Electric Drive Power And Control Electronics 2 JX4, Removing And Installing: Installing

Power electronics sealed with seal:

-- Replacing the seal -1-.

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-- Replace the alignment pin -2-.

-- Remove the coolant connecting piece -3- from the three-phase current drive.

-- Carefully clean the opening for the coolant connecting piece on the three-phase current drive and on the power electronics.

-- Coat the new coolant connecting piece -3- with lithium lubricating grease and insert in the three-phase current drive.

Lithium lubricating grease. Refer to Parts Information.

Continuation for all vehicles

Power electronics sealed with a fluid gasket:

Clean the sealing surfaces:

-- Seal the openings on the three-phase current drive and the power electronics.

CAUTION:

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 Scraper:VAS 294 027 .

-- Remove the sealant residue using the Brass Wire Brush:VAS 294 025 .

-- Replace the alignment pin -1-.

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-- Remove the coolant connecting piece -2- from the three-phase current drive.

-- Carefully clean the opening for the coolant connecting piece on the three-phase current drive and on the power electronics.

-- Coat the new coolant connecting piece -3- with lithium lubricating grease and insert in the three-phase current drive.

Lithium lubricating grease. Refer to Parts Information.

-- Clean the three-phase current drive sealing surfaces and the power electronics 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.

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-- Apply the sealant -1- to the clean sealing surface -arrow- on the three-phase current drive, as shown.

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Condition

Sealant bead thickness: 3 mm
Within 5 minutes of applying the sealant, install the power electronics and tighten the screws.

Continuation for all vehicles

-- Position the power electronics -1- on the three-phase current drive. At the same time pay attention to the alignment pin and the coolant connecting piece -arrows-.

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-- Install the bolts -arrows- evenly hand-tight in a diagonal sequence.

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-- Tighten the bolts -arrows- to the required tightening specification.

-- Tighten the bolts -1- for the busbars.

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-- Position the cover -1- and tighten the bolts -arrows- evenly in a diagonal sequence.

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Further installation is performed in reverse order of removal, while noting the following:

If the Electric Drive Power and Control Electronics 2 -JX4- was replaced:

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

Continuation