ELECTRIC TRACTIONMOTORASSEMBLY: EXPLODEDVIEW For tastenings wih no species tightening toque vais, rete to the Table of Standard Torquestanen trast Get tomato Mere Designations Informationsgar 2ELECTRIC TRACTION MOTOR BRUSH: REMOVAL - REFITTING A~ one or more warnings ar present inthis procedure A Sot of trim removal levers. Car. 1363 protective gloves Location and specifications (tightening torques, parts always replaced, etc.)(see 10B, electric machine WARNING [To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before camying out any repair: m (cee Electric vehicle power electronics : Precautions for the repair), = Vehicle: Precautions for the repa MOVAI 1. REMOVAL PREPARATION OPERATION S Lockout the vehiclevenic ockout - Removal of lockout . @ Remove the electric powertrain assemblyElectric powertrain assembly : Removal - Refitting . © Place the electric powertrain assembly on the working table. G Remove the electric vehicle charger and converterElectric vehicle charger and converter: Removal - Refitting 9 Place the electric traction motor assembly on the working table. 2. REMOVAL OPERATION OFit a dust proof mask(ref: 77 01 422 836).G Wear clean protective gloves. me, ts v3 im Se} 163017 Remove (see 4 ls lm the six fixation screws(1) of the acces flap to electric traction motor brushes, im the acces flap to electric traction motor brushes(2) & Clean using a vacuum cleaner with a plastic nozzle pen or flatthe electric traction motor brushes compartments./ 163018 a Remove (see 10B, Electric machine , Traction motor assembly: Exploded view! 7 the two fixation screws(4) of the electric traction motor brushes, . the electric traction motor brushes. a Clean using a vacuum cleaner with a plastic nozzle pen or flatthe electric traction motor brushes compartments.CAUTION To avoid any impurities insertion, do not blast with compressed air. The use of unspecified cleaning products may damage the components (see Vehicle: "Parts and consumables for repair"), Note: The dust proof mask can be removed. as 4. REFITTING OPERATION a Refit (see 10B, Electric machine . Traction motor assembly: Exploded view) 7 . the new electric traction motor brushes by passing the wiring through the inner of the electrical machine, the two fixation screws of the electric traction motor brushes. a Torque tighten the two fixation screws of the electric traction motor brushes(see 10B, Electric machine. Traction motor assembly: Exploded view) . a Mark always the screws with a paint markerof a color different from the original. a Clip the electric traction motor brushes wiring clip. a Remove the retainer from the electric traction motor brushes.Refit (see 10B, Electric machine , Traction motor assembly: Exploded view! 7. the acces flap to electric traction motor brushes, the six fixation screws of the acces flap to electric traction motor brushes. Torque tighten the six fixation screws of the acces flap to electric traction motor brushes(see 10B, Electric machine , Traction motor assembly: Exploded view) . a Mark always the screws with a paint markerof a color different from the original. 2. FINAL OPERATION a Proceed in the reverser order to removal.ELECTRIC TRACTION MOTORFANASSEMBLY : REMOVAL -REFITTING Note, one or more warnings are present in this procedure Locations and specifications (tightening torques, parts always to be replaced, etc. Electric powertrain CAUTION To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair t= (cee Electric vehicle power electronics : Precautions for the repair), Vehicle: Precautions for the repait MOVAI 4. REMOVAL PREPARATION OPERATION 9 Lockout the vehiclevehicle: Lockout - Removal of lockout . 2. REMOVAL OPERATIONO Disconnect from the electric traction motor fan assembly the electric traction motor signal wiring connector(t) m the motor wiring connector(2) Loosen the hose clamp of the front air distribution duct. 5 Disconnect the front air distribution duct from the electric traction motor fan assembly. & Move aside the front air distribution duct.@ Remove the electric traction motor fan assembly screws(3)161929 ~ > Unclip the centring pins(4) of the electric traction motor fan assembly. Remove the electric traction motor fan assembly. GS 4. REFITTING OPERATION & Refit the electric traction motor fan assembly.© Clip the centring pins of the electric traction motor fan assembly. Refit the electric traction motor fan assembly screws. Torque tighten the electric traction motor fan assembly screws(see 10B, Electric machine , Traction motor assembly: Exploded view) . Mark always the screws with a paint markerof a color different from the original. 2. FINAL OPERATION & Proceed in the reverse order to removal. BSS Repair 4x01301x03.01497-1--1-xml =ELECTRIC TRACTION POWER ELECTRONICS FUSES : REMOVAL - REFITTING A~ one or more warnings are present in this procedure A Beene eee) Equipment required Diagnostic tool Parts always to be replaced: WARNING To avoid ail risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair: X10/5AM - X38/APL03/450/5AM : Location and specifications (tightening torques, parts always to be replaced, etc.) (see 17. Power electronics, Electric vehicle charger assembly: Exploded view) . X10/5AQ/601 : Location and specifications (tightening torques, parts always to be replaced, etc.)(see ATE. Power electronics. Electric powertrain assembly; Exploded view) . EW 1. REMOVAL PREPARATION OPERATIONWARNING DANGER: HIGH VOLTAGE VEHICLE. Risks of serious burns or electric shocks that may prove fatal. Before carrying out any work on the vehicle, it is essential that you follow the instructions regarding vehicle lockout. This work must be carried out by an employee who is qualified and authorised to work on a high-voltage onboard networkvehice: Precautions for the repair . | Lockout the vehiclevehiclo: Lockout - Removal of lockout . DF Remove (see 17E. Power electronics. Electric powertrain assembly: Exploded view): the fuse flap bolts, the fuse flap, the fuse flep seal 2. REMOVAL OPERATION D Remove (see 176, Power electronics, Electric powertrain assembly: Exploded view): ® the fuse nuts, Im the fuse washers, m the fuses. GE 1. REFITTING PREPARATION OPERATION Note: Systematicly replace the two fuses together at the same time,a parts always to be replaced ® fuses a parts always to be replaced & Seal of the flap of the electric traction power electronics fuses’ 2. REFITTING OPERATION Gi Refit (see 17E, Power electronics, Electric powertrain assembly : Exploded view): im the two fuses, ® the new fuse washers, m the new fuse nuts Torque tighten the fuse nuts(see 17E, Power electronics, Electric powertrain assembly: Exploded view) . Refit (see 17E, Power electronics, Electric powertrain assembly : Exploded view) : im the new fuse flap seal. 1 the fuse flap, 1m the fuse flap bolts. Torque tighten the fuse flap bolts(see 17E, Power electronics, Electric powertrain assembly : Exploded view) 3. FINAL OPERATION © Proceed in the reverse order to removal. & Remove the lockout of the vehicleVehicle: Lockout - Removal of lockout . Q Apply the After repair procedure using the Diagnostic toolDiagnostic tool : Use : -Computer concerned by the After repair procedure: mrElectric vehicle charger" Component controlled by this computer concerned by the After repair procedure: tm Electric traction power electronics fuses"ES Repair 0202016.01857ELECTRIC TRACTION REDUCTION GEARINGASSEMBLY: EXPLODEDVIEW & fon (0) eat. an { \ ae su ance — dam 6 bon, on th no specie tahtening torque vals, refer tothe Table of Standard TorquesMarke Designations Informations + Bor 2 ‘ierent outset oo or Wing terete ov sei.) 88 236, arn ein ea a: eRe 2 Nut 7 ‘Geeroxconaicabe seve sop i————_fy/77?TYTS SSS 6 Bok 7 a @ Ciane ° Clamp 0 Clamp 1 Bok 2 Bracket < 2 Tlfancbon ach (688.2, econ aoe scons: ela) Bok 6 Bor F 6 Nut 7 Gears (588.26, Reacon asx Ancona: onl ten) SI rn Bok Es Topi shaip set {280 etc au shin se ance) Too tig the pray sha seal (20) a Dire utp sea (a 20 etna ce dal Sena) Tool fr Rg ferent cpt seals 19°) Ey Sus 73 |__ Sectvactonreucton gearing fer pig (48230, seacmn Foci ao on gen Da 24 | Ecc aston redken gang fier lg sea (e48 230,neacen er, Pech ao mc gen ee 2 craton reduction gearing 26 [lei vactonresuton gening dan pug eel Z| Eleane wacton reaueton gene ara pun SS Page S04 ad aELECTRIC TRACTION REDUCTION GEARING CONTROL CABLE : ADJUSTMENT A~ fone or more warnings are present in this procedure A WARNING To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair: Vehicle: Precautions for the repair Location and specifications (tightening torques, parts always to be replaced, etc.)(see 37A, Mechanical PTS 4. ADJUSTMENT PREPARATION OPERATION 5 Position the vehicle on a two-post liftVehicle: Towing and lifting . WARNING DANGER: Risk of serious injury due to short-circuiting or untimely triggering of an electrical system (pyrotechnic components, windscreen wiper motor, fan assembly etc.) following possible re-supply of the 12-volt supply circuit by the voltage converter. Please follow the instructions regarding lockout of the 12 V supply circuit. If the procedure fails, do not continue with your task and ask an employee who is qualified and authorised to work on a high-voltage onboard network to perform fault finding Vehicle: Precautions for the repair . Lockout the 12V supply circuiti2 v supply circuit : Lockout - Removal of lockout , O Remove: m the engine undertray, m the centre console.Unlock the white clip(1) elector in position D. Place the gear sSS v1 @: 2 Ly’ Py iq al > k \S > 0 3 ‘ y ( JIS <4 iN :Lock the white clip(s) Check that the system is operating correctly. 3. FINAL OPERATION © Proceed in the reverse order to removal. & Remove the lockout of the 12V supply circuiti2 v supply circuit : Lockout - Removal of lockout .BS Repair-4xO1x08x01-01%67ELECTRIC TRACTION REDUCTION GEARING CONTROL CABLE : REMOVAL -REFITTING A~ fone or more warnings are present in this procedure A WARNING To avoid all risk of damage to the systems, apply the safety and cleanliness instructions and operation recommendations before carrying out any repair: Vehicle: Precautions for the repair Location and specifications (tightening torques, parts always replaced, etc.)(see 37A, Mechanical Ere 4. REMOVAL PREPARATION OPERATION [Position the vehicle on a two-post liftVehicle: Towing and lifting . WARNING DANGER: HIGH VOLTAGE VEHICLE. Risks of serious burns or electric shocks that may prove fatal. Before carrying out any work on the vehicle, it is essential that you follow the instructions regarding vehicle lockout. This work must be carried out by an employee| who is qualified and authorised to work on a high-voltage onboard networkvehicle: Precautions for the repair Lockout the vehiclevehicle: Lockout - Removal of lockout . © Remove the engine undertray. Remove the 12V batteryBattery: Removal - Refitting . 4.© Unclip the anchoring ball joint(s) using an open-jawed spanner. [ Unclip the sheath stop from the electric traction reduction gearing control cable: m by pressing the tab(2), 1m by pulling the electric traction reduction gearing control cable. Remove (see 37A, Mechanical component controls, Gear control assembly: Exploded view) : 1 the electric traction reduction gearing contro! cable stop screw, lm the electric traction reduction gearing control cable stop, 1m the tunnel seal screws, 1 the electric traction reduction gearing control cable. GN) 1. REFITTING PREPARATION OPERATIONea x ee 1 ya E- w fe 2. REFITTING OPERATIONExploded view ) . © Refit (see 37A, Mechanical component controls. Gear control assembly: Exploded view) 1m the electric traction reduction gearing control cable stop, m the electric traction reduction gearing control cable stop screw. 2 Torque tighten the electric traction reduction gearing control cable stop screw.(see 37A, Mechanical component controls, Gear control assembly: Exploded view 2 Clip the sheath stop from the electric traction reduction gearing control cable. © Clip the anchoring ball joint. © Adjust the electric traction reduction gearing control cable(see 37A, Mechanical component controls, Electric traction reduction gearing control cable : Adjustment) . Check that the system is operating correctly. & Proceed in the reverse order to removal. S Remove the lockout of the vehiclevehicle: Lockout - Removal of lockout . BS Repei-4x01405x01-O1437-13-Laml zaELECTRIC TRACTION REDUCTION GEARING CONTROL UNIT : REMOVAL - REFITTING A~ one or more warnings are present in this procedure A eee Airbag computer protector Location and specifications (tightening torques, parts always replaced, etc.)(see 37A, Mechanical ree 4. REMOVAL PREPARATION OPERATION © Position the vehicle on a two post liftvehicle: Towing and lifting . WARNING DANGER: Risk of serious injury due to short-circuiting or untimely triggering of an electrical system (pyrotechnic components, windscreen wiper motor, fan assembly etc.) following possible re-supply of the 12-volt supply circuit by the voltage converter. Please follow the instructions regarding lockout of the 12 V supply circuit. If the procedure fails, do not continue with your task and ask an employee who is qualified and authorised to work on a high-voltage onboard network to perform fault finding Vehicle: Precautions for the repair . G Lockout the 12V supply circuiti2 v supply circuit : Lockout - Removal of lockout , & Remove the centre console.eduction gearing control unit in position P. Put the electric traction rDisconnect the connector(s) from the electric traction reduction gearing control unit. © Unclip the wiring on the electric traction reduction gearing control unit at(s) .Unlock the white clip(7).. Remove (see 37A, Mechanical component controls, Gear control assembly: Exploded view) 7 the electric traction reduction gearing control unit nuts, . the electric traction reduction gearing contro! unit,aN) 4. REFITTING PREPARATION OPERATION a Put the electric traction reduction gearing lever and the electric traction reduction gearing control unit in position P. a parts always to be replaced: Airbag computer protector 2. REFITTING OPERATION a Proceed in the reverse order to removal. a Adjust the electric traction reduction gearing control unit(see 37A, Mechanical component controls, Electric traction reduct control cable : Adjustment a Check that the system is operating correctly. a Remove the lockout of the 12V supply circuiti2 v supply circuit : Lockout - Removal of lockout BS Reps Oro =~ELECTRIC TRACTION REDUCTION GEARING : DRAINING -FILLING Cero oil recovery tray SAM 400 G Locations and specifications (tightening torques, parts to always be replaced, etc.)(see 23C, Reduction gear, Electric traction reduction gearing assembly: Exploded view) . 4. PARTS AND CONSUMABLES FOR THE REPAIR G Part for repair: lm the manual electric traction gearing drain plug seal. & consumables for repair: ™@ electric traction gearing oil(see Manual gearbox oil: Specifications) . 2. DRAINING OPERATION & Position the vehicle on a two-post liftvehicle: Towing and lifting - G Remove: m the engine undertray bolts, m the engine undertray. & Position the oil recovery trayunder the electric traction gearing.Y XC = ~~ / Z YI ANG \ JSS > OG Remove the drain plug(1) . Let the oil flow out of the electric traction gearing in the oil recovery tray.152342 © Refit a new seal on the drain plug with the groove(2) facing the plug G Refit the drain plug fitted with its new seal. Torque tighten the drain plug(see 23C. Reduction gear, Electric traction reduction gearing assembly: Exploded iow). 3, FILLINGPPR, pep ar af ies ae a’ es (( Gey < f (] A S\ r AS / : sAN | t ag =92081 Fill the electric traction gearing using a syringe containing recommended oilgleciric traction reduction gearing oils : Specifications until the oil overflows out of the filler cap hole: a Refit the filler cap. a Wipe any oil run-off with a cloth. a Remove the oil recovery tray. a Refit the engine undertray.BS Repair x01305.01073 1-L.xmlELECTRIC TRACTION REDUCTIONGEARINGOILS : SPECIFICATIONS 4. OIL REDUCER: SAM XXX TYPE OF OIL FOR REDUCTION GEARING TRANSELF TRX 75W80 or TRANSELF NFP 75W80 TRANSELF TRX 75W80 or TRANSELF NFP 75W80 TRANSELF TRX 75W80 or TRANSELF NFP 75W80 2. STANDARD AND PART NUMBER OF THE OIL:DESIGNATION TRANSELF TRX 75W80 or TRANSELF NFP 75W80 STANDARD APIGL4 MIL-L-2105 CorD PARTNUMBER 7711573523 (5 litres) BS ‘Repair-14x01x05x1 1-02x08-1-I-LxmlELECTRIC TRACTION REDUCTIONGEARINGOILS : SPECIFICATIONS 4. OIL REDUCER: SAM XXX TYPE OF OIL FOR REDUCTION GEARING TRANSELF TRX 75W80 or TRANSELF NFP 75W80 TRANSELF TRX 75W80 or TRANSELF NFP 75W80 TRANSELF TRX 75W80 or TRANSELF NFP 75W80 2. STANDARD AND PART NUMBER OF THE OIL:DESIGNATION TRANSELF TRX 75W80 or TRANSELF NFP 75W80 STANDARD APIGL4 MIL-L-2105 CorD PARTNUMBER 7711573523 (5 litres) BS ‘Repair-14x01x05x1 1-02x08-1-I-Lxml