Opel CORSA-E RALLY 2022 Manual
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Opel CORSA-E RALLY 2022 Manual

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Summary of Contents for Opel CORSA-E RALLY 2022

  • Page 2 VEHICLE DOCUMENTATION PREFACE We are proud that you decided to purchase an Opel Corsa-e Rally, the latest result of Opel´s profound experience in the development and construction of sports, rally and racing cars. The following document give the user an option to consult all necessary data, settings and operating instructions for servicing and operating your competition vehicle.
  • Page 3 VEHICLE DOCUMENTATION TABLE OF CONTENT 1. TECHNICAL DOCUMENTATION ..............5 2. DRIVER HANDBOOK ..................194 3. TIGHTENING TORQUES ................205 4. LIFETIME TABLE ................... 255 5. APPENDIX ..................... 258 List of abbreviations A ............Ampere kWh ..........Kilowatt-hour ABS ......Anti-lock braking system L1 .............

  • Page 4: Table Of Contents

    TECHNICAL DOCUMENTATION TECHNICAL DOCUMENTATION 1.1 GENERAL OPERATION ....6 1.5.17 Seat ..........175 1.5.18 Night lamp ........176 1.1.1 Specific vehicle operations ....6 1.5.19 Speakers .......... 177 1.1.2 Towing transport ........9 1.6 KEY, DOORS AND WINDOWS ..178 1.2 TECHNICAL SPECS ......

  • Page 5: General Operation

    TECHNICAL DOCUMENTATION 1.1 GENERAL OPERATION 1.1.1 SPECIFIC VEHICLE OPERATIONS 1. To start the vehicle, both (2x) Emergency switches must be turned on. You will find one on the outside of the car near the wipers and one inside the car on the switch panel. 2.
  • Page 6 TECHNICAL DOCUMENTATION 8. DRIVE MODES Sticker Drive-mode Text displayed in cluster  Rain mode o Reduced torque characteristic for slippery surface. Sport o Steering setting „Sport“ from series vehicle with reduced power steering.  Dry mode (Automatically activated) o Special pedal map for rally cars to ensure full performance on dry tracks.
  • Page 7 TECHNICAL DOCUMENTATION 10. PARKING WITH FLY-OFF-HANDBRAKE  Location of fly-off-handbrake locking mechanism.  Turn the mechanism upwards to lock the fly-off- handbrake.  Fly-off-handbrake locked. 11. BONNET OPENING / CLOSING 1. Unlock the lever by pressing the latch. 2. Turn the lever to move the spline out the latch.

  • Page 8: Towing Transport

    TECHNICAL DOCUMENTATION 1.1.2 TOWING TRANSPORT TOWING TRANSPORT  Tow on a platform.  Tow with the front wheels lifted. TOWING HOOKS  Front tow hook.  Rear tow hook. CAUTION Check before towing:  Lever in Neutral position (N)  Ignition OFF ...

  • Page 9: Technical Specs

    TECHNICAL DOCUMENTATION 1.2 TECHNICAL SPECS Electric engine: Synchronic Power: 100 kW (136 hp) Torque: 260 Nm Battery Lithium-Ion, 50 kWh (capacity): 0 – 50 km/h: 2,8 seconds 0 – 100 km/h: 8,1 seconds Top speed: 150 km/h 0 – 80 % SoC: 30 minutes with 100 kW charger Driving modes: RACE DRY, RACE WET, STREET...

  • Page 10: Safety Specs

    TECHNICAL DOCUMENTATION  Spare tire kit which includes spare tire with rim, car jack, brackets for spare tire and wheel cross.  Communication kit which includes Tripmaster Monit Rally Q20 for recce, Stilo intercom amplifier with two Stilo WRC DES headsets for liaison. ...

  • Page 11: Safety Instructions

     The tightening torques can be found in Chapter 3 (see Page 205).  If in doubt, contact Opel Motorsport technical support immediately.  After each competition event, a visual inspection of all safety-relevant components must be carried out. Among other areas that require special attention: o Suspension components o Underbody protective plates and mounts.
  • Page 12 TECHNICAL DOCUMENTATION HV-STATUS INDICATION IN THE SERVICE PARC Service Work Service Work Symbol Definition Vehicle HV-system  HV-system off, checked and secured  HV-system active  Vehicle switched off  System error at HV-system V2, 02/2022 Page 13 of 293...

  • Page 13: Rescue Sheet

    TECHNICAL DOCUMENTATION 1.4.1 RESCUE SHEET V2, 02/2022 Page 14 of 293...
  • Page 14 TECHNICAL DOCUMENTATION STORED HAZARDOUS SUBSTANCES For the current rescue sheet, click on the following link: https://www.ifz-berlin.de/ret_eng_pdf/eng_ov_corsa_e_rally.pdf V2, 02/2022 Page 15 of 293...
  • Page 15 TECHNICAL DOCUMENTATION The vehicle is equipped with a security system that shows the current status of the HV system visually and acoustically. The meanings of the different colors and the acoustic signal are explained here. HV-SYSTEM MASTER ALARM INDICATION Master alarm indicator Description Situation NO LIGHTS...
  • Page 16 TECHNICAL DOCUMENTATION FRONT: REAR: INTERIOR: V2, 02/2022 Page 17 of 293...

  • Page 17: Special Safety Precautions

    TECHNICAL DOCUMENTATION 1.4.2 SPECIAL SAFETY PRECAUTIONS In case of a system error following safety instructions must be observed to ensure that the crew and people involved are safe. Please follow the safety instructions described below. SYSTEM ERROR SAFE PRECAUTIONS 1. Master Alarm Indicators display a SYSTEM ERROR. Activate both external EMERGENCY OFF with a non-conductive object.

  • Page 18: Case Of Fire

    TECHNICAL DOCUMENTATION 1.4.3 CASE OF FIRE ACTIVATION OF THE INTEGRATED FIRE EXTINGUISHING SYSTEM External activation of Internal activation of fire extinguishing system fire extinguishing system WARNING Rescue workers should always protect themselves with personal protective equipment, including breathing apparatus and take appropriate measures to protect civilians. FIRE EXTINGUISHING SYSTEM Fire extinguisher nozzles engine Fire extinguisher nozzles interior...
  • Page 19 TECHNICAL DOCUMENTATION MANUAL FIRE EXTINGUISHER V2, 02/2022 Page 20 of 293...

  • Page 20: Safety Messages On The Display

     May illuminate together with other control indicators and a corresponding message in the Driver Information Centre.  Seek the support of Opel Motorsport immediately. Engine Fault Illuminates permanently when the ignition is switched on.  A fault was detected in the electric engine or the high-voltage battery.

  • Page 21: Service Guidelines - Operating Instructions

    TECHNICAL DOCUMENTATION 1.5 SERVICE GUIDELINES – OPERATING INSTRUCTIONS 1.5.1 OPERATION SYMBOLS Symbols Meaning ACTION SYMBOLS Remove Fit / Refit Unclip / Uncouple / Release Couple up / Clip in place / Position Reconnect / Connect Disconnect Always replace / new Part Drill INDICATION Order of operation (from 1 to 5)

  • Page 22: Charging

    TECHNICAL DOCUMENTATION 1.5.2 CHARGING CHARGING STATION Domestic Several CEE Charging Wallbox Column load power socket socket station DC 230 V AC 230 V AC 230 V AC (1 phase) (1 phase) (1 phase) DC up to 500 Connection 230 V AC V or up to 400 V three- 400 V three-...
  • Page 23 TECHNICAL DOCUMENTATION CHARGING CABLE Universal charging cable Mode 2 cable Mode 3 cable Mobile “Wallbox” Charging at a domestic power Public charging point All EU plug-types socket “Type 2” on “Type 2” On “Type 2” “Schuko” on “Type 2” Single-phase up to three-phase Single-phase up to three-phase Single-phase up to 10A (8A) Up to 2.3kW (1.8kW)

  • Page 24: Hv-System

    TECHNICAL DOCUMENTATION 1.5.3 HV-SYSTEM CIRCUIT DIAGRAM ESSENTIAL The complete circuit diagram can be found in the appendix. (see Page 260) V2, 02/2022 Page 25 of 293...
  • Page 25 TECHNICAL DOCUMENTATION HV DEACTIVATION/REACTIVATION WARNING Any personnel working on an electric vehicle must have an electric vehicle specific training and authorization to work on these vehicles. Please observe the regulations applicable in the respective country. This chapter shows the principle of HV deactivation and reactivation. A detailed description of the HV deactivation and reactivation can be found in the “Measurement Log HV-System Corsa-e Rally”...
  • Page 26 Essential: Put on insulating gloves and a hard hat with visor (visor lowered). Essential: In the event of a failure when checking for the absence of voltage, stop the switch-off procedure and escalate the issue to the technical support of Opel Motorsport. V2, 02/2022...
  • Page 27 Essential: In the event of a failure when checking for the absence of voltage, stop the deactivation process and escalate the issue to the technical support of Opel Motorsport.  Check for the absence of voltage between the following points by using the voltage absence verifier.
  • Page 28 TECHNICAL DOCUMENTATION  After you have carried out all steps of the HV - deactivation and the measurement log is completely filled mark the vehicle as follows: o Information sign on the windshield that this vehicle is unlocked. o Green HV status indicator on the roof of the vehicle.
  • Page 29 TECHNICAL DOCUMENTATION A) TRACTION BATTERY - POTENTIAL EQUALIZATION MEASUREMENT  Check the resistance between the ground point and the traction battery at following points. o Point 1  Ground point o Point 2  Ground point o Point 3  Ground point o Point 4 ...
  • Page 30 TECHNICAL DOCUMENTATION D) ON-BOARD CHARGER - POTENTIAL EQUALIZATION MEASUREMENT  Check the resistance between the ground point and the on-board charger at following points: o Point 1  Ground point o Point 2  Ground point o Point 3  Ground point o Point 4 ...
  • Page 31 Value of the measurement must be higher than 2M  ꭥ Essential: The resistance value must be more than 2M . In the event of failure, stop the procedure and escalate the issue to the technical support of Opel Motorsport. V2, 02/2022 Page 32 of 293...
  • Page 32 ꭥ Essential: The resistance value must be more than 2M . In the event of failure, stop the procedure and escalate the issue to the technical support of Opel Motorsport. J) REASSEMBLE THE VEHICLE  Connect the air conditioning charging connector (1) to the on-board charger.
  • Page 33 TECHNICAL DOCUMENTATION  Check the resistance between the on-board charging cover (1) and the chassis at following point: o Point 1  Ground point  Use the multimeter with the setting for resistance measurement.  The value of the measurement must be less than ꭥ...
  • Page 34 TECHNICAL DOCUMENTATION 7. Checking Caution: All high voltage connectors must be correctly locked. There is a risk that fault codes will appear in the hybrid control ECU.  Check if the measurement protocol is completely filled in  Check if the HV-system can be switched on by switching on the ignition and go to position "READY".
  • Page 35 TECHNICAL DOCUMENTATION TRACTION BATTERY – REPLACEMENT WARNING Any personnel working on an electric vehicle must have an electric vehicle-specific training and authorization to work on these vehicles. Please observe the regulations applicable in the respective country. 1. Preliminary operations  Place the vehicle on a 2-post lift (see Page 58).
  • Page 36 TECHNICAL DOCUMENTATION  Disconnect the connectors [at h, j,  Unclip the charging socket harness [8] [at  Remove the 4 bolts from the HV battery [10]. Caution: Do not damage or crush the electrical power harnesses ‎ with the lifting table. Caution: Do not damage or crush the HV battery cooling circuit pipes.
  • Page 37 TECHNICAL DOCUMENTATION 3. Refit / Assemble Tightening torques  Traction battery on Page 226  Position the centring guides ‎ [ 12116] on the body  [at m, n, p, Caution: Do not damage or crush the electrical power harnesses ‎ with the lifting table. Caution: Do not damage or crush the HV battery cooling circuit pipes.
  • Page 38 TECHNICAL DOCUMENTATION 12 V BATTERY- REPLACEMENT WARNING Any personnel working on an electric vehicle must have an electric vehicle-specific training and authorization to work on these vehicles. Please observe the regulations applicable in the respective country. 1. Preliminary operations  Switch off the ignition.
  • Page 39 TECHNICAL DOCUMENTATION  Separate the tongue  Detach the assembly of the electric drive train supervisor ECU and its bracket in the direction of the arrow.  Unclip  Remove: o The 3 bolts o The 12V battery support 4. Refit / Assemble battery support Tightening torques ...
  • Page 40 TECHNICAL DOCUMENTATION DIRECT TRANSFORMER COVER – REPLACEMENT 1. Remove / Disassemble  Unclip the 3 covers.  Remove the 4 bolts. 2. Refit / Assemble Tightening torques:  Standard tightening torques see Page 206.  Proceed in reverse order to removal. V2, 02/2022 Page 41 of 293...
  • Page 41 TECHNICAL DOCUMENTATION ON-BOARD CHARGER / DIRECT VOLTAGE TRANSFORMER – REPLACEMENT WARNING Any personnel working on an electric vehicle must have an electric vehicle-specific training and authorization to work on these vehicles. Please observe the regulations applicable in the respective country. 1.
  • Page 42 TECHNICAL DOCUMENTATION 3. Refit / Assemble Tightening torques  On-board charger / direct voltage transformer on Page 207.  Earth Cable nut on Page 230.  Standard tightening torques on Page 206.  Refit: o The on-board charger / direct voltage transformer assembly o The on-board charger / direct voltage transformer assembly o The nuts o The bolts [3],...
  • Page 43 TECHNICAL DOCUMENTATION CHARGING SOCKET COVER - REPLACEMENT WARNING Any personnel working on an electric vehicle must have an electric vehicle-specific training and authorization to work on these vehicles. Please observe the regulations applicable in the respective country. 1. Preliminary operations ...
  • Page 44 TECHNICAL DOCUMENTATION CHARGING SOCKET - REPLACEMENT WARNING Any personnel working on an electric vehicle must have an electric vehicle-specific training and authorization to work on these vehicles. Please observe the regulations applicable in the respective country. 1. Preliminary operations  Place the vehicle on a 2-post lift (see Page 58).
  • Page 45 TECHNICAL DOCUMENTATION 3. Refit /Assemble Tightening torques  Charging socket unit on Page 227.  Refit the charging socket [2].  Refit the bolts [3].  Reconnect the electrical harness [at b, c,  Clip the ‎ p ower harnesses ‎...
  • Page 46 TECHNICAL DOCUMENTATION CHARGING SOCKET HARNESS - REPLACEMENT WARNING Any personnel working on an electric vehicle must have an electric vehicle-specific training and authorization to work on these vehicles. Please observe the regulations applicable in the respective country. 1. Preliminary operations ...
  • Page 47 TECHNICAL DOCUMENTATION  Disconnect the charging socket harness [at c, 3. Refit / Assemble Tightening torques  Charging socket unit on Page 227.  Reconnect the charging socket harness [at c, d]  Refit the nuts [2].  Clip the charging socket harness [3] [at b] ...
  • Page 48 TECHNICAL DOCUMENTATION ELECTRIC POWER CIRCUIT CONNECTORS – DISCONNECT / RECONNECT WARNING Any personnel working on an electric vehicle must have an electric vehicle-specific training and authorization to work on these vehicles. Please observe the regulations applicable in the respective country. 1.
  • Page 49 TECHNICAL DOCUMENTATION 4. Electric air conditioning compressor 4.1 Disconnection  Pull the tabs [at ‎ h ] and unlock the lockin the direction of the arrow.  Press on the tabs [at‎ j] and disconnect the power connector in the direction of the arrow. 4.2 Reconnection ...
  • Page 50 TECHNICAL DOCUMENTATION 5.3 Disconnection  Slide the latch [at q] in the direction of the arrow.  Press [at p] and disconnect the power connector halfway.  Press [at n] and disconnect the power connector 5.4 Reconnection  Reconnect the power connector. ...
  • Page 51 TECHNICAL DOCUMENTATION 5.7 Disconnection  Slide the latch [at s] in the direction of the arrow.  Press the tab [at u] and pivot the power connector 5.8 Reconnection  Reconnect the power connector  Lock the power connector 5.9 Disconnection ...
  • Page 52 TECHNICAL DOCUMENTATION 6. Electric drive machine / Electric drive machine inverter 6.1 Disconnection  Press [at‎ y] and slide the latch in the direction of the arrow [z].  Press [at x] and disconnect the power connector in the direction of the arrow [w]. 6.2 Reconnection ...
  • Page 53 TECHNICAL DOCUMENTATION ELECTRIC DRIVE MACHINE SUPPLY ELECTRICAL HARNESS - DISCONNECT / RECONNECT WARNING Any personnel working on an electric vehicle must have an electric vehicle-specific training and authorization to work on these vehicles. Please observe the regulations applicable in the respective country.

  • Page 54: Fluids

    TECHNICAL DOCUMENTATION 1.5.4 FLUIDS Useage Fluid Specification Quantity Gearbox Complete Elf HTX 750 – 75W-140 LS 80W140 5L 1,4 Liter PSA part number: PSA cooling water About 13l Radiator 1637756480 Brakes BREMBO-HTC 1,5 Liter Notice Draining / Refilling operations:  Reduction gear see Page 92.

  • Page 55: Underbody Protection Plates

    TECHNICAL DOCUMENTATION 1.5.5 UNDERBODY PROTECTION PLATES UNDERBODY PROTECTION PLATES - REPLACEMENT 1. Preliminary operations  Place the vehicle on a 2-post lift (see Page 58). 2. Front  Support the underbody protection plate with a pallet truck.  Loosen and remove all 4 bolts ...

  • Page 56: Lifting The Vehicle

    TECHNICAL DOCUMENTATION 1.5.6 LIFTING THE VEHICLE A) SERVICE STANDS 1. Preliminary operations  Immobilize the vehicle by putting the gearbox lever on “P” (see Page 9). 2. Overview  Service stand [c].  The vehicle is equipped with two lift pick-up mounts on each side [a,b], into which the optional service stands can be inserted.
  • Page 57 TECHNICAL DOCUMENTATION B) 2-POST LIFT 1. Preliminary operations  Immobilize the vehicle by putting the gearbox lever on “P” (see Page 9). 2. Overview  Lifting Points  The lifting points for the 2-post lift are located underneath the lift pick-up mounts used for the service stands.

  • Page 58: Vehicle Front

    TECHNICAL DOCUMENTATION 1.5.7 VEHICLE FRONT FRONT WHEEL ARCH – REPLACEMENT 1. Preliminary operations  Remove the front wheel (see Page 134). 2. Remove / Disassemble  Remove the 10 bolts on the front bumper.  Remove the 2 Nuts on the front bumper deflector. ...
  • Page 59 TECHNICAL DOCUMENTATION Symmetrical operation  Unclip and remove. Symmetrical operation  Remove the bolt from the brake cooling channel. Symmetrical operation  Remove the 4 bolts.  Remove the wheel arch. 3. Refit / Assemble  Proceed in reverse order to removal. 4.
  • Page 60 TECHNICAL DOCUMENTATION FRONT BUMPER – REPLACEMENT 1. Preliminary operations  Remove the front wheel arches (see Page 59). 2. Remove / Disassemble  Disconnect the cable in the front wheel arch.  Disconnect front beeper cable (X43).  Remove the 6 bolts. ...
  • Page 61 TECHNICAL DOCUMENTATION  Remove the front bumper through unclipping it. 3. Refit / Assemble  Proceed in reverse order to removal. 4. Additional operations  Refit the front wheel arches (see Page 59). V2, 02/2022 Page 62 of 293...
  • Page 62 TECHNICAL DOCUMENTATION FRONT BUMPER FRAME – REPLACEMENT 1. Preliminary operations  Remove the front bumper (see Page 61). 2. Remove / Disassemble Symmetrical operation  Remove the bolt. Symmetrical operation  Remove the two bolts.  Put the speaker aside. Symmetrical operation ...
  • Page 63 TECHNICAL DOCUMENTATION BONNET – REPLACEMENT 1. Preliminary operations  2. Remove / Disassemble  Disconnect the cable [a].  Disconnect the windshield washer fluid tube [b].  Unclip [at 2,3,4] Caution: Two persons are needed for the next operation.  Remove the 4 bolts.
  • Page 64 TECHNICAL DOCUMENTATION FRONT HEADLAMPS – REPLACEMENT 1. Preliminary operations  Remove the front bumper (see Page 61). 2. Remove / Disassemble Symmetrical operation  Remove the 2 bolts at [1].  Remove the Nut at [2].  Unclip the headlamp. Symmetrical operation ...
  • Page 65 TECHNICAL DOCUMENTATION FRONT FENDER – REPLACEMENT 1. Preliminary operations  Remove the front headlamps (see Page 65). 2. Remove / Disassemble Symmetrical operation  Remove the 2 bolts [1].  Remove the bolt [2].  Remove the 2 bolts [3]. Symmetrical operation ...
  • Page 66 TECHNICAL DOCUMENTATION Notice: In the event of replacement  Drill out the heads of the rivets [11]; Using a drill with a 10 mm diameter bit.  Drill the bodies of the remaining rivets; Using a drill with a 6 mm diameter bit. ...
  • Page 67 TECHNICAL DOCUMENTATION EXTERIOR MIRROR – REPLACEMENT 1. Preliminary operations  2. Remove / Disassemble Symmetrical operation  Remove the 5 bolts. Symmetrical operation  Open the connector anchorage [1].  Disconnect the plug [2].  Remove the 3 bolts [3]. ...
  • Page 68 TECHNICAL DOCUMENTATION WIPER MOTOR AND WIPER MECHANISM – REPLACEMENT 1. Preliminary operations  2. Remove / Disassemble 2.1. Wiper arms  Remove the covers [1].  Remove: o The nuts o The windscreen wiper arms o The scuttle panel (see Page 70). 2.2.
  • Page 69 TECHNICAL DOCUMENTATION SCUTTLE PANEL – REPLACEMENT 1. Preliminary operations  Remove the windscreen wiper arms (see Page 69). 2. Remove / Disassemble  Unclip and remove the right-hand side scuttle panel.  Unclip and remove the left-hand side scuttle panel. 3.

  • Page 70: Vehicle Rear

    TECHNICAL DOCUMENTATION 1.5.8 VEHICLE REAR REAR WHEEL ARCH – REPLACEMENT 1. Preliminary operations  Remove the rear wheels (see Page 134). 2. Remove / Disassemble Symmetrical operation  Remove the bolt [1].  Remove the 2 nuts [2]. Symmetrical operation ...
  • Page 71 TECHNICAL DOCUMENTATION REAR TAILLIGHT – REPLACEMENT 1. Preliminary operations  2. Remove / Disassemble Symmetrical operation  Disconnect the cable [1].  Remove the Nut [2].  Remove the taillight by unclipping it [3]. 3. Optional operations Symmetrical operation  Unclip and remove the rear taillight on the tailgate.
  • Page 72 TECHNICAL DOCUMENTATION REAR BUMPER - REPLACEMENT 1. Preliminary operations  Remove the rear wheel arches (see Page 71).  Remove the rear taillights (see Page 72). 2. Remove / Disassemble Symmetrical operation  Remove the bolt. Symmetrical operation  Pull in the direction of the arrow to unclip. ...
  • Page 73 TECHNICAL DOCUMENTATION  Remove the 2 bolts.  Remove the bumper by unclipping it. 3. Optional operations Notice: Replace the rivets with new ones when reassembling.  Separate the rivets by drilling [1].  Remove the support bracket [2].  Remove the 5 bolts [1].
  • Page 74 TECHNICAL DOCUMENTATION REAR IMPACT BAR – REPLACEMENT 1. Preliminary operations  Remove the rear bumper (see Page 73). 2. Remove / Disassemble  Remove the 6 bolts.  Remove the rear impact bar. 3. Refit / Assemble Tightening torques  Rear impact bar see Page 243.
  • Page 75 TECHNICAL DOCUMENTATION REAR UNDERBODY PROTECTOR – REPLACEMENT 1. Preliminary operations  2. Remove / Disassemble  Remove the 4 bolts [1].  Remove the 5 bolts [2].  Disconnect the speaker cable under the cover (X41).  Remove the underbody protector [a]. 3.

  • Page 76: Doors

    TECHNICAL DOCUMENTATION 1.5.9 DOORS FRONT DOOR – REPLACEMENT 1. Preliminary operations  2. Remove / Disassemble Symmetrical operation  Remove the door check strap bolt [4].  Remove the circlips [2].  Remove the shafts [3].  Disengage the door [1];Be careful not to damage the front fender.
  • Page 77 TECHNICAL DOCUMENTATION 4. Adjustment  Remove the bolt [7].  Remove the door hinges [6].  Cut the indexing pins c]; Using a hacksaw.  Refit the hinges without tightening. Caution: Apply corrosion treatments in the indexing zone  Remove the hinges. ...
  • Page 78 TECHNICAL DOCUMENTATION 5. Refit / Assemble Tightening torques  Front door see Page 245.  Position the front door [1].  Reconnect the connector  Refit the sleeve [5].  Refit the front door [1].  Refit the shafts [3]. ...
  • Page 79 TECHNICAL DOCUMENTATION REAR DOOR - REPLACEMENT 1. Preliminary operations  2. Remove / Disassemble Symmetrical operation  Remove the door check strap bolt [4].  Remove the circlips [2].  Remove the shafts [3].  Disengage the door [1];Be careful not to damage the front door.
  • Page 80 TECHNICAL DOCUMENTATION 4. Adjustment  Remove the bolt [7].  Remove the door hinges [6].  Cut the indexing pins c]; Using a hacksaw.  Refit the hinges without tightening. Caution: Apply corrosion treatments in the indexing zone  Remove the hinges. ...
  • Page 81 TECHNICAL DOCUMENTATION 5. Refit / Assemble Tightening torques  Rear door see Page 245.  Position the rear door [1].  Reconnect the connector  Refit the sleeve [5].  Refit the rear door [1].  Refit the shafts [3]. ...

  • Page 82: Powertrain

    TECHNICAL DOCUMENTATION 1.5.10 POWERTRAIN OVERVIEW DRIVETRAIN COMPONENTS On-board charger / DCDC converter Electric Motor (electrical drive machine) Reduction gearbox V2, 02/2022 Page 83 of 293...
  • Page 83 TECHNICAL DOCUMENTATION ELECTRICAL DRIVE MACHINE AND REDUCTION GEAR ASSEMBLY – REPLACEMENT WARNING Any personnel working on an electric vehicle must have an electric vehicle-specific training and authorization to work on these vehicles. Please observe the regulations applicable in the respective country.
  • Page 84 TECHNICAL DOCUMENTATION  Unclip the electric drive train cooling circuit pipe [5] [at  Detach and move aside : o The cooling circuit pipe o The cooling circuit pipe [5].  Disconnect the coolant - air conditioning heat exchanger connector ...
  • Page 85 TECHNICAL DOCUMENTATION Notice: Make marks on the ground to reference the position of the power train.  Position the lifting table  Position the tools  Fix the supports  Slightly raise the lifting table to put the electric drive machine and reduction gear assembly under stress.
  • Page 86 TECHNICAL DOCUMENTATION  Refit: o The coolant - air conditioning heat exchanger o The bolts  Clip the electrical harness  Reconnect the coolant - air conditioning heat exchanger connector  Couple up: o The cooling circuit pipe o The cooling circuit pipe ...
  • Page 87 TECHNICAL DOCUMENTATION REDUCTION GEAR – REPLACEMENT 1. Preliminary operations  Remove the electrical drive machine and reduction gear assembly (see Page 84). 2. Replacement parts  Seal [10] 3. Remove / Disassemble  Remove: o The electric drive machine and reduction gear assembly left-hand bracket ‎...
  • Page 88 TECHNICAL DOCUMENTATION  Remove the seal [10]. 4. Refit / Assemble Tightening torques:  Coupling of engine on reduction gear see Page 214.  Reduction gear support see Page 211.  Mounting of the electric drive machine and reduction gear assembly see Page 209. ...
  • Page 89 TECHNICAL DOCUMENTATION REDUCTION GEAR – DISASSEMBLE / REASSEMBLE 1. Preliminary operations  Remove the electrical drive machine and reduction gear assembly (see Page 84).  Uncouple the reduction gear from the electrical drive machine (see Page 88). 2. Remove / Disassemble ...
  • Page 90 TECHNICAL DOCUMENTATION  Remove 8 bolts of the ring gear and remove the differential. 3. Refit / Assemble Tightening torques  Reduction gear external components see Page 212.  Reduction gear internal components see Page 213. Notice: Secure the bolts with Loctite 262. Notice: Note the sequence when tightening the bolts.
  • Page 91 TECHNICAL DOCUMENTATION REDUCTION GEAR – DRAINING/FILLING 1. Preliminary operations  Place the vehicle on a 2-post lift (see Page 58).  Remove the front underbody protection plate (see Page 56). 2. Parts that always have to be replaced  Drain cap seal. 3.
  • Page 92 TECHNICAL DOCUMENTATION DRIVESHAFT - REPLACEMENT 1. Preliminary operations  Place the vehicle on a 2-post lift (see Page 58).  Remove the front wheels (see Page 134.  Remove the front underbody protection plate (see Page 56).  Drain the reduction gear (see Page 92). 2.
  • Page 93 TECHNICAL DOCUMENTATION 4. Remove / Disassemble Caution: Never use the vehicle brake to loose the driveshaft nut as this can damage the brake disc mounting bolts. Caution: Do not use a pneumatic gun while removing and reinstalling the drive shaft nut. ...
  • Page 94 TECHNICAL DOCUMENTATION 4.1. Left-hand driveshaft Caution: Take care not to twist the brake hose. Notice: In order not to damage the LH driveshaft gaiter, disengage the pivot and swivel the damper body by a quarter turn.  Disengage the LH driveshaft from the wheel hub. ...
  • Page 95 TECHNICAL DOCUMENTATION 6.2. Right-hand driveshaft seal with driveshaft bearing Caution: Do not lubricate the seal.  Refit the right-hand transmission seal [10]; Using tool [0346-W] and a mallet. 6.3. Left-hand driveshaft  Engage the driveshaft in the differential.  Engage the driveshaft splines in the wheel hub. 6.4.
  • Page 96 TECHNICAL DOCUMENTATION ELECTRIC DRIVE TRAIN SUPERVISOR ECU - REPLACEMENT 1. Preliminary operations  2. Remove / Disassemble  Disconnect the 2 connectors  Separate the tongue  Detach the assembly of the electric drive train supervisor ECU and its bracket (In the direction of the arrow).

  • Page 97: Cooling Circuit

    TECHNICAL DOCUMENTATION 1.5.11 COOLING CIRCUIT OVERVIEW COOLING CIRCUIT Description Water pump Water pump bracket Radiator water inlet hose Radiator outlet hose PTBCC coolant pipe exchanger PTBCC coolant inlet pipe PTBCC coolant pipe battery pump PTBCC coolant inlet pipe PTBCC coolant inlet pipe Intermediate pipe Expan bottle cool outlet pipe Battery cooling CLNT exchanger...
  • Page 98 TECHNICAL DOCUMENTATION ELECTRIC DRIVE TRAIN COOLING CIRCUIT – DRAINING/FILLING/DEGASSING 1. Checking the coolant fluid  Check the pH of the coolant; Using reactive strips.  The pH value of the coolant should be between 6,3 and 8.  Replace the coolant if the pH value is out of tolerance. 2.
  • Page 99 TECHNICAL DOCUMENTATION 4. Draining Notice: Position a clean tray under the vehicle to collect the electric drive train cooling circuit coolant. Caution: Use a container large enough to collect all of the electric drive train cooling circuit coolant.  Remove the expansion tank cap. ...
  • Page 100 TECHNICAL DOCUMENTATION 5. Filling Caution: If the electric drive train cooling circuit is contaminated, rinse with clean water. Caution: Always use new coolant. Caution: Each filling operation must always be followed by an electric drive train cooling circuit degassing procedure. Notice: The receptacle must be positioned slightly lower than the equipment for filling by vacuum.
  • Page 101 TECHNICAL DOCUMENTATION 6. Degassing  Position the tool [0173 / CH-52423-1], [0173-B / CH- 52423-2], [0173-C / EN-52423] on the filler neck.  Close the closer ‎ [ 0173-C / EN-52423] on the filling cylinder ‎ [ 0173 / CH-52423-1]. ...
  • Page 102 TECHNICAL DOCUMENTATION RADIATOR FAN - REPLACEMENT 1. Preliminary operations  Place the vehicle on a 2-post lift (see Page 58).  Remove the front underbody protection plate (see Page 56). 2. Remove / Disassemble  Unclip the electrical harness [at a] ...
  • Page 103 TECHNICAL DOCUMENTATION 3. Refit / Assemble Tightening torques  Air conditioning circuit see Page 234.  Cooling system see Page 231. Caution: Do not damage the air conditioning condenser fins.  Refit the cooling fan assembly ‎ [  Reintroduce the cooling fan assembly‎ fixing tabs into their housing [at d, ...
  • Page 104 TECHNICAL DOCUMENTATION ELECTRIC DRIVE TRAIN COOLING CIRCUIT COOLANT PUMP - REPLACEMENT 1. Preliminary operations  Place the vehicle on a 2-post lift (see Page 58).  Remove the front underbody protection plate (see Page 56). 2. Additional tools  Hose clamp [4153-T]. 3.
  • Page 105 TECHNICAL DOCUMENTATION 4. Refit / Assemble  Refit the electric drive train cooling circuit electric coolant pump ‎ [  Couple electric drive train cooling circuit pipes ‎ [ 2] and [3].  Reclip  Remove the tools [4153-T].  Reconnect : o The connector [at f]...
  • Page 106 TECHNICAL DOCUMENTATION TRACTION BATTERY COOLING CIRCUIT COOLANT PUMP - REPLACEMENT 1. Preliminary operations  Place the vehicle on a 2-post lift (see Page 58).  Remove the front underbody protection plate (see Page 56). 2. Additional tools  Hose clamp [4153-T]. 3.
  • Page 107 TECHNICAL DOCUMENTATION  To ensure sufficient cooling, it is important to plug the plug with the red cable into the drive train cooling pump and the plug with the green cable into the traction battery cooling pump [b]. 5. Additional operations ...
  • Page 108 TECHNICAL DOCUMENTATION COOLING CIRCUIT 2-WAY SOLENOID VALVES – REPLACEMENT WARNING Any personnel working on an electric vehicle must have an electric vehicle-specific training and authorization to work on these vehicles. Please observe the regulations applicable in the respective country. 1. Preliminary operations ...
  • Page 109 TECHNICAL DOCUMENTATION COOLING CIRCUIT 3-WAY SOLENOID VALVES – REPLACEMENT 1. Preliminary operations  Place the vehicle on a 2-post lift (see Page 58).  Remove the front underbody protection (see Page 56).  Remove the front right-hand wheel arch (see Page 59). ...
  • Page 110 TECHNICAL DOCUMENTATION HEATING CIRCUIT COOLANT PUMP - REPLACEMENT 1. Preliminary operations  Place the vehicle on a 2-post lift (see Page 58).  Remove the front underbody protection plate (see Page 56).  Remove the 12V battery and the battery support (see Page 39). 2.
  • Page 111 TECHNICAL DOCUMENTATION ELECTRIC COOLANT HEATER – REPLACEMENT WARNING Any personnel working on an electric vehicle must have an electric vehicle-specific training and authorization to work on these vehicles. Please observe the regulations applicable in the respective country. 1. Preliminary operations ...
  • Page 112 TECHNICAL DOCUMENTATION 3. Refit / Assemble Tightening torques  Electric coolant heater see Page 233.  Refit: o The electric coolant heater and the earth cable ‎ o The nuts o The earth cable o The nut [3].  Clip the earth cable [2] [at ...
  • Page 113 TECHNICAL DOCUMENTATION WATER CONDENSER - REPLACEMENT Essential: Follow the safety instructions before working on the air conditioning circuit (see Page 117). 1. Preliminary operations  Remove the on-board charger / direct transformer cover (see Page 41)  Remove the electric drive train supervisor ECU (see Page 97). ...
  • Page 114 TECHNICAL DOCUMENTATION  Remove : o The nuts o The water condenser ‎ [ 5]  Uncouple and move aside the water condenser ‎ [ 5] pipe [3] [at 5. Refit / Assemble Tightening torques:  Water Condenser see Page 233. ...

  • Page 115: Air Conditioning Circuit

    TECHNICAL DOCUMENTATION 1.5.12 AIR CONDITIONING CIRCUIT OVERVIEW AIR CONDITIONING CIRCUIT Description Air conditioned Freon tube Air conditioned Freon tube Air conditioned Freon tube Air conditioned Freon tube Air conditioned Freon tube Air conditioned Freon tube O-ring O-ring O-ring O-ring Cooling circuit valve Cooling circuit valve Valve plugs set Valve plugs set...
  • Page 116 TECHNICAL DOCUMENTATION AIR CONDITIONING SAFETY INSTRUCTIONS Essential: The compressor lubricant is extremely hygroscopic; Use new fluid for any operation. Caution : Never switch on the air conditioning system if the refrigerant circuit is drained. Do not remove the compressor filler plug when the circuit is full. 1.
  • Page 117 TECHNICAL DOCUMENTATION ELECTRIC AIR CONDITIONING COMPRESSOR – REPLACEMENT WARNING Any personnel working on an electric vehicle must have an electric vehicle-specific training and authorization to work on these vehicles. Please observe the regulations applicable in the respective country. Essential: Follow the safety instructions before working on the air conditioning circuit (see Page 117). 1.
  • Page 118 TECHNICAL DOCUMENTATION  Remove : o The 3 bolts o The electric air conditioning compressor [7]. 5. Refit / Assemble Tightening torques:  Components of the air conditioning system see Page 234. Caution: Never refit an electric air conditioning compressor that has suffered an impact. Caution: Check that the air conditioning ducts [1] and [4] upstream and downstream of the electric air conditioning compressor [7] are clean.
  • Page 119 TECHNICAL DOCUMENTATION ELECTRIC AIR CONDITIONING COMPRESSOR - DRAINING Essential: Follow the safety instructions before working on the air conditioning circuit (see Page 117). 1. Quantity of oil to be removed Notice: New electric air conditioning compressors are delivered filled with oil. Therefore, oil must be removed.
  • Page 120 TECHNICAL DOCUMENTATION AIR CONDITIONING CONDENSER – REPLACEMENT Essential: Follow the safety instructions before working on the air conditioning circuit (see Page 117). 1. Preliminary operations  Place the vehicle on a 2-post lift (see Page 58).  Drain the electric air conditioning circuit; Using an air conditioning filling and recycling station. ...
  • Page 121 TECHNICAL DOCUMENTATION 5. Refit / Assemble Tightening torques  Components of the air conditioning system see Page 234.  Refit: o The new O-ring seals on the air conditioning ducts o The air conditioning condenser o The bolts [3]. Caution: When refitting the air conditioning ducts, the clamp contact face ‎ " A" must be touching the engine compartment air conditioning evaporator ‎...
  • Page 122 TECHNICAL DOCUMENTATION AIR CONDITIONING DUCTS – REPLACEMENT WARNING Any personnel working on an electric vehicle must have an electric vehicle-specific training and authorization to work on these vehicles. Please observe the regulations applicable in the respective country. Essential: Follow the safety instructions before working on the air conditioning circuit (see Page 117). 1.
  • Page 123 TECHNICAL DOCUMENTATION  Remove : o The nuts o The high pressure air conditioning pipe (Electric air conditioning compressor / Water condenser ) o The high pressure air conditioning pipe (Water condenser / Air conditioning duct )  Remove : o The nuts [8],[11] [12]...
  • Page 124 TECHNICAL DOCUMENTATION  Remove : o The nuts [24] o The high pressure air conditioning pipe [25] (Controlled pressure relief valve / Heating unit ) 5. Refit / Assemble Tightening torques  Components of the air conditioning system see Page 234. Caution: Check that the air conditioning pipes are clean.
  • Page 125 TECHNICAL DOCUMENTATION 6. Additional operations  Refit the front bumper (see Page 61).  Refit the front underbody protection plate (see Page 56).  Essential: Reactivate the vehicle HV-System (see Page 26).  Fill and bleed the drive train cooling circuit (see Page 99). ...
  • Page 126 TECHNICAL DOCUMENTATION AIR CONDITIONING PRESSURE RELIEF VALVE - REPLACEMENT WARNING Any personnel working on an electric vehicle must have an electric vehicle-specific training and authorization to work on these vehicles. Please observe the regulations applicable in the respective country. Essential: Follow the safety instructions before working on the air conditioning circuit (see Page 117). 1.
  • Page 127 TECHNICAL DOCUMENTATION 5. Refit / Assemble Tightening torques  Pressure Relief Valve see Page 235. Caution: Check that the air conditioning pipes are clean.  Replace: o The air conditioning pipe O-rings (new); Lubricate the new seals with compressor oil o The air conditioning pressure reducer O-ring (new);...
  • Page 128 TECHNICAL DOCUMENTATION CONTROLLED PRESSURE RELIEF VALVE – REPLACEMENT WARNING Any personnel working on an electric vehicle must have an electric vehicle-specific training and authorization to work on these vehicles. Please observe the regulations applicable in the respective country. Essential: Follow the safety instructions before working on the air conditioning circuit (see Page 117). 1.
  • Page 129 TECHNICAL DOCUMENTATION  Remove the 2 bolts [6].  Disassemble the controlled pressure relief valve from its bracket [8]. 5. Refit / Assemble Tightening torques  Components of the air condition system see Page 234.  Assemble the controlled pressure relief valve onto its bracket [8].
  • Page 130 TECHNICAL DOCUMENTATION AIR CONDITIONING HEAT EXCHANGER – REPLACEMENT WARNING Any personnel working on an electric vehicle must have an electric vehicle-specific training and authorization to work on these vehicles. Please observe the regulations applicable in the respective country. Essential: Follow the safety instructions before working on the air conditioning circuit (see Page 117). 1.
  • Page 131 TECHNICAL DOCUMENTATION  Remove: o The bolts o The air conditioning heat exchanger 5. Refit / Assemble Tightening torques  Components of the air conditioning system see Page 234.  Air conditioning heat exchanger see Page 235.  Refit: o The air conditioning heat exchanger o The bolts ...

  • Page 132: Wheels

    TECHNICAL DOCUMENTATION 1.5.13 WHEELS OVERVIEW WHEELS 1. Rims  7x17 Braid Fullrace  20mm Offset 2. Tires Brand Description Size FIA homologated Michelin Pilot Sport diff. specs. 19/63-17 Pirelli P Zero RK diff. specs. 205/45 R17 V2, 02/2022 Page 133 of 293...
  • Page 133 TECHNICAL DOCUMENTATION WHEEL – REPLACEMENT 1. Preliminary operations  Lift and support the vehicle (see Page 57). 2. Remove / Disassemble  Remove the 4 wheel nuts.  Remove the wheel. 3. Refit / Assemble Tightening torques  Wheels see Page 225. Caution: Carefully apply the wheel nuts by hand to avoid damaging the thread.

  • Page 134: Brake System

    TECHNICAL DOCUMENTATION 1.5.14 BRAKE SYSTEM OVERVIEW BRAKE SYSTEM Circuit Description Front brake circuit Rear brake circuit Fly-Off-Handbrake Hydraulic block (ABS/ESP) Brake servo unit Brake fluid reservoir Front Description Wheel hub Brake caliper Brake disc Front axle shim Brake bleeding screw Rear Description Wheel hub...
  • Page 135 TECHNICAL DOCUMENTATION BRAKE SYSTEM SAFETY INSTRUCTIONS Caution: Non-compliance with the cleanliness requirements can lead to contamination and malfunctioning of the braking system. 1. General safety instructions  Wear lint-free gloves coated with polyurethane on the palm and the end of the fingers. ...
  • Page 136 TECHNICAL DOCUMENTATION ADDITIONAL INFORMATION TO THE BRAKING SYSTEM 1. Fly-off-handbrake  Unlocked [a].  Locked [b]. 2. Rear Pressure Adjustment  The pressure output for the rear brake circuit can be set by turning the adjustment valve [c].  To decrease the rear pressure, unscrew the thumbwheel [1].
  • Page 137 TECHNICAL DOCUMENTATION BRAKE CIRCUIT – DRAINING/FILLING/BLEEDING 1. Preliminary operations  Lift the vehicle (see Page 57).  Remove the wheels (see Page 134). 2. Additional tools  Brake bleeding unit 3. Bleeding order 1. Rear right-hand wheel. 2. Rear left-hand wheel. 3.
  • Page 138 TECHNICAL DOCUMENTATION 5. Draining the reservoir  Remove the brake fluid reservoir  Drain the brake fluid reservoir as much as possible; Using a clean syringe. 6. Filling the reservoir Caution: Use only clean fluid free from bubbles. Avoid any introduction of impurities into the hydraulic system.
  • Page 139 TECHNICAL DOCUMENTATION FRONT BRAKE CALIPERS AND FRONT BRAKE HOSES – REPLACEMENT 1. Preliminary operations  Place the vehicle on a 2-post lift (see Page 58).  Remove the front wheels (see Page 134).  Remove the front brake pads (see Page 142). 2.
  • Page 140 TECHNICAL DOCUMENTATION  Move aside the brake caliper.  Remove the bolts [5].  Remove the front brake disc [6]. 5. Cleaning  Clean the brake disc and the brake caliper, using an approved brake cleaning product.  Leave to drip dry. ...
  • Page 141 TECHNICAL DOCUMENTATION FRONT BRAKE PADS – REPLACEMENT 1. Preliminary operations  Place the vehicle on a 2-post lift (see Page 58).  Remove the front wheel (see Page 134). 2. Additional tools  Piston pushing tool. 3. Replacement parts  Brake pads o Pagid/TMD RST 3 904705188A o Ferodo FM1000;...
  • Page 142 TECHNICAL DOCUMENTATION REAR BRAKE CALIPERS AND FRONT BRAKE HOSES – REPLACEMENT 1. Preliminary operations  Place the vehicle on a 2-post lift (see Page 58).  Remove the rear wheel (see Page 134). 2. Additional tools  Piston pushing tool. ...
  • Page 143 TECHNICAL DOCUMENTATION  Remove: o The brake pads o The sound-deadening pads [6].  Remove: o The 2 bolts o The brake caliper bracket. 5. Remove / Disassemble brake disc Essential: Always replace the brake pads if replacing the discs. ...
  • Page 144 TECHNICAL DOCUMENTATION 8. Refit / Assemble brake disc Tightening torques  Rear braking system see Page 217.  Refit: o The rear brake disc [11] o The bolt [10]. 9. Refit / Assemble brake caliper Caution: Do not turn the rear motorised brake caliper piston to push it back. Caution: At each removal, always clean the thread of the screws [5].
  • Page 145 TECHNICAL DOCUMENTATION REAR BRAKE PADS – REPLACEMENT 1. Preliminary operations  Place the vehicle on a 2-post lift (see Page 58).  Remove the rear wheel (see Page 134). 2. Additional tools  Piston pushing tool.  Pedal press. 3. Replacement parts ...
  • Page 146 TECHNICAL DOCUMENTATION 6. Check Caution: No trace of grease, oil or lubricant can be tolerated on the brake pads.  Visually check: o The sealing around the rear motorised brake caliper piston. o That the protective gaiters are in good condition and correctly adjusted. o The wear of the brake discs.
  • Page 147 TECHNICAL DOCUMENTATION BRAKE SYSTEM ELECTRIC VACUUM PUMP – REPLACEMENT 1. Preliminary operations  Remove the front right-hand wheel arch (see Page 59). 2. Remove / Disassemble Caution: Before any operations, wait until the electric vacuum pump has cooled down.  Disconnect: o The electric vacuum pump connector [at a]...
  • Page 148 TECHNICAL DOCUMENTATION  Detach the electric vacuum pump [10] assembly and its bracket in the direction of the arrow.  Remove the electric vacuum pump [10]. 3. Refit / Assemble Tightening torques  Brake system vacuum pump see Page 218. ...

  • Page 149: Suspension

    TECHNICAL DOCUMENTATION 1.5.15 SUSPENSION FRONT SUBFRAME - REPLACEMENT 1. Preliminary operations  Place the vehicle on a 2-post lift (see Page 58).  Remove the 12V battery and the battery support (see Page 39).  Remove the front wheel arches (see Page 59) ...
  • Page 150 TECHNICAL DOCUMENTATION 4. Remove / Disassemble  Disconnect the connectors  Remove the nut [1]. Symmetrical operation  Remove the nut [2].  Uncouple the steering ball-joint; Using the extractor [CH-161-B].  Remove: o The nut o The bolt/nut assembly ...
  • Page 151 TECHNICAL DOCUMENTATION  Position a lifting tool to retain the front sub-frame.  Remove : o The bolts o The bolts [10] o The bolt [11] o The bolts [12], [13] o The front subframe with a lifting table 5. Refit / Assemble Tightening torques ...
  • Page 152 TECHNICAL DOCUMENTATION FRONT ANTI-ROLL BAR - REPLACEMENT 1. Preliminary operations  Remove the front subframe (see Page 150). 2. Remove / Disassemble Notice: Picture differs from rally car.  Remove the bolts [1]. Notice: Picture differs from rally car.  Remove: o Bearings in the direction of the arrows...
  • Page 153 TECHNICAL DOCUMENTATION FRONT WISHBONE – REPLACEMENT 1. Preliminary operations  Place the vehicle on a 2-post lift (see Page 58).  Remove the front wheel arches (see Page 59). 2. Additional tools  Hub carrier ball joint uncoupling lever [0622] 3.
  • Page 154 TECHNICAL DOCUMENTATION  Refit the front wheels (see Page 134). FRONT HUB CARRIER – REPLACEMENT 1. Preliminary operations  Place the vehicle on a 2-post lift (see Page 58).  Put aside the front brake caliper and remove the front brake discs (see Page 140). 2.
  • Page 155 TECHNICAL DOCUMENTATION Notice: Picture differs from rally car.  Unscrew the nut and turn it anti-clockwise until it is level with the steering ball joint rod.  Uncouple the steering ball-joint; Using the extractor [CH-161-B] [5].  Remove the nut [4]. Caution: Take care not to damage the suspension lower arm ball-joint gaiter.
  • Page 156 TECHNICAL DOCUMENTATION FRONT SPRING-SHOCK ABSORBER – REPLACEMENT 1. Preliminary operations  Place the vehicle on a 2-post lift (see Page 58).  Remove the front wheels (see Page 134)  Remove the scuttle panel (see Page 70). 2. Replacement parts Description: Quantity (per side): ...
  • Page 157 TECHNICAL DOCUMENTATION 4. Refit / Assemble Tightening torques  Front hub carrier see Page 220.  Suspension strut see Page 221.  Engage the front damper-spring assembly in the wheel arch.  Refit: o The front spring-shock absorber assembly. o The nut [6]. o The spacers o The bolts o The nuts...
  • Page 158 TECHNICAL DOCUMENTATION REAR SUSPENSION – REPLACEMENT 1. Preliminary operations  Place the vehicle on a 2-post lift (see Page 58).  Remove the rear wheels (see Page 134).  Remove the rear suspension springs (see Page 165).  Remove the “Panhard” type rear bar (see Page 163). 2.
  • Page 159 TECHNICAL DOCUMENTATION 4. Replacement parts Description: Quantity (per side):  Bolt rear shock absorber  Bolt-nut assembly rear suspension yoke  Bolts rear suspension yoke 5. Remove / Disassemble Caution: Do not open the braking system on the brake caliper. Symmetrical operation ...
  • Page 160 TECHNICAL DOCUMENTATION Symmetrical operation  Lift the elevating platform [0004-Z / WE-160002-A].  Remove: o The 3 bolts o The rear suspension. 6. Refit / Assemble Tightening torques  Rear shock absorber see Page 222.  Crossmember see Page 223. ...
  • Page 161 TECHNICAL DOCUMENTATION REAR HUB CARRIER – REPLACEMENT 1. Preliminary operations  Place the vehicle on a 2-post lift (see Page 58).  Remove the rear wheels (see Page 134).  Remove the rear brake calipers and the rear brake discs (see Page 141) ...
  • Page 162 TECHNICAL DOCUMENTATION REAR PANHARD BAR – REPLACEMENT 1. Preliminary operations  Place the vehicle on a 2-post lift (see Page 58).  Remove the rear suspension springs (see Page 165). 2. Additional tools  Component lift. 3. Remove / Disassemble ...
  • Page 163 TECHNICAL DOCUMENTATION REAR DAMPER/SHOCK ABSORBER – REPLACEMENT 1. Preliminary operations  Place the vehicle on a 2-post lift (see Page 58).  Remove the rear wheel arch (see Page 71).  Remove the rear suspension spring (see Page 165). Essential: The suspension shock absorbers are removed-refitted one side at a time. 2.
  • Page 164 TECHNICAL DOCUMENTATION REAR SUSPENSION SPRINGS – REPLACEMENT 1. Preliminary operations  Place the vehicle on a 2-post lift (see Page 58).  Remove the rear wheel (see Page 134) 2. Additional tools  Spring compressor [0920-A] [WE18Z103A]  Jaws [0920-M5] [WE18Z403A] 3.
  • Page 165 TECHNICAL DOCUMENTATION 4. Refit / Assemble Caution: Check the condition of the suspension spring (signs of impact, scratches or corrosion spots); The paint coating on the suspension spring should not be damaged. Caution: The colour markings [at a] on the rear suspension spring [3] must be directed at the lower section towards the rear of the vehicle.
  • Page 166 TECHNICAL DOCUMENTATION REAR WHEEL SPEED SENSOR – REPLACEMENT 1. Preliminary operations  Place the vehicle on a 2-post lift (see Page 58).  Remove the rear wheel (see Page 134). 2. Remove / Disassemble  Disconnect the electrical harness connector ...

  • Page 167: Steering

    TECHNICAL DOCUMENTATION 1.5.16 STEERING STEERING WHEEL – REPLACEMENT 1. Remove / Disassemble Caution: Before any operations; Put the wheels in the straight ahead position.  Remove the bolt [1].  Remove the steering wheel [2]. 2. Refit / Assemble Tightening torques ...
  • Page 168 TECHNICAL DOCUMENTATION STEERING MOUNTED CONTROLS - REPLACEMENT 1. Preliminary operations  Remove the steering wheel (see Page 168). 2. Remove / Disassemble Caution: Before any operations; Put the wheels in the straight ahead position.  Unclip and move aside the top cover. ...
  • Page 169 TECHNICAL DOCUMENTATION STEERING COLUMN – REPLACEMENT 1. Preliminary operations  Remove the steering mounted controls (see Page 169). 2. Replacement parts Description: Quantity:  Bolt-nut assembly steering universal joint 3. Remove / Disassemble  Remove the bolt-nut assembly [2].  Remove the clamp ...
  • Page 170 TECHNICAL DOCUMENTATION STEERING MECHANISM – REPLACEMENT 1. Preliminary operations  Place the vehicle on a 2-post lift (see Page 58).  Remove the front subframe (see Page 150). 2. Replacement parts Description: Quantity:  Nuts (steering mechanism / front subframe) ...
  • Page 171 TECHNICAL DOCUMENTATION STEERING RODS – REPLACEMENT 1. Preliminary operations  Lift and support the vehicle (see Page 58).  Remove the front wheel (see Page 134). 2. Additional tools  Roller wrench [0721-AY] [CH-6247]  Steering rack anti-rotation tool [0721-B] [CH-52289] ...
  • Page 172 TECHNICAL DOCUMENTATION 4.2. Steering rod  Unclip the clip ; Using a thin screwdriver.  Remove: o The clip ; Using universal pliers o The steering rack gaiter Caution: The tool [0721-B / CH-52289] must be put in place on the teeth of the steering mechanism. Caution: Position the tool [0721-B / CH-52289] as close as possible to the steering ball joint.
  • Page 173 TECHNICAL DOCUMENTATION 5.1. Steering rod  Refit the steering track rod [3]; Using the [0721-AY / CH-6247] tool.  Remove : o The tool [0721-AY / CH-6247] o The tool [0721-B / CH-52289] o The protection pads  Refit : o The new steering rack gaiter o The new steering rack gaiter clip [5];...

  • Page 174: Seat

    TECHNICAL DOCUMENTATION 1.5.17 SEAT SEAT FIXATION – REPLACEMENT 1. Remove / Disassemble Symmetrical operation  Remove the bolts  Remove the seat.  Remove the bolts  Remove the seat bracket. 2. Refit / Assemble Tightening torques  Seat see Page 248. ...

  • Page 175: Night Lamp

    TECHNICAL DOCUMENTATION 1.5.18 NIGHT LAMP NIGHT LAMP – REPLACEMENT 1. Remove / Disassemble  Disconnect the cable  Remove the 4 bolts.  Remove the lamp. 2. Refit / Assemble Tightening torques  Night lamp see Page 239.  Proceed in reverse order to removal. 3.

  • Page 176: Speakers

    TECHNICAL DOCUMENTATION 1.5.19 SPEAKERS SPEAKERS MOUNTING LOCATION 1. Front and rear speakers  The two front speakers are mounted behind the front bumper.  The rear speakers are positioned at the rear underbody protector. 2. Amplifier  The amplifier is positioned behind the driver‘s and co- driver‘s seats.

  • Page 177: Key, Doors And Windows

    TECHNICAL DOCUMENTATION Batteries do not belong in CENTRAL LOCKING SYSTEM KEY, DOORS household waste. They must Unlocks and locks doors, AND WINDOWS be disposed of at an load compartment and the appropriate recycling charging socket cover. collection point. A pull on an interior door handle unlocks the respective door.

  • Page 178: Automatic Locking

    TECHNICAL DOCUMENTATION Operation with buttons on discharged, the front door the electronic key can be locked or unlocked with the mechanical key. Manual unlocking To lock the other doors, remove the black cover by using a key. The central locking system can also be operated with Insert key carefully and move the buttons on the electronic...

  • Page 179: Heated Rear Window

    TECHNICAL DOCUMENTATION Pushing or pulling gently to 5. Repeat for each window. : interval wiping the first detent: window : off 1.6.3 HEATED REAR moves up or down as long as : single wipe the switch is operated. WINDOW Do not use if the windscreen Pushing or pulling firmly to Operated by pressing is frozen.

  • Page 180: Warning Ligths And Indicators

    TECHNICAL DOCUMENTATION 1.7.2 WARNING The recorded distance since Rear fog lights the last reset is displayed in LIGTHS, GAUGES AND Active emergency the Driver Information INDICATORS braking Centre. Door open Two trip odometer pages are INSTRUMENT CLUSTER selectable in the trip / fuel Charge cord The following instrument information menu for...

  • Page 181: Displays

    TECHNICAL DOCUMENTATION The control indicator colours EXTERIOR LIGHT mean: illuminates green. : danger, important The exterior lights are on. reminder LOW BEAM yellow: warning, information, fault illuminates green. green : confirmation of Illuminated when low beam activation is on. Turn the adjuster wheel to blue : confirmation of select a page in the trip / fuel High beam...

  • Page 182: Vehicle Messages

    TECHNICAL DOCUMENTATION After refuelling, the range is Displays the current distance WARNING CHIMES updated automatically after for trip 2 since a certain When starting the engine or a brief delay. reset. whilst driving When the fuel level is low, a The values of trip 2 page can A warning chime will sound message appears on the...
  • Page 183 TECHNICAL DOCUMENTATION HIGH BEAM HEADLIGHTS WHEN REAR FOG LIGHT DRIVING ABROAD When driving in countries where traffic drives on the opposite side of the road, the headlights do not have to be adjusted. TURN LIGHTS Push to switch from low to Operated by pressing high beam.

  • Page 184: Interior Lighting

    TECHNICAL DOCUMENTATION 1.8.2 INTERIOR ● manual air recirculation MANUAL SETTINGS LIGHTING Climate control system ● demisting and defrosting settings can be changed by INSTRUMENT PANEL activating the following ILLUMINATION CONTROL functions: ● heated rear window and exterior mirrors Fan speed In automatic mode, temperature, fan speed and air distribution are regulated...
  • Page 185 TECHNICAL DOCUMENTATION : to front and rear foot The air conditioning system windscreen mists up from well and windscreen cools and dehumidifies outside, activate windscreen (dries) when outside wiper and deactivate To return to automatic air temperature is above a distribution, press AUTO.

  • Page 186: Air Vents

    TECHNICAL DOCUMENTATION 1.9.2 AIR VENTS FIXED AIR VENTS ● heating functionality Additional air vents are ● leakage check ADJUSTABLE AIR VENTS located beneath the ● check of drive belts windscreen and door Centre air vents in the ● cleaning of condenser and windows and in the foot instrument panel evaporator drainage...

  • Page 187: Vehicle Care

    TECHNICAL DOCUMENTATION After releasing the selector The vehicle is not designed Coolant level lever, it will return to the to stay in N for extended Caution centre position. periods of time. It will automatically shift into P. Too low coolant level can P: This position locks the cause engine damage.

  • Page 188: Bulb Replacement

    TECHNICAL DOCUMENTATION WIPER BLADE Bulb check REPLACEMENT After a bulb replacement switch on the ignition, Windscreen operate and check the lights. HALOGEN HEADLIGHTS Halogen headlights with separate bulbs for low beam and high beam / daytime 3. Detach the bulb from the running light.

  • Page 189: Electrical System

    TECHNICAL DOCUMENTATION TAIL LIGHTS 3. Replace and insert the new bulb into socket by Light assembly in the body turning clockwise. 4. Insert the bulb socket into the reflector and turn clockwise. Centre high-mounted brake light 6. Remove and replace the Have lights repaired by a bulbs: workshop in case of failure.
  • Page 190 TECHNICAL DOCUMENTATION Some functions are protected by several fuses. Electric vehicle Fuses may also be inserted control unit without existence of a Engine function. compartment relay Fuse extractor AC/DC converter / A fuse extractor may be DC/DC converter located in the cover of the High voltage battery After having changed left side of the instrument...
  • Page 191 Exterior mirror of the instrument Climate control adjustment panel) module / radio PEAK Breaklight faceplate Heated front seats Box – Main Alarm / Opel Seat massage Switch – Remote Connect function Amplifier – EVSMA Sound Electronic shifter Module module /...
  • Page 192 TECHNICAL DOCUMENTATION FUSE FOR ADDITIONAL LOOM AND NIGHT LAMP The Fuses are located in front of the 12V battery. No. Circuit Additional loom fuse Night lamp fuse V2, 02/2022 Page 193 of 293...
  • Page 193 DRIVER HANDBOOK DRIVER HANDBOOK 2.1 ENGINE COMPARTMENT ....195 Overview ............195 Detailed Description ........195 2.2 DRIVER COMPARTMENT ....200 Cockpit .............. 200 Driving modes ..........200 Switch panel ............. 201 PEAK safety system battery check....201 Lugage compartment ........202 Stilo DG-10 (Option) ........

  • Page 194: Engine Compartment

    DRIVER HANDBOOK 2.1 ENGINE COMPARTMENT OVERVIEW DETAILED DESCRIPTION  Fire extinguisher nozzle  Circuit breaker for HV-system V2, 02/2022 Page 195 of 293...
  • Page 195 DRIVER HANDBOOK  Fire extinguishing nozzle  Brake fluid reservoir (Fill level should be between “min” and “max”)  Main relay  Fire extinguishing nozzle  Coolant reservoir (Fill level should be between “min” and “max”)  Window cleaner reservoir V2, 02/2022 Page 196 of 293...
  • Page 196 DRIVER HANDBOOK  Brake system vacuum pump  Air conditioning heat exchanger  On-board charger / direct voltage transformer (without cover)  Electric drive train supervisor ECU V2, 02/2022 Page 197 of 293...
  • Page 197 DRIVER HANDBOOK  Water condenser  12V battery  Fuse box  Radiator Fan  Air conditioning condenser  Electric drive train coolant pump  Traction battery coolant pump V2, 02/2022 Page 198 of 293...
  • Page 198 DRIVER HANDBOOK  ABS/ESP hydraulic block  Additional loom fuse  Night lamp fuse V2, 02/2022 Page 199 of 293...

  • Page 199: Driver Compartment

    DRIVER HANDBOOK 2.2 DRIVER COMPARTMENT COCKPIT  Digital display  Switch panel  Tripmaster  Lever  Driving-modes  Fire extinguisher nozzles  Rear brake circuit adjustable regulation valve  Fly-off-handbrake lock  Tripmaster foot switch  Driver foot rest ...

  • Page 200: Switch Panel

    DRIVER HANDBOOK SWITCH PANEL  Ignition  Main switch / Emergency off  Night lamp on/off  Central locking  Horn  Fire extinguisher  PEAK safety system battery check  Sound on/off  PEAK safety system LED indicator  Warning lights PEAK SAFETY SYSTEM BATTERY CHECK ...

  • Page 201: Lugage Compartment

    DRIVER HANDBOOK LUGAGE COMPARTMENT 1 1 1 1  Helmet net attachment points  Warning triangle  First aid kit and safety west V2, 02/2022 Page 202 of 293...
  • Page 202 DRIVER HANDBOOK  Additional weights positioned behind the driver seat  Crotch belt fixation under the driver and co-driver seat  Shoulder belt fixation at roll cage  Spare wheel fixation and wheel cross  Jack fixation V2, 02/2022 Page 203 of 293...

  • Page 203: Stilo Dg-10 (Option)

    DRIVER HANDBOOK STILO DG-10 (OPTION) V2, 02/2022 Page 204 of 293...
  • Page 204 TIGHTENING TORQUES TIGHTENING TORQUES 3.1 STANDARD TIGHTENING 3.11.1 Electric drive train cooling ....231 TORQUES ..........206 3.12 AIR CONDITIONING ..... 234 3.2 UNDERBODY PROTECTION 3.13 EXTERIOR PARTS ......239 PLATES ..........207 3.14 BODYWORK ........241 3.3 ENGINE ..........208 3.14.1 Front section ........

  • Page 205: Standard Tightening Torques

    TIGHTENING TORQUES 3.1 STANDARD TIGHTENING TORQUES Screw quality 10.9 12.9 Standard Metric Threads in Nm M4 (x0.7) M5 (x0.8) M6 (x1.0) M8 (x1.25) M10 (x1.5) M12 (x1.75) Standard Fine Threads in Nm M8 x1.0 M10 x1.25 M12 1.25 M12 x1.5 Conversion factors: 1 Nm 8,85 Ib in...

  • Page 206: Underbody Protection Plates

    TIGHTENING TORQUES 3.2 UNDERBODY PROTECTION PLATES secure it lb in lb ft Front underbody protection plate Front underbody protection plate Rear underbody protection plate HV battery front Rear underbody protection plate HV battery rear V2, 02/2022 Page 207 of 293...

  • Page 207: Engine

    TIGHTENING TORQUES 3.3 ENGINE 3.3.1 ELECTRIC DRIVE TRAIN ELECTRIC DRIVE MACHINE ASSEMBLY, ELECTRIC DRIVE MACHINE INVERTER AND REDUCTION GEAR secure it lb in lb ft Bolt (Park finger locking actuator / Reduction gear ) 88,5 Bolt (Filler plug / Reduction gear ) Bolt (Drain cap / Reduction gear ) Bolt (On-board charger/direct voltage transformer assembly / On-board charger bracket )

  • Page 208: Mounting Of The Electric Drive Train

    TIGHTENING TORQUES 3.3.2 MOUNTING OF THE ELECTRIC DRIVE TRAIN LEFT HAND BRACKET secure it lb in lb ft Bolts (Left-hand bracket / Crossmember) Loctite 262 Bolts (Left-hand bracket / Front left-hand chassis leg) REDUCTION GEAR AND ELECTRIC DRIVE MACHINE FLEXIBLE MOUNTING Order of tightening the bolts: secure it lb in...
  • Page 209 TIGHTENING TORQUES RIGHT-HAND BRACKET secure it lb in lb ft Bolts (Right-hand bracket / Crossmember) Loctite 262 Bolts (Right-hand bracket / Front right chassis leg ) REDUCTION GEAR AND REAR ELECTRIC DRIVE MACHINE RIGHT-HAND FLEXIBLE MOUNTING Order of tightening the bolts: ‎...
  • Page 210 TIGHTENING TORQUES TORQUE REACTION ROD AND REDUCTION GEAR SUPPORT ‎ Order of tightening the bolts: secure it lb in lb ft Bolts (Torque reaction rod / Front subframe) 1062 Always to be Bolts (Reduction gear mount) replaced whenever Bolts (Torque reaction rod / Reduction gear mount) removed V2, 02/2022 Page 211 of 293...

  • Page 211: Gearbox

    TIGHTENING TORQUES 3.4 GEARBOX 3.4.1 REDUCTION GEAR EXTERNAL COMPONENTS Order of tightening the bolts: secure it lb in lb ft Bolts (Reduction box casing / Reduction box casing) Bolts (Reduction box casing / Reduction box casing) DRAIN CAP secure it lb in lb ft Drain plug...
  • Page 212 TIGHTENING TORQUES INTERNAL COMPONENTS Order of tightening the bolts: secure it lb in lb ft Bolts ( differential / crown wheel) Loctite 262 OIL FILLER NECK secure it lb in lb ft Bolts (Oil filler neck / Reduction box casing) PARK LATCH MODULE secure it lb in...

  • Page 213: Coupling Of Engine On Reduction Box

    TIGHTENING TORQUES 3.4.2 COUPLING OF ENGINE ON REDUCTION BOX secure it lb in lb ft Nuts (Coupling of engine on reduction box) Bolts (Coupling of engine on reduction box) Bolts (Coupling of engine on reduction box) V2, 02/2022 Page 214 of 293...

  • Page 214: Driveshaft

    TIGHTENING TORQUES 3.5 DRIVESHAFT bearing secure it lb in lb ft Driveshaft nut 2832 Driveshaft bearing V2, 02/2022 Page 215 of 293...

  • Page 215: Brakes

    TIGHTENING TORQUES 3.6 BRAKES FRONT BRAKE (FRONT BRAKE DISC: 323 MM DIAMETER) secure it lb in lb ft Bolts (Front brake disc) Bleed screw Bolts (Front brake caliper) 1018 Union (flexible hose / Front brake caliper) Bolts (Front brake caliper bracket) Loctite 243 V2, 02/2022 Page 216 of 293...
  • Page 216 TIGHTENING TORQUES REAR BRAKE secure it lb in lb ft Bolts (Rear brake disc) Bleed screw Union ( flexible hose / rear brake caliper) Bolts ( rear brake caliper) Bolts (Rear brake caliper support) Loctite 243 Bolts (Rear wheel speed sensor) MASTER CYLINDER –...
  • Page 217 TIGHTENING TORQUES ABS / ESP HYDRAULIC BLOCK secure it lb in lb ft Connections (Hydraulic block (ABS/ESP)) Bolts (Hydraulic block (ABS/ESP) / Bracket ) Connections (Hydraulic block (ABS/ESP)) MECHANICAL VACUUM PUMP secure it lb in lb ft Nuts (Vacuum pump) Bolts (Vacuum pump support) Nut (Vacuum pump) Nuts (Vacuum pump support)

  • Page 218: Suspension

    TIGHTENING TORQUES 3.7 SUSPENSION 3.7.1 FRONT SUSPENSION FRONT SUBFRAME secure it lb in lb ft Bolt-nut assembly (Lower suspension arm / Front subframe) Bolt-nut assembly (Lower suspension arm / Front subframe) Always to be replaced Bolts (Front subframe rear crossmember / Body) whenever removed Bolts (Front subframe)
  • Page 219 TIGHTENING TORQUES FRONT HUB CARRIER secure it lb in lb ft Always to be Flanged nuts (Anti-roll bar rod) replaced whenever Flanged nuts (Anti-roll bar rod) removed Nut wing joint wishbone Wing joint in hub carier Loctite 290 2036 Drive shaft nut 2832 Nut (Steering ball-joint) Always to be...
  • Page 220 TIGHTENING TORQUES FRONT SUSPENSION STRUT secure it lb in lb ft Always to be Nuts fixation damper replaced whenever Fixation uniball bearing top mount removed V2, 02/2022 Page 221 of 293...

  • Page 221: Rear Suspension

    TIGHTENING TORQUES 3.7.2 REAR SUSPENSION REAR HUB CARRIER secure it lb in lb ft Always to be replaced Bolts (Rear hub / Rear crossmember) 1018 whenever removed REAR SHOCK ABSORBER secure it lb in lb ft Nut (Rear shock absorber / Body) Always to be replaced Nut (Bump stop / Rear crossmember)
  • Page 222 TIGHTENING TORQUES CROSSMEMBER secure it lb in lb ft Always to be bolts (Rear axle yoke / Body) replaced whenever Bolt-nut assembly (Rear axle yoke / Rear flexible mounting) 1151 removed REAR “PANHARD” BAR secure it lb in lb ft bolts (Rear bar / Bracket (Rear bar) ) Always to be replaced...

  • Page 223: Steering

    TIGHTENING TORQUES 3.8 STEERING STEERING COLUMN secure it lb in lb ft Nuts (Steering column / Crossmember) bolt (Steering column / Crossmember) Always to be replaced Nut (Steering universal joint / Valve stem) whenever removed STEERING MECHANISM secure it lb in lb ft Always to be replaced...

  • Page 224: Wheels

    TIGHTENING TORQUES 3.9 WHEELS secure it lb in lb ft Bolts (Wheel fixation)) 1062 V2, 02/2022 Page 225 of 293...

  • Page 225: Electrical Parts

    TIGHTENING TORQUES 3.10 ELECTRICAL PARTS 3.10.1 HV SYSTEM TRACTION BATTERY secure it lb in lb ft Bolt (Traction battery / Body) Marked screws (with arrows) fix battery protection too Bolt (Traction battery / Body) ELECTRIC POWER CIRCUIT CONNECTORS secure it lb in lb ft Bolt (Electric power circuit connectors / Electric drive machine...
  • Page 226 TIGHTENING TORQUES CHARGING SOCKET UNIT secure it lb in lb ft Bolt (Charging socket unit / Body) Nut (Earth cable / Body) MAIN RELAY secure it lb in lb ft Relay to body Wire to Relay Wire to Relay V2, 02/2022 Page 227 of 293...

  • Page 227: System

    TIGHTENING TORQUES 3.10.2 LV SYSTEM 12V BATTERY secure it lb in lb ft Bolts (Earth cable / Body) Nut (12V battery charge status control unit / 12V battery) Bolts (12V battery retaining clamp / 12V battery support) DRIVE TRAIN SUPERVISOR ECU secure it lb in lb ft...
  • Page 228 TIGHTENING TORQUES SUPPLIES PROTECTION AND MANAGEMENT UNIT secure it lb in lb ft Always to be Nuts (Electrical harnesses / Supplies protection and replaced management unit) whenever removed Nuts (Electrical harnesses / Supplies protection and management unit) ENGINE FUSE AND RELAY BOX secure it lb in lb ft...
  • Page 229 TIGHTENING TORQUES 12V BATTERY SWITCH secure it lb in lb ft Always to be Nuts (Electrical harnesses / Supplies protection and replaced management unit) whenever removed Nut (12V battery switch / 12V battery switch support) Nuts (Fuse holder / 12V battery switch support) EARTH POINTS ON THE BODY IN THE ENGINE COMPARTMENT secure it lb in...

  • Page 230: Cooling System

    TIGHTENING TORQUES 3.11 COOLING SYSTEM 3.11.1 ELECTRIC DRIVE TRAIN COOLING COOLING CIRCUIT SOLENOID VALVES secure it lb in lb ft Nuts (2-way solenoid valve / On-board charger bracket ) Bolts (3-way solenoid valve / Front electric drive machine) ELECTRIC DRIVE TRAIN COOLING CIRCUIT DISTRIBUTOR secure it lb in lb ft...
  • Page 231 TIGHTENING TORQUES ELECTRIC DRIVE TRAIN COOLING PIPE secure it lb in lb ft Nut (Electric drive train cooling pipe / On-board charger bracket ) WATER OUTLET MANIFOLD secure it lb in lb ft Bolt (Water outlet manifold / Front electric drive machine) NON RETURN VALVE secure it lb in...
  • Page 232 TIGHTENING TORQUES WATER CONDENSER secure it lb in lb ft Nuts (Water condenser / On-board charger bracket ) Nuts (Water condenser / On-board charger bracket ) ELECTRIC COOLANT HEATER secure it lb in lb ft Nut (Electric coolant heater / Electric coolant heater bracket) COOLING FAN secure it lb in...

  • Page 233: Air Conditioning

    TIGHTENING TORQUES ELECTRICAL COOLING HARNESS MOUNTING secure it lb in lb ft Nuts (Electrical harness mounting / Steering mechanism ) 3.12 AIR CONDITIONING ELECTRIC AIR CONDITIONING COMPRESSOR secure it lb in lb ft Bolt (Electric air conditioning compressor) V2, 02/2022 Page 234 of 293...
  • Page 234 TIGHTENING TORQUES WATER CONDENSER secure it lb in lb ft Nuts (Water condenser ) COOLANT – AIR CONDITIONING HEAT EXCHANGER secure it lb in lb ft Bolts (Coolant - air conditioning heat exchanger ) CONTROLLED PRESSURE RELIEF VALVE secure it lb in lb ft Bolts(Controlled pressure relief valve )
  • Page 235 TIGHTENING TORQUES CONDENSER secure it lb in lb ft Bolts(Condenser) AIR CONDITIONING FLUID PIPING modified design and new part number in rally car secure it lb in lb ft Nuts (Air conditioning fluid piping / Water condenser ) Nuts (Air conditioning fluid piping / Compressor) Nuts (Air conditioning fluid piping / Dehydrator) Nuts (Air conditioning fluid piping / Air conditioning fluid piping)
  • Page 236 TIGHTENING TORQUES modified design and new part number in rally car secure it lb in lb ft Nuts (Air conditioning fluid piping / Water condenser ) Nuts (Air conditioning fluid piping / Compressor) Nuts (Air conditioning fluid piping / Controlled pressure relief valve ) Nuts (Air conditioning fluid piping / Air conditioning fluid piping)
  • Page 237 TIGHTENING TORQUES modified design and new part number in rally car secure it lb in lb ft Nuts (Air conditioning fluid piping / Condenser) Nuts (Air conditioning fluid piping / Condenser) Nuts (Air conditioning fluid piping / Valve) Nuts (Air conditioning fluid piping / Pressure relief valve ) Nuts (Air conditioning fluid piping / Pressure relief valve ) Nuts (Air conditioning fluid piping / Controlled pressure relief valve )

  • Page 238: Exterior Parts

    TIGHTENING TORQUES 3.13 EXTERIOR PARTS LIGHT POD secure it lb in lb ft Bolts (Light pod) BONNET LOCK secure it lb in lb ft Bolts (lock to bonnet) V2, 02/2022 Page 239 of 293...
  • Page 239 TIGHTENING TORQUES MAIN SWITCH secure it lb in lb ft Bolts (Main switch to cover) V2, 02/2022 Page 240 of 293...

  • Page 240: Bodywork

    TIGHTENING TORQUES 3.14 BODYWORK 3.14.1 FRONT SECTION FRONT BUMPER secure it lb in lb ft Bolts (Front bumper / Front wing) FRONT FENDER secure it lb in lb ft Bolts (Front fender / Front fender support) Bolts (Front fender / Front fender support) Bolts (Front fender / Outer sill / Front bumper) Bolts (Front fender / Front pillar) Bolts (Front fender / Front fender support)
  • Page 241 TIGHTENING TORQUES FRONT HEADLAMP secure it lb in lb ft Bolts (Front headlamp) Nut (Front headlamp) BONNET secure it lb in lb ft Nuts (Engine bonnet hinges / Bonnet) Bolts (Engine bonnet hinges / Front wing support) V2, 02/2022 Page 242 of 293...

  • Page 242: Rear Section

    TIGHTENING TORQUES FRONT IMPACT BAR secure it lb in lb ft Bolts (Front bumper frame / Body) 3.14.2 REAR SECTION TAILGATE secure it lb in lb ft Bolts (Tailgate hinges / Tailgate) Nut (Tailgate hinges / Body) V2, 02/2022 Page 243 of 293...
  • Page 243 TIGHTENING TORQUES TAILGATE SPOILER secure it lb in lb ft Bolts (Tailgate spoiler / Tailgate) REAR BUMPER secure it lb in lb ft Bolts (Rear bumper / Rear wing) Bolts (Rear bumper central support / Body) REAR IMPACT BAR secure it lb in lb ft Bolts (Rear impact bar / Body)

  • Page 244: Openings And Access

    TIGHTENING TORQUES 3.14.3 OPENINGS AND ACCESS FRONT DOOR secure it lb in lb ft Bolts (Front pillar door hinge / Front pillar) Bolts (Front pillar door hinge / Front door) Bolts (Front door lock) Bolts (Front door striker plate) Bolts (Door check strap / Front pillar) Nuts (Door check strap / Front door) V2, 02/2022 Page 245 of 293...
  • Page 245 TIGHTENING TORQUES REAR DOOR secure it lb in lb ft Bolts (Rear door hinge / Centre pillar) Bolts (Rear door hinge / Rear door) Bolts (Rear door lock) Bolts (Rear door striker plate) Bolts (Door check strap / Rear pillar) Nuts (Door check strap / Rear door) DOOR TRIM (FRONT / REAR) secure it...

  • Page 246: Passenger Compartment

    TIGHTENING TORQUES 3.15 PASSENGER COMPARTMENT AIRBAGS AND PRETENSIONERS ECU secure it lb in lb ft Nuts (Airbags and pretensioners ECU / Electronic control unit support) DASHBOARD secure it lb in lb ft Bolts (Dashboard / Upper bulkhead) Bolts (Dashboard / Dashboard crossmember) Bolts (Dashboard / Dashboard crossmember) V2, 02/2022 Page 247 of 293...
  • Page 247 TIGHTENING TORQUES STEERING WHEEL secure it lb in lb ft Bolts (Steering wheel adaptor / Steering column) SEAT secure it lb in lb ft Bracket to body (4 bolts per seat) Seat to bracket (4 bolts per seat) V2, 02/2022 Page 248 of 293...
  • Page 248 TIGHTENING TORQUES FOOT REST (DRIVER / CO-DRIVER) secure it lb in lb ft Bolts V2, 02/2022 Page 249 of 293...
  • Page 249 TIGHTENING TORQUES SPARE WHEEL BRACKET secure it lb in lb ft Fasteners spare wheel bracket Fasteners spare wheel bracket HAND FIRE EXTINGUISHER secure it lb in lb ft Bolts (Manual fire extinguisher bracket) V2, 02/2022 Page 250 of 293...
  • Page 250 TIGHTENING TORQUES FIRE EXTINGUISHER secure it lb in lb ft Bolts (Fire extinguisher bracket; other side same, total 4 bolts) IP-BEAM secure it lb in lb ft Bolts (IP-beam fixation) V2, 02/2022 Page 251 of 293...
  • Page 251 TIGHTENING TORQUES SHIFTER secure it lb in lb ft Shifter to bracket Bracket to cockpit Bracket to body SAFETYLIGHTBOX secure it lb in lb ft Bracket to body Safetylightbox to bracket V2, 02/2022 Page 252 of 293...
  • Page 252 TIGHTENING TORQUES FLY-OFF HANDBRAKE secure it lb in lb ft Fly off handbrake to bracket and body Brake pipe fitting V2, 02/2022 Page 253 of 293...
  • Page 253 TIGHTENING TORQUES PEDAL BRACKETS secure it lb in lb ft Nuts (Bracket / Bulkhead) Always to be replaced Bolt-nut assembly (Brake pedal / Pedal bracket) whenever removed Nuts (Accelerator pedal) secure it lb in lb ft Always to be replaced Nuts (Bracket / Bulkhead) whenever removed...
  • Page 254 MILEAGE MILEAGE 4.1 REPLACEMENTS ......256 4.2 REVISIONS ........256 4.3 FLUID EXCHANGE ......257 V2, 02/2022 Page 255 of 293...
  • Page 255 MILEAGE 4.1 REPLACEMENTS Name Exchange [SS km] Remark Driveshaft 1500 Wishbone 1500 Steering rod 1500 Front upright: Wheel hub 1500 Knuckle Wheel bolts Bearing Rear Axle ASM: Wheel hub 1500 Bushings Wheel bolts Bearing Brake caliper front 1500 Brake caliper rear 1500 Master brake cylinder 3000...
  • Page 256 MILEAGE 4.3 FLUID EXCHANGE Name Exchange [SS km] Remark Cooling gas Once a year Gearbox oil After each event Check once a year of the Cooling liquid properties Service Gearbox oil change  After the first 50km.  Afer each event. ...
  • Page 257 APPENDIX APPENDIX 5.1 SETUP SHEET ......................259 5.2 CIRCUIT DIAGRAMS ..................... 260 5.3 MEASUREMENT LOG HV – SYSTEM CORSA-E RALLY ........261 5.4 MESSPROTOKOLL HV – SYSTEM CORSA-E RALLY ........... 278 V2, 02/2022 Page 258 of 293...

  • Page 258: Setup Sheet

    APPENDIX 5.1 SETUP SHEET V2, 02/2022 Page 259 of 293...

  • Page 259: Circuit Diagrams

    APPENDIX 5.2 CIRCUIT DIAGRAMS ESSENTIAL Circuit diagram of the series harness can be found at Service Box or Online Racing Shop. Motorsport harness: V2, 02/2022 Page 260 of 293...

  • Page 260: Measurement Log Hv-System Corsa-E Rally

    MEASUREMENT LOG HV-SYSTEM CORSA-E RALLY 5.3 MEASUREMENT LOG HV – SYSTEM CORSA-E RALLY HV – REACTIVATION WARNING Any personnel working on an electric vehicle must have an electric vehicle specific training and authorization to work on these vehicles. Please observe the regulations applicable in the respective country.
  • Page 261 MEASUREMENT LOG HV-SYSTEM CORSA-E RALLY 1. CHECK CENTRAL GROUND POINT Measuremt point from battery negative to main relay (contact to body) ‎‎‎‎‎‎‎‎‎‎‎‎‎ mΩ ꭥ Target value: Less than 10 m  Important: This ground point is used for all following measurements. Important: The resistance value measured here must be added to all following potential equlization measurements.
  • Page 262 MEASUREMENT LOG HV-SYSTEM CORSA-E RALLY 2. POTENTIAL EQUALIZATION MEASUREMENT HV – TRACTION BATTERY  Component clean and dry ☐ ☐  No visible damage to the component present ☐ ☐  All screws and mounting parts present ☐ ☐ If one or more questions are answered with the responsible electrically qualified person must be consulted.
  • Page 263 MEASUREMENT LOG HV-SYSTEM CORSA-E RALLY POTENTIAL EQUALIZATION MEASUREMENT HV – ELECTRIC DRIVE MACHINE  Component clean and dry ☐ ☐  No visible damage to the component present ☐ ☐  All screws and mounting parts present ☐ ☐ If one or more questions are answered with the responsible electrically qualified person must be consulted.
  • Page 264 MEASUREMENT LOG HV-SYSTEM CORSA-E RALLY 4. POTENTIAL EQUALIZATION MEASUREMENT HV – AIR CONDITIONING COMPRESSOR  Component clean and dry ☐ ☐  No visible damage to the component present ☐ ☐  All screws and mounting parts present ☐ ☐ If one or more questions are answered with the responsible electrically qualified person must be consulted.
  • Page 265 MEASUREMENT LOG HV-SYSTEM CORSA-E RALLY 5. POTENTIAL EQUALIZATION MEASUREMENT HV – ON-BOARD CHARGER  Component clean and dry ☐ ☐  No visible damage to the component present ☐ ☐  All screws and mounting parts present ☐ ☐ If one or more questions are answered with the responsible electrically qualified person must be consulted.
  • Page 266 MEASUREMENT LOG HV-SYSTEM CORSA-E RALLY 6. POTENTIAL EQUALIZATION MEASUREMENT HV – AUXILIARY HEATER  Component clean and dry ☐ ☐  No visible damage to the component present ☐ ☐  All screws and mounting parts present ☐ ☐ If one or more questions are answered with the responsible electrically qualified person must be consulted.
  • Page 267 MEASUREMENT LOG HV-SYSTEM CORSA-E RALLY 7. POTENTIAL EQUALIZATION MEASUREMENT HV – CHARGING SOCKET  Component clean and dry ☐ ☐  No visible damage to the component present ☐ ☐  All screws and mounting parts present ☐ ☐  Measuring adapter present and plugged in ☐...
  • Page 268 MEASUREMENT LOG HV-SYSTEM CORSA-E RALLY 8. PREPARATION INSULATION MEASUREMENT HV – SYSTEM Measuring device: Calibrated until: VISUAL CHECK MEASURING DEVICE  Cables and display ok? ☐ ☐ SET THE MEASURING DEVICE TO NOMINAL VOLTAGE AND CHECK FOR FUNCTION  Measuring device set to nominal voltage? [Target = 500V] ☐...
  • Page 269 MEASUREMENT LOG HV-SYSTEM CORSA-E RALLY 9. INSULATION MEASUREMENT HV – ON-BOARD CHARGER  Remove the cover of the on-board charger by unscrewing the 8 torx screws with a magnetic tool. Do the following measurements: Measured values: Connector C1: ꭥ HV +  Ground point ...
  • Page 270 MEASUREMENT LOG HV-SYSTEM CORSA-E RALLY 10. INSULATION MEASUREMENT – CHARGING SOCKET  Disconnect the air conditioner charging connector from the on-board charger and put it aside to get representative values for the next measurement. Do the following measurements: Measured values: ...
  • Page 271 MEASUREMENT LOG HV-SYSTEM CORSA-E RALLY  Reconnect the air conditioner charging connector to the on-board charger CHECK THE MEASURING DEVICE FOR FUNCTION AGAIN:  CHANGES THE SEGMENT DISPLAY BETWEEN OPEN MEASURING TIPS AND ☐ ☐ MEASURING TIPS KEPT TOGETHER (PRESS FUNC)? If the answer is No, check the measuring device and repeat the measurement.
  • Page 272 MEASUREMENT LOG HV-SYSTEM CORSA-E RALLY 11. ACTIVATION HV - SYSTEM Follow the steps below in order: Done  Remove the padlock from e-Service Plug and insert plug again ☐  ☐ CONNECT 12V BATTERY  Switch on both emergency switches (inside and outside) ☐...
  • Page 273 MEASUREMENT LOG HV-SYSTEM CORSA-E RALLY HV – DEACTIVATION WARNING Any personnel working on an electric vehicle must have an electric vehicle specific training and authorization to work on these vehicles. Please observe the regulations applicable in the respective country. Vehicle / VIN: Name: Location: Date:...
  • Page 274 MEASUREMENT LOG HV-SYSTEM CORSA-E RALLY Remove the black plastic cover of the on-board charger.  Remove the cover of the on-board charger by unscrewing the  8 torx screws with a magnetic tool. Do the following measurements: Measured values: Connector C1: HV + ...
  • Page 275 MEASUREMENT LOG HV-SYSTEM CORSA-E RALLY Measured values: Charging socket: DC +  DC -  (target = less than 3 volt) _______________ V If any value of these measurements is above 3 volts, wait 5 minutes and repeat measurement. If one of the measured values is still above 3 volts after waiting 5 minutes, stop work IMMEDIATELY and inform the responsible electrically qualified person.
  • Page 276 MEASUREMENT LOG HV-SYSTEM CORSA-E RALLY List of abbreviations ꭥ ..............Ohm L3 ..............Line 3 A ..............Ampere mꭥ ............. Milliohm AC ..........Alternating current Mꭥ............Megaohm DC ............. Direct current N ..............Neutral EFK ......Electrically qualified person OBC .........

  • Page 277: Messprotokoll Hv-System Corsa-E Rally

    MESSPROTOKOLL HV-SYSTEM CORSA-E RALLY 5.4 MESSPROTOKOLL HV – SYSTEM CORSA-E RALLY HV – INBETRIEBNAHME WARNUNG Das Personal, das an einem Elektrofahrzeug arbeitet, muss eine elektrofahrzeugspezifische Ausbildung und eine Berechtigung für die Arbeit an diesen Fahrzeugen haben. Bitte beachten Sie die im jeweiligen Land geltenden Vorschriften.
  • Page 278 MESSPROTOKOLL HV-SYSTEM CORSA-E RALLY 1. CHECK ZENTRALER MASSEPUNKT Messpunkt von Batterie Minus zur Karosserie ‎‎‎‎‎‎‎‎‎‎‎‎‎ mΩ ꭥ SOLL – Wert: Kleiner als 10 m  Wichtig: Dieser Massepunkt wird für alle folgenden Messungen benutzt. Wichtig: Der hier gemessene Widerstandswert muss bei allen folgenden Potentialausgleichsmessungen addiert werden.
  • Page 279 MESSPROTOKOLL HV-SYSTEM CORSA-E RALLY 2. POTENTIALAUSGLEICHSMESSUNG HV – BATTERIE Nein  Komponente sauber und trocken ☐ ☐  Keine sichtbaren Beschädigungen an der Komponente vorhanden ☐ ☐  Alle Schrauben und Befestigungsteile vorhanden ☐ ☐ Falls eine oder mehrere Fragen mit Nein beantwortet werden, muss Rücksprache mit der Verantwortlichen Elektrofachkraft gehalten werden.
  • Page 280 MESSPROTOKOLL HV-SYSTEM CORSA-E RALLY 3. POTENTIALAUSGLEICHSMESSUNG HV – ANTRIEBSMOTOR Nein  Komponente sauber und trocken ☐ ☐  Keine sichtbaren Beschädigungen an der Komponente vorhanden ☐ ☐  Alle Schrauben und Befestigungsteile vorhanden ☐ ☐ Falls eine oder mehrere Fragen mit Nein beantwortet werden, muss Rücksprache mit der Verantwortlichen Elektrofachkraft gehalten werden.
  • Page 281 MESSPROTOKOLL HV-SYSTEM CORSA-E RALLY 4. POTENTIALAUSGLEICHSMESSUNG HV – KLIMAKOMPRESSOR Nein  Komponente sauber und trocken ☐ ☐  Keine sichtbaren Beschädigungen an der Komponente vorhanden ☐ ☐  Alle Schrauben und Befestigungsteile vorhanden ☐ ☐ Falls eine oder mehrere Fragen mit Nein beantwortet werden, muss Rücksprache mit der Verantwortlichen Elektrofachkraft gehalten werden.
  • Page 282 MESSPROTOKOLL HV-SYSTEM CORSA-E RALLY 5. POTENTIALAUSGLEICHSMESSUNG HV – ON-BOARD CHARGER Nein  Komponente sauber und trocken ☐ ☐  Keine sichtbaren Beschädigungen an der Komponente vorhanden ☐ ☐  Alle Schrauben und Befestigungsteile vorhanden ☐ ☐ Falls eine oder mehrere Fragen mit Nein beantwortet werden, muss Rücksprache mit der Verantwortlichen Elektrofachkraft gehalten werden.
  • Page 283 MESSPROTOKOLL HV-SYSTEM CORSA-E RALLY 6. POTENTIALAUSGLEICHSMESSUNG HV – ZUHEIZER Nein  Komponente sauber und trocken ☐ ☐  Keine sichtbaren Beschädigungen an der Komponente vorhanden ☐ ☐  Alle Schrauben und Befestigungsteile vorhanden ☐ ☐ Falls eine oder mehrere Fragen mit Nein beantwortet werden, muss Rücksprache mit der Verantwortlichen Elektrofachkraft gehalten werden.
  • Page 284 MESSPROTOKOLL HV-SYSTEM CORSA-E RALLY 7. POTENTIALAUSGLEICHSMESSUNG HV – LADEBUCHSE Nein  Komponente sauber und trocken ☐ ☐  Keine sichtbaren Beschädigungen an der Komponente vorhanden ☐ ☐  Alle Schrauben und Befestigungsteile vorhanden ☐ ☐  Messadapter vorhanden und eingesteckt ☐...
  • Page 285 MESSPROTOKOLL HV-SYSTEM CORSA-E RALLY 8. VORBEREITUNG ISOLATIONSMESSUNG Messgerät: Kalibriert bis: Nein SICHTPRÜFUNG MESSGERÄT  Kabel und Anzeige in Ordnung? ☐ ☐ MESSGERÄT AUF NOMINALSPANNUNG EINSTELLEN UND AUF FUNKTION Nein PRÜFEN.  Messgerät auf Nominalspannung eingestellt? [SOLL = 500V] ☐ ☐ ...
  • Page 286 MESSPROTOKOLL HV-SYSTEM CORSA-E RALLY 9. ISOLATIONSMESSUNG HV – ON-BOARD CHARGER  Entfernen Sie die Abdeckung des On-Board Chargers indem Sie die 8 Torx-Schrauben mit einem magnetischen Werkzeug abschrauben. Führen Sie folgende Messungen durch: Gemessene Werte: Stecker C1: ꭥ HV + gegen Karosserie Masse ...
  • Page 287 MESSPROTOKOLL HV-SYSTEM CORSA-E RALLY 10. ISOLATIONSMESSUNG - LADEBUCHSE  Trennen Sie den Ladeanschluss der Klimaanlage vom On- Board Charger und legen Sie ihn beiseite, um repräsentative Werte für die nächste Messung zu erhalten. Führen Sie folgende Messungen durch: Gemessene Werte: ...
  • Page 288 MESSPROTOKOLL HV-SYSTEM CORSA-E RALLY  Stecken Sie den Ladeanschluss der Klimaanlage wieder an den On-Board Charger an. Nein MESSGERÄT ERNEUT AUF FUNKTION PRÜFEN.  ÄNDERT SICH DIE SEGMENTANZEIGE ZWISCHEN OFFENEN MESSSPITZEN UND ZUSAMMENGEHALTENEN MESSSPITZEN (FUNC ☐ ☐ DRÜCKEN) Falls mit Nein beantwortet, Messgerät prüfen lassen und Messung erneut durchführen. ...
  • Page 289 MESSPROTOKOLL HV-SYSTEM CORSA-E RALLY 11. AKTIVIERUNG HV - SYSTEM Folgende Schritte der Reihenfolge nach ausführen: Erledigt  Schloss von e-Service Plug entfernen und Stecker wieder einstecken ☐  ☐ 12V BATTERIE ANKLEMMEN  Beide Hauptschalter einschalten (innen und aussen) ☐ ...
  • Page 290 MESSPROTOKOLL HV-SYSTEM CORSA-E RALLY HV – DEAKTIVIERUNG WARNUNG Das Personal, das an einem Elektrofahrzeug arbeitet, muss eine elektrofahrzeugspezifische Ausbildung und eine Berechtigung für die Arbeit an diesen Fahrzeugen haben. Bitte beachten Sie die im jeweiligen Land geltenden Vorschriften. Fahrzeug / VIN: Name: Ort: Datum:...
  • Page 291 MESSPROTOKOLL HV-SYSTEM CORSA-E RALLY Entfernen Sie die schwarze Kunststoffabdeckung des On-  Board Chargers. Entfernen Sie die Abdeckung des On-Board Chargers indem  Sie die 8 Torx-Schrauben mit einem magnetischen Werkzeug abschrauben. Führen Sie folgende Messungen durch: Gemessene Werte: Stecker C1: HV + ...
  • Page 292 MESSPROTOKOLL HV-SYSTEM CORSA-E RALLY Gemessener Wert: Ladebuchse: DC +  DC -  (Sollwert = kleiner als 3 Volt) _______________ V Wenn ein Wert dieser Messungen über 3 Volt ist, 5 Minuten warten und Messung wiederholen. Ist einer der gemessenen Werte nach 5 Minuten Wartezeit noch immer über 3 Volt, Arbeit SOFORT einstellen und verantwortliche Elektrofachkraft informieren...
  • Page 293 MESSPROTOKOLL HV-SYSTEM CORSA-E RALLY Abkürzungsverzeichnis L3............Phase 3 ꭥ ............... Ohm A ............Ampere mꭥ ............Milliohm AC ..........Wechselstrom Mꭥ............. Megaohm DC ........... Gleichstrom N ............Neutral EFK ..........Elektofachkraft OBC ........On-Board Charger GND ............Masse PE............. Schutzleiter HV ............

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