12 35 005 Remove/Install/Replace Electric Machine

12 35 005 Remove/Install/Replace Electric Machine

Special tools required:







WARNING: High-voltage system - danger to life.







WARNING:
The following points must be strictly observed prior to starting work:
- De-energize the high-voltage system
- Observe safety information for working with hybrid cars.







Necessary preliminary tasks:
- Clamp off battery negative lead
NOTE: Before disconnecting the minus battery cable, it must be ensured that the vehicle goes to sleep. Observe a waiting period of at least 2 minutes.

- Remove automatic transmission
- Remove belt pulley
- Remove tensioning pulley







IMPORTANT: Risk of damage. Do not apply force to the crankshaft sensor wheel during the dismantling and installation procedure. Do not use crankshaft sensor wheel as a torque support or levering aid.







Release screws (1).
Tightening torque 12 36 1AZ.
Remove sealing cap (2).







Open flap of high-voltage interlock loop (1).

Installation note:
Check seal (2) for damage. If damaged, seal must be replaced.
Clean sealing surfaces.







Release screw (1).
Tightening torque 12 36 2AZ.
Remove cover of high-voltage interlock loop (2) by sliding it forwards.







Release screws (1).
Tightening torque 12 36 3AZ.

IMPORTANT:
No loose parts such as screws must be left inside service flap after reassembly.
Make sure screw connections are correctly seated.







Unfasten plug connection (1) and disconnect.
Undo screws (2) from shielding plate (3).
Tightening torque 12 35 1AZ.







Rotate rotor (1) in direction of arrow until stator screws (2) are accessible.

IMPORTANT: Only the two lower stator screws (2) may be undone during this work operation.

Undo stator screws (2).
Tightening torque 12 35 2AZ.







Secure special tool 11 8 090 with three screws (1) to vibration damper.
Secure special tool 11 8 090 with belt tensioner bolt (2) to timing case cover.
Tightening torque 11 28 1AZ.







Only slacken crankshaft bolts in this work operation. Only unscrew crankshaft bolts by one turn.

Installation note:
Tighten crankshaft bolts crosswise. Tightening torque 12 35 3AZ.







Undo screws (1) of special tool 11 8 090.







Rotate rotor (1) in direction of arrow until hole patterns of assembly screws (2) and fitting screws (3) correspond with those of stator.







IMPORTANT:
Risk of damage to electric machine.
Electric machine must not be rotated after installing the fitting screws.

Screw in the special tool 12 0 012 (fitting screws).
Tightening torque 12 35 5AZ.

NOTE:
When the electric machine is replaced, the special tool 12 0 012 (fitting screws) remains with the component. Enclose special tool 12 0 012 (fitting screws) with set of special tools 12 0 010 (screw set) after assembling the new part.







IMPORTANT: One crankshaft bolt must remain screwed in to prevent the crankshaft from falling down.

Undo crankshaft bolts.

Installation note:
Attention. Screw in bolt as far as they will go. The tightening torque must not be applied until the following work operation.







Undo stator screws (1, 2, 3, 4).
Observe screw-fitting sequence:
1. Tighten screw 1. Tightening torque 12 35 2AZ.
2. Tighten screw 2. Tightening torque 12 35 2AZ.
3. Tighten screw 3. Tightening torque 12 35 2AZ.
4. Tighten screw 4. Tightening torque 12 35 2AZ.







Screw in special tool 12 0 013 (fitting screws).
Tightening torque 12 35 6AZ.

NOTE: When the electric machine is replaced, the special tool 12 0 013 (fitting screws) remains with the component. Enclose special tool 12 0 013 (fitting screws) with set of special tools 12 0 010 (screw set) after assembling the new part.

Installation note:
Attention. The special tool 12 0 012 (fitting screws) may not be removed during this work operation. Only remove special tool 12 0 013 (fitting screws).







Screw in special tool 12 0 011 (guide pins).







IMPORTANT: Additional assembly weight. This work operation must be performed with 2 additional persons.

Secure special tool 12 0 001 (fitting aid) to electric machine with special tool 12 0 002 (screws).
Tightening torque 24 40 1AZ.
Undo crankshaft bolt (1).
Carefully guide electric machine (2) towards the rear at guide pins and remove at special tool 12 0 001 (fitting aid).

Installation note:
Attention. Screw in crankshaft bolt (1) as far as it will go. Tightening torque may only be applied in one of the following work operations.
Push electric machine (2) until it reaches limit position. Electric machine (2) must be lying against crankshaft.







IMPORTANT:
Put down electric machine (1) in a clean working area.
Do not put electric machine (1) onto temperature sensor holder (2) and power rails (3).
Do not lift electric machine (1) at temperature sensor holder (2) and power rails (3).
If the electric machine is replaced, return defective part in original packaging.







Installation note:
Pay attention to crankshaft position (1). Crankshaft (2) must be in the 150° before TDC firing position before fitting the electric machine. The 150° before TDC firing position can be checked with special tool 11 8 570.
Procedure is described under Checking camshaft timing.







Clean sealing surface of dust boot (1).
Check sealing surface of dust boot (1) for damage. If damaged, dust boot (1) must be replaced.







Replacement:
Carry out vehicle programming/coding.







Connect BMW diagnosis system:
1. Service functions
2. Powertrain
3. Hybrid car
4. Electrical machine electronics
5. Rotor position sensor adjustment