Electric drive

Kapitelübersicht

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety measures for working on vehicles with high-voltage system
  1
• 1.2 Safety precautions when working in the vicinity of high-voltage components
  2
• 1.4 Safety precautions when working on the cooling system
  2
• 2 Identification
  3
• 2.1 Engine number/engine data
  3
• 3 Repair instructions
  4
• 3.1 Contact corrosion
  4
• 3.2 Routing and attachment of lines
  4
• 3.3 Fitting radiator and condensers
  4
• 3.4 Using impact drivers
  4
• 3.5 Rules for cleanliness
  5
• 4 Hazard classification of high-voltage system
  6
• Removing and installing engine
  13
• 1 Removing and installing rear motor
  13
• 1.1 Assembly overview – motor
  13
• 1.2 Removing engine
  15
• 1.3 Securing engine on engine and gearbox support
  22
• 1.4 Installing engine
  26
• 2 Rear assembly mountings
  31
• Cooling
  32
• 1 Cooling system/coolant
  32
• 1.1 Connection diagram - coolant hoses
  32
• 1.2 Overview of fitting locations – cooling system
  34
• 1.3 Assembly overview – cooling system
  36
• 1.4 Checking cooling system for leaks
  40
• 1.5 Draining coolant
  43
• 1.6 Filling cooling system
  44
• 1.7 Checking filling quality
  54
• 1.8 Removing and installing coolant expansion tank
  56
• 2 Coolant pump, regulation of cooling system
  59
• 2.1 Assembly overview - electric coolant pump
  59
• 2.2 Removing and installing coolant pump for high-voltage battery V590
  60
• 2.3 Removing and installing coolant pump for low-temperature circuit V468
  62
• 2.4 Assembly overview – coolant valves
  63
• 2.5 Removing and installing mixing valve for high-voltage battery pre-heating V683
  64
• 2.6 Removing and installing temperature sensor G18
  67
• 3 Radiator, radiator fan
  71
• 3.1 Assembly overview - radiator/radiator fan
  71
• 3.2 Assembly overview – radiator cowl and radiator fan
  71
• 3.3 Removing and installing radiator module
  72
• 3.4 Dismantling and assembling radiator module
  74
• 3.5 Removing and installing radiator cowl with radiator fan
  77
• 3.6 Removing and installing radiator fan V7
  78
• 3.7 Removing and installing control motor for radiator roller blind V711
  79
• Electric drive systems
  81
• 1 High-voltage components
  81
• 1.1 Overview of fitting locations - high-voltage components
  81
• 2 Warning stickers
  82
• 2.1 Checking warning stickers
  82
• 3 High-voltage battery unit
  87
• 3.1 Visual inspection of high-voltage battery 1 AX2
  87
• 3.2 Diagnosis of high-voltage battery 1 AX2
  88
• 3.3 Leakage test of high-voltage battery 1 AX2
  88
• 3.4 Searching for leaks from high-voltage battery
  89
• 3.5 Removing and installing high-voltage battery 1 AX2
  89
• 3.6 Raising high-voltage battery 1 AX2
  109
• 3.7 Opening high-voltage battery 1 AX2
  112
• 3.8 Closing high-voltage battery 1 AX2
  113
• 3.9 Voltage and insulation measurement
  118
• 3.10 Opening electrical circuit
  120
• 3.11 Removing and installing battery regulation control unit J840
  127
• 3.12 Charging and discharging battery modules
  129
• 3.13 Renewing lower part of battery housing
  130
• 4 High-voltage battery components
  132
• 4.1 Overview of fitting locations - battery modules
  132
• 4.2 Assembly overview – high-voltage battery
  136
• 4.3 Removing battery module
  147
• 4.4 Installing battery module
  152
• 4.5 Removing and installing battery modules control unit
  157
• 4.6 Removing and installing connecting element
  159
• 5 Power and control electronics for electric drive
  175
• 5.1 Assembly overview - power and control electronics for electric drive
  175
• 5.2 Removing and installing power and control electronics for electric drive
  175
• 6 Electric drive motor
  185
• 6.1 Assembly overview – electric drive motor
  185
• 6.2 Calibrating three-phase current drive VX54
  187
• 6.3 Removing and installing drive motor rotor position sender 1 G713
  187
• 6.4 Leak testing of electric drive motor
  188
• 7 Engine control unit
  199
• 7.1 Assembly overview – engine/motor control unit
  199
• 7.2 Removing and installing engine control unit J623
  199
• 7.3 Removing and installing bracket for engine/motor control unit J623
  200
• 8 De-energising high-voltage system
  201
• 9 Re-energising high-voltage system
  203
• 10 Potential equalisation lines
  204
• 10.1 Overview of fitting locations - potential equalisation lines
  204
• 11 Charging socket
  205
• 11.1 Assembly overview – charging socket
  205
• 11.2 Removing and installing high-voltage battery charging socket 1 UX4
  206
• 11.3 Manual release mechanism for charging socket
  208
• 12 Charging unit for high-voltage battery
  210
• 12.1 Assembly overview – charging unit for high-voltage battery
  210
• 12.2 Removing and installing charging unit 1 for high-voltage battery AX4
  210
• 13 Vehicle noise/engine sound
  215
• 13.1 Overview of fitting locations – vehicle noise/engine sound
  215
• 13.2 Removing and installing engine sound generator module 1 RX21
  215
• 14 Accelerator pedal
  217
• 14.1 Assembly overview - accelerator module
  217
• 14.2 Removing and installing accelerator pedal module GX2
  217
• 15 Voltage converter A19
  219
• 15.1 Assembly overview - voltage converter A19
  219
• 15.2 Removing and installing voltage converter A19
  219