EJE116-120 Service manual 2007-Up

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Tools: Vice,
Circlip pliers
Rng spanner,
Puller,
Drill,
4.0 mm metal drill bit,
M5 tap,
M5 threaded rod,
M5 nuts,
27 mm spanner socket, long or suitable tube,
Washers, i.d.:
12 mm,
10 mm,
8 mm,
6 mm.

4. Take off the pinion with the puller.

1. Remove the motor.
2. Clamp the rear motor shaft in the vice.
3. Remove the circlip from the shaft.
5. Take the feather key out of the shaft.
6. Remove the bearing bush with the puller.
7. Take the shaft washer out of the bearing bush.
8. Remove the O-ring from the bearing bush.
9. Take the shaft sealing ring out of the bearing bush.
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The following parts have now been removed:

10. Take out the sensor bearing with the puller.

11. Pull the sensor cable out of the cable gland;
remove the sensor bearing.
The removed sensor bearing will, in all probability, be damaged
and must not be reused.
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When fitting the new sensor bearing, proceed with extreme care.
The bearing will be damaged by mechanical jolts, impacts or
twisting of any kind. Do not use a hammer!

So that the sensor bearing and the other parts can be pulled on to
the motor shaft without any damage, the shaft thread must be
drilled out to 4.0 mm and then an M5 thread tapped in it.
To do this cover the motor housing.
If necessary remove any swarf from the motor housing.

Sensor cable

1. Guide the sensor cable through the cable gland to the

outside.
To do this the plug connectors must be pulled apart. Note down
the wire / pin connections and after threading the cable,
reassemble the plug connections.
2. Place the sensor bearing on the shaft.
3. Screw the M5 threaded rod into the motor shaft.
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6. Replace the shaft sealing ring and O-ring on the bearing

4. Push the 27 mm spanner socket, long or suitable tube and bush.
12, 10, 8 and 6 mm - washers over the threaded rod. 7. Position the shaft washer between the bearing bush and
5. Screw on the M5 nut, carefully tighten with the ring spanner sensor bearing.
and push the sensor bearing into its position.
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8. Tighten the bearing bush using the 27 mm spanner socket,
long or suitable tube, threaded rod, washers and nut.
9. Insert the feather key in the motor shaft.
10. Place the pinion on the shaft.
11. Tighten the pinion using the 27 mm spanner socket, long or
suitable tube, threaded rod, washers and nut.
12. Fit the circlip in front of the pinion.
13. Refit the motor.