
The cleaning solution "D 291 091 A1" acts as an activator 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 three-phase current drive:
Sealant. Refer to the Parts Information.
-- Cut free the tube nozzle on the front mark so that the diameter is 3 mm.
-- Apply the sealant -arrow- to the clean sealing surface on the three-phase current drive, as shown.
Condition
- Sealant bead thickness: approximately 2 through 3 mm
- Within 5 minutes of applying the sealant, install the power electronics and tighten the screws.
-- Position the power electronics -1- on the three-phase current drive. At the same time pay attention to the connector.
-- Install the bolts -arrows- evenly hand-tight in a diagonal sequence.
-- Tighten the bolts -arrows-.
Prepare the Anti-Rotation: T10614 for tightening the bolts for the busbars:
-- Loosen the bolts -C- for the holding plates -B- one turn.
Condition
- The holding plates -B- 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-.
-- In order to tighten the bolts of the busbars, press the holding plates -B- to the left and fasten the bolts -C- hand-tight.
-- Tighten the bolts -arrows- for the busbars -1-.
-- Remove the bolts -arrows- and remove the anti-rotation protector -A-.
Install cover:
-- Clean the three-phase current drive sealing surfaces -arrow- and the cover using Clean with Cleaning Solution "D 291 091 A1".
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.
-- Apply the sealant -arrow- to the clean sealing surface on the three-phase current drive, as shown.
Sealant. Refer to the Parts Information.
Condition
- Sealant bead thickness: approximately 2 through 3 mm
- Within 5 minutes of applying the sealant, install the cover and tighten the screws.
-- Attach the double bolts -1- and the bolts -arrows- and tighten. Tightening sequence. Refer to Overview - Electric Drive Power and Control Electronics JX1 or Overview - Electric Drive Power and Control Electronics JX1 .
-- Perform the leak test. Refer to Electric Drive Motor Leak Test, Rear Motor .
Further installation is performed in reverse order of removal, while noting the following:
If the Electric Drive Power and Control Electronics -JX1- was replaced:
-- Perform the necessary Function/Functions using the Vehicle Diagnostic Tester. Refer to Diagnostic Entries .
Continuation