Remove/install electric motor

AR08.10-S-0010EV

Remove/install electric motor

26.11.2019

Engine

780.994 in model 639.603/703

with code MA0 (E-CELL 60 kW)

Shown on model 639.6 up to vehicle identification number (VIN) 745075

1.1

Electrical connectors

4

Water collector

8

Screw

1.2

Electrical connector

5

Electrical connector

M5

Electric motor

2

Charge wiring harness

6

Electrical wiring harness

N24

DC/AC converter control unit

3

Clip

7

Potential compensation line of electric motor

N83/1

DC/DC converter control unit

Shown on MODEL 639.6 up to FIN 745075

9

Screw

13

Vacuum line

M5

Electric motor

10

Transmission

14

Screw/bolt (MODEL 639.6 up to VIN 745075, MODEL 639.7 up to VIN 717332)

M43

High-voltage battery coolant pump (model 639.6 up to VIN 745075, model 639.7 up to VIN 717332)

11

Shift and selector cable bracket

15

Retaining clamps (MODEL 639.6 up to VIN 745075, MODEL 639.7 up to VIN 717332)

M43/1

Low temperature coolant pump

12

Brake booster

10

Transmission

16

Potential compensation line of electric motor

17

Screw

18

Right rear engine support

19

Bolts

M5

Electric motor

 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

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

 

Remove/install

1

Open engine hood and secure against falling down

2

Perform power disconnect on high voltage system

AR54.10-S-1160EV

 Installation: Only perform initial startup of the high-voltage system after checking the potential equalization lines at the remaining high-voltage components.

3

Remove front bumper

AR88.20-S-2000S

4

Drain coolant in low temperature coolant circuit

Engine 780.994 in model 639.603/703
with code MA0 (E-CELL 60 kW)Low temperature cooling circuit

AR20.00-S-1140EV

5

Drain coolant in battery cooling circuit

Engine 780.994 in model 639.603 ## up to 745075, 639.703 ## up to 717332
with code MA0 (E-CELL 60 kW)Battery cooling circuit

AR20.00-S-1140EW

6

Remove splash guard

AR61.30-S-0010EV

7

Disconnect electrical connection (5) from DC/DC converter control unit (N83/1)

AR54.00-S-0050-01EY

 Cover electrical connections with  protective covers.

 Set of protective covers

*001589019100

8

Remove screw/bolt (8) of electric motor potential equalization line (7)

 Bolt, potential equalization line to electric motor

*BA08.10-N-1001-01A

9

Remove electrical wiring harness (6) on electric motor (M5).

 Installation: Check retaining clamp of electrical wiring harness (6) for damage, replace if necessary.

10

Remove engine hood

AR88.40-S-3000S

11

Remove charge wiring harness (2) on water collector (4)

 Installation: Check clamp (3) for damage, replace if necessary.

12

Remove water collector (4)

AR83.25-S-1402S

13

Release and disconnect electrical connections (1.1) and electrical connection (1.2) on DC/AC converter control unit (N24)

AR54.00-S-0050-01EV

 Cover electrical connections with  protective covers.

 Set of protective covers

*001589019100

 Set of protective caps

*001589029100

 Unlocking tool

*245589006300

14

Remove retaining frame for high voltage system components

AR54.21-S-5000EV

15

Remove vacuum pump

AR43.05-S-1320EV

16

Disconnect hose and line connections on electric motor (M5)

AR08.10-S-0010-03EV

 Bolt, potential equalization line to electric motor

*BA08.10-N-1001-01A

 Nut, power supply cable to plug connection box

*BA54.10-N-1005-01D

17

Remove screw/bolts (9) and bind high-voltage battery coolant pump (M43) to the side

Engine 780.994 in model 639.603 ## up to 745075, 639.703 ## up to 717332
with code MA0 (E-CELL 60 kW)Battery cooling circuit

 Do not separate coolant hoses.

 Installation: Align high-voltage battery coolant pump (M43). The horizontal coolant connection must point parallel to the electric motor (M5) to the firewall.

18

Unfasten screw/bolts (14) on retaining clamps (15), pull low temperature coolant pump (M431) out of the retaining clamps (15) and place to one side

 Do not separate coolant hoses.

 Installation: Observe installation position of low temperature coolant pump (M43/1) to the upper retaining clamp (15). Align low temperature coolant pump (M43/1) when inserting in the retaining clamps (15).

 Bolt, low temperature coolant pump clamp to transmission carrier

*BA20.10-N-1001-01U

 Bolt, low temperature coolant pump clamp to transmission

*BA20.10-N-1002-01U

19

Remove shift and selector cable bracket (11) and lay to one side with attached shift and selector cable on the RH suspension strut tower

AR26.60-S-0637-01EV

Long-life grease

*BR00.45-Z-1001-06A

20

Disassemble and remove vacuum line (13) on brake booster (12)

21

Remove front axle shafts

AR33.30-S-6530EV

22

Remove electric motor (M5) with transmission (10)

AR08.10-S-0005-02EV



Bond felt strip to mounting plate for removal of electric motor

WF58.50-S-0810-01A


Carefully lift out electric motor (M5) with transmission (10).
The surrounding components, coolant hoses, electrical lines and brake lines can be damaged otherwise.

 Nut, front engine mount to major assembly carrier

*BA22.10-N-1003-01R

 Bolt, engine mount at rear right to engine support at rear right

*BA22.10-N-1004-01R

 Bolt, engine mount at rear left to engine support at rear left

*BA22.10-N-1005-01R

 Bolt, engine support to electric motor bolt M8 x 30 - 10.9

*BA22.10-N-1006-01R

 Bolt, engine support to transmission bolt M8 x 30 - 10.9

*BA22.10-N-1007-01R

 C clamp

*639589016200

 Support plate

*906589016200

23

Remove transmission (10) from electric motor (M5)

When replacing the electric motor (M5).

AR26.10-S-0020EV

24

Remove screw/bolts (19) and take off engine support at rear right (18) on the electric motor (M5)

When replacing the electric motor (M5).

 Installation: Replace screws/bolts (19).

 Bolt, engine support to electric motor bolt M8 x 30 - 10.9

*BA22.10-N-1006-01R

25

Remove screw/bolt (17) and electric motor remove potential compensation cable (16) on electric motor (M5).

When replacing the electric motor (M5).

 Bolt, potential equalization line to electric motor

*BA08.10-N-1001-01A

26

Install in the reverse order

27

Check potential equalization lines

AR54.18-S-0101-02EV

 Prior to initial startup of the high voltage system, a visual inspection of the potential equalization lines and their connections at the remaining high-voltage components must be performed.
Tighten the screws/bolts or nuts of the potential equalization lines if necessary.

 Screw/bolt, potential equalization line to charging mode 1 and 2 control unit

*BA54.21-N-1006-01B

 Screw/bolt, potential equalization line to DC/DC converter control unit

*BA54.21-N-1002-01B

 Screw/bolt, potential equalization line to high-voltage distributor module

*BA54.10-N-1004-03A

 Nut, potential equalization line to battery management system

*BA54.10-N-1002-02A

 Nut, electric motor potential equalization to body

*BA08.10-N-1002-01A

 Bolt, potential equalization line to electric motor

*BA08.10-N-1001-01A

 Electric motor

Number

Designation

Model 639.603/703 with engine 780.994
with code MA0 (E-CELL 60 kW)

BA08.10-N-1001-01A

Bolt, potential equalization line to electric motor

M8

Nm

14

 Electric motor

Number

Designation

Model 639.603/703 with engine 780.994
with code MA0 (E-CELL 60 kW)

BA08.10-N-1002-01A

Nut, electric motor potential equalization to body

M8

Nm

14

 Coolant pump, coolant thermostat

Number

Designation

Engine 780.994 in model 639.603/703
with code MA0 (E-CELL 60 kW)

BA20.10-N-1001-01U

Bolt, low temperature coolant pump clamp to transmission carrier

Nm

20

 Coolant pump, coolant thermostat

Number

Designation

Engine 780.994 in model 639.603/703
with code MA0 (E-CELL 60 kW)

BA20.10-N-1002-01U

Bolt, low temperature coolant pump clamp to transmission

Nm

20

 Engine mounts, engine supports

Number

Designation

Engine 780.994 in model 639.603/703

BA22.10-N-1003-01R

Nut, front engine mount to major assembly carrier

M10

Nm

45

 Engine mounts, engine supports

Number

Designation

Engine 780.994 in model 639.603/703

BA22.10-N-1004-01R

Bolt, engine mount at rear right to engine support at rear right

M101.5100

Nm

120

 Engine mounts, engine supports

Number

Designation

Engine 780.994 in model 639.603/703

BA22.10-N-1005-01R

Bolt, engine mount at rear left to engine support at rear left

M101.5100

Nm

120

 Engine mounts, engine supports

Number

Designation

Engine 780.994 in model 639.603/703

BA22.10-N-1006-01R

Bolt, engine support to electric motor bolt M8 x 30 - 10.9

Stage 1

Nm

20

Stage 2

°

90

 Engine mounts, engine supports

Number

Designation

Engine 780.994 in model 639.603/703

BA22.10-N-1007-01R

Bolt, engine support to transmission bolt M8 x 30 - 10.9

Stage 1

Nm

20

Stage 2

°

90

 High-voltage battery

Number

Designation

Model 639.603/703
with code MA0 (E-CELL 60 kW)

BA54.10-N-1002-02A

Nut, potential equalization line to battery management system

M8

Nm

16

 High-voltage distributor

Number

Designation

Model 639.603/703 with engine 780.994
with code MA0 (E-CELL 60 kW)

BA54.10-N-1004-03A

Screw/bolt, potential equalization line to high-voltage distributor module

M8

Nm

14

 Battery

Number

Designation

Model 636, 639

BA54.10-N-1005-01D

Nut, power supply cable to plug connection box

Nm

10

 DC/DC converter control unit

Number

Designation

Model 639.603/703 with engine 780.994
with code MA0 (E-CELL 60 kW)

BA54.21-N-1002-01B

Screw/bolt, potential equalization line to DC/DC converter control unit

M8

Nm

14

 DC/DC converter control unit

Number

Designation

Model 639.603/703 with engine 780.994
with code MA0 (E-CELL 60 kW)

BA54.21-N-1006-01B

Screw/bolt, potential equalization line to charging mode 1 and 2 control unit

M6

Nm

6

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-06A

Long-life grease

A 000 989 63 51 11