Remove/install power electronics

AR08.20-P-0011LF

Remove/install power electronics

26.11.2019

Model

222.004/057/104/157/163/173

Show on model 222.157

1

Seal

5c

Coolant line

27

Electrical line

2

Right major assembly dividing wall

20

High-voltage distributor

28

Electrical line

3

Right reinforcement

24

Electrical line, terminal 30

29

3-phase high-voltage lines

4

Bracket

25

Electrical connector

F32/3

Engine compartment prefuse box

5a

Coolant hose

26

Electrical line, equipotential bonding

N129/1

Power electronics control unit

5b

Coolant hose

Show on model 222.157

5b

Coolant hose

9

Bracket

26

Electrical line, equipotential bonding

6

Bolts

20

High-voltage distributor

N129/1

Power electronics control unit

Shown: model 222.163

4

Bracket

9

Bracket

28

Electrical line

4a

Bracket

20

High-voltage distributor

29

3-phase high-voltage lines

5a

Coolant hose

25

Electrical connector

30

Electrical line

5b

Coolant hose

26

Electrical line, equipotential bonding

N129/1

Power electronics control unit

6

Bolts

27

Electrical line

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

 Danger

Risk of death when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC)

Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines.

AS00.00-Z-0035-01A

 Warning

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.

Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

General information on handling vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system

AH00.00-Z-0300-01A

Topical note

Notes on coolant

AH20.00-N-2080-01A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Topical note

Notes on battery

AH54.10-P-0001-01A

 

Remove/install

1

Perform disable for the high voltage on-board electrical system

AR54.10-P-1150LF

2.1

Disconnect ground line for on-board electrical system battery on left rear longitudinal member

Model 222.004/057/104/157

AR54.10-P-0003LF

2.2

Disconnect ground line at the on-board electrical system battery

Model 222.163/173

AR54.10-P-0003LF

3

Remove front and rear rights cover in the engine compartment

 Installation: After leak test, remove front and rear rights cover in the engine compartment

4

Detach seal (1) and remove right major assembly dividing wall (2)

5

Remove hose couplings on windshield washer system with bracket from right reinforcement (3)

Model 222.004/057/104/157/163/173
with code 874 (MAGIC VISION CONTROL, heated)

AR82.30-P-6100LF

6

Remove right reinforcement (3)

 Bolt, reinforcement to firewall/longitudinal member/reinforcement, center

*BA62.25-P-1001-01B

7

Loosen engine compartment prefuse box (F32/3) and lay to the front

AR54.15-P-1330LF

8

Remove electrical lines (27) from high-voltage distributor (20) and set aside

Model 222.163/173 with engine 276

AR08.00-P-0101-01LFH


Model 222.163/173
It is essential to observe the work instructions and notes listed in the linked description!
Otherwise, damage can occur at the connector for the high voltage on-board electrical system, causing contact problems and damage to the high voltage on-board electrical system!


Cover connection for electrical line (27) on high-voltage distributor (20).
Otherwise, the shielding may be damaged.

 Model 222.163/173
with code ME05 (Hybrid drive 85 kW-94 kW variant (incl. plug-in))Safety screw, release lever for high-voltage connection

*BA08.20-P-1009-01E

 Model 222.004/057/104/157Bolt, high-voltage connector to high-voltage distributor

*BA54.10-P-1001-03C

9.1

Remove electrical line on terminal 30 (24) from power electronics control unit (N129/1) and close off connections with suitable protective cover

Model 222.004/057/104/157

 Installation:
Ensure that the contact surfaces are absolutely clean.
Otherwise contact problems and damage to high voltage on-board electrical system can occur.

 Installation: Ensure correct seating and scuff-free routing of the electrical line for terminal 30 (24).

 Model 222.004/057/104/157
with code ME04 (Mild hybrid drive)Nut, electrical line for circuit 30 to power electronics

*BA08.20-P-1005-01E

 Set of protective caps

*001589009100

9.2

Remove electrical line (30) from high-voltage distributor (20) and set aside. Close off connections with suitable protective cover

Model 222.163/173


Cover connection for electrical line (30) on high-voltage distributor (20).
Otherwise damage will occur.

 Set of protective caps

*001589009100

10

Release and disconnect electrical connection (25) to power electronics control unit (N129/1). Close off connections with suitable protective cover

 Set of protective caps

*001589009100

11

Remove electrical line for potential equalization (26) on suspension strut tower

 Installation:
Ensure scrupulous cleanliness.
Otherwise the high voltage on-board electrical system may be damaged.

 Installation: Ensure correct seating and scuff-free routing of the electrical line for potential equalization (26).

 Nut, potential equalization to body

*BA08.20-P-1007-01E

12.1

Remove bracket (4) from electrical line (28) and 3­phase high-voltage lines (29) on rear major assembly dividing wall

Model 222.004/057/104/157

12.2

Remove bracket (4a) from electrical line (28) and 3­phase high-voltage lines (29) on rear major assembly dividing wall

Model 222.163/173

13

Drain coolant at radiator

AR20.00-P-1142LF

14

Unclamp coolant hose (5a) and remove from power electronics control unit (N129/1)

 Collect escaping coolant with several rags.

 Hose clamp pliers

*003589033700

 Clamp

*000589403700

15

Close off connection fittings on power electronics control unit (N129/1) using suitable protective cover

 Set of protective caps

*001589029100

16.1

Disconnect coolant hose (5b), remove from coolant line (5c) and close off openings with suitable stop plugs

Model 222.004/057/104/157

 Collect escaping coolant with several rags.

 Clamp

*000589403700

 Record plug

*129589009100

 Hose clamp pliers

*003589033700

16.2

Unclamp coolant hose (5b) and remove from power electronics control unit (N129/1)

Model 222.163/173

 Collect escaping coolant with several rags.

 Hose clamp pliers

*003589033700

 Clamp

*000589403700

17.1

Close off coolant hose (5b) and coolant line (5c) using suitable protective cover

Model 222.004/057/104/157

 Set of protective caps

*001589029100

17.2

Close off connection fittings on power electronics control unit (N129/1) and coolant hose (5b) using suitable protective cover

Model 222.163/173

 Set of protective caps

*001589029100

 Set of protective caps

*001589009100

18

Remove bolts (6)

 Bolt, power electronics to bracket

*BA08.20-P-1001-01E

19

Pad upper engine cover with clean rags

20

Remove power electronics control unit (N129/1) with high-voltage distributor (20), electrical line (28) and 3-phase high-voltage lines (29) upwards and lay on the upper engine cover


Do not damage electrical line (28), 3-phase high-voltage lines (29) and high-voltage connection on high-voltage distributor (20).
Otherwise the high voltage on-board electrical system may be damaged.

21

Remove high-voltage distributor (20) from power electronics control unit (N129/1) and close off with suitable protective cover

Model 222.163/173

AR54.10-P-1400-01LFH

Model 222.004/057/104/157

AR54.10-P-1400-01LF


Always observe the work instructions and notes listed in the linked descriptions.
Otherwise, the high-voltage distributor (20) and power electronics control unit (N129/1) can be damaged and contact problems and damage can occur on the high-voltage on-board electrical system!

 Model 222.004/057/104/157
with code ME04 (Mild hybrid drive)
Model 222.163/173
with code ME05 (Hybrid drive 85 kW-94 kW variant (incl. plug-in))Bolt, power distributor to power electronics

*BA08.20-P-1004-01E

 Set of protective covers

*001589039100

 Long wedge

*115589035900

22

Change electrical line potential equalization (26) at new power electronics control unit (N129/1)

When replacing the power electronics control unit (N129/1).

 Bolt/nut, potential equalization to power electronics

*BA08.20-P-1006-01E

23

Change bracket (9) on new power electronics control unit (N129/1)

When replacing the power electronics control unit (N129/1).

 Bolt, bracket for prefuse box in engine compartment to power electronics control unit

*BA08.20-P-1008-01E

24

Change coolant hose (5b) on new power electronics control unit (N129/1)

Model 222.004/057/104/157
When replacing the power electronics control unit (N129/1).

 Hose clamp pliers

*003589033700

25

Install in the reverse order

26

Commission power electronics control unit (N129/1) with diagnostic system

When replacing the power electronics control unit (N129/1).



AD00.00-P-2000-04B

 The work procedure for the commissioning can be found in the following control unit:
- electric motor control unit
- in the initial "Control units" menu, select the menu item "Initial startup" under "Adaptations" and perform the complete procedure.

27

Remove diagnostic system

When replacing the power electronics control unit (N129/1).



AD00.00-P-2000-04B



Check

28

Check cooling system for leak tightness

AR20.00-P-1010LF

 Warning

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

29

Perform an engine test run; check cooling system and engine for proper operation and leaktightness

30

Install front and rear rights cover in the engine compartment

 Control units

Number

Designation

MODEL 222 with CODE ME04

MODEL 222 with CODE ME05

BA08.20-P-1001-01E

Bolt, power electronics to bracket

M8

Nm

23

23

 Control units

Number

Designation

MODEL 222 with CODE ME04

MODEL 222 with CODE ME05

BA08.20-P-1004-01E

Bolt, power distributor to power electronics

M5

Nm

6

–

M6

Nm

–

15

 Control units

Number

Designation

MODEL 222 with CODE ME04

BA08.20-P-1005-01E

Nut, electrical line for circuit 30 to power electronics

M8

Nm

16

 Control units

Number

Designation

MODEL 222 with CODE ME04

MODEL 222 with CODE ME05

BA08.20-P-1006-01E

Bolt/nut, potential equalization to power electronics

M8

Nm

16

16

 Control units

Number

Designation

MODEL 222 with CODE ME04

MODEL 222 with CODE ME05

BA08.20-P-1007-01E

Nut, potential equalization to body

M8

Nm

9

9

 Control units

Number

Designation

MODEL 222 with CODE ME04

MODEL 222 with CODE ME05

BA08.20-P-1008-01E

Bolt, bracket for prefuse box in engine compartment to power electronics control unit

M6

Nm

6

6

 Control units

Number

Designation

MODEL 222 with CODE ME05

BA08.20-P-1009-01E

Safety screw, release lever for high-voltage connection

Nm

4

 High-voltage distributor

Number

Designation

Model 222

BA54.10-P-1001-03C

Bolt, high-voltage connector to high-voltage distributor

Nm

5,5

 Firewall

Number

Designation

Model 222

BA62.25-P-1001-01B

Bolt, reinforcement to firewall/longitudinal member/reinforcement, center

M6

Nm

9

M8

Nm

30