Remove/install high-voltage distributor

AR54.10-P-1400GQA

Remove/install high-voltage distributor

02.12.2019

Model

166.063

1

Bolts

4

Rear section of cable duct

6

Elastomer bearing

2

Nut

5

Electrical subharness

7

High-voltage distributor

3

Rear engine cross member

10

Screw

12

Cable duct

13

Screw

11

Cable duct cover

4

Rear section of cable duct

12

Cable duct

7

High-voltage distributor

20

Bolts

 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

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

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-1150GQA

2

Remove right and left side underfloor paneling at the front

AR61.30-P-1001GQ

3

Remove heat shield from high-voltage distributor (7)

4

Disconnect HV connectors for high-voltage PTC heater and electric refrigerant compressor

5

Detach connector for high-voltage on-board electrical system

AR08.00-P-0101-01LFH

 Bolt, high-voltage connector to high-voltage distributor

*BA54.10-P-1001-03E

6

Protect open HV connectors on electrical lines and on high-voltage distributor (7) against moisture

 Set of protective covers

*001589019100

 Set of protective caps

*001589029100

7

Unscrew elastomer bearing (6)

8

Detach drive shaft at arrow (A)

AR41.10-P-0050GQ

9

Unscrew nuts (2) from rear engine crossmember (3) for exhaust system bracket

10

Unscrew bolts(1) of bracket for exhaust system from automatic transmission

11

Remove rear engine cross member(3)

AR22.10-P-1180GQ

12

Lower automatic transmission as far as possible


Pay attention to the oil lines of the automatic transmission.
Otherwise they may be damaged.

13

Unclip electrical subharness from automatic transmission

14

Unclip high-voltage line to electric refrigerant compressor from automatic transmission

15

Unscrew bolt (10) from cable duct cover (11) in top of transmission tunnel


The automatic transmission must be lowered as far as possible.
Otherwise, access to the bolt (10) may not be possible.

 Bolt, hoop guard to transmission

*BA08.10-P-1002-01F

16

Lift cable duct cover (11) slightly and remove towards the rear

17

Unscrew bolts (20) from cable duct (12)

18

Unclip electrical subharness from cable duct (12)

19

Unclip cable duct (12) from automatic transmission upwards (arrows B)

20

Unscrew bolt (13) from 3-phase connector


The automatic transmission must be lowered as far as possible.
Otherwise access to the bolt (13) is not guaranteed.

 The bolt (13) remains on the 3-phase connector.

 Bolt, 3-phase high-voltage line coupling connector to electrical machine housing

*BA08.10-P-1001-01F

21

Pull off cable duct (12) together with 3-phase connector towards the rear

 Installation:
The 3-phase connector must not be damaged, primarily on the metal band.
Otherwise electromagnetic shielding is not guaranteed.

22

Detach high-voltage distributor (7) from power electronics

AR54.10-P-1400-01GQA

23

Secure the high-voltage distributor (7) using suitable means to prevent if from falling


The 3-phase line must not be subjected to tension.
Otherwise it could be damaged.

24

Unclip electrical subharness (5) from rear section of cable duct (4)

25

Unclip high-voltage line of high-voltage PTC heater from rear section of cable duct (4)

26

Unscrew nuts fastening rear section of cable duct (4)

27

Unclip high-voltage line of electric refrigerant compressor from rear section of cable duct (4)

28

Remove high-voltage distributor (7) with 3-phase line and cable duct (12)

29

Protect the 3-phase connector against dirt and moisture

 Set of protective caps

*001589029100

30

Install in the reverse order

 Electric motor

Number

Designation

Model 166
with code ME05 (Hybrid drive 85 kW-94 kW variant (incl. plug-in))

BA08.10-P-1001-01F

Bolt, 3-phase high-voltage line coupling connector to electrical machine housing

Nm

10

 Electric motor

Number

Designation

Model 166
with code ME05 (Hybrid drive 85 kW-94 kW variant (incl. plug-in))

BA08.10-P-1002-01F

Bolt, hoop guard to transmission

Nm

15

 High-voltage distributor

Number

Designation

Model 166
with code ME05 (Hybrid drive 85 kW-94 kW variant (incl. plug-in))

BA54.10-P-1001-03E

Bolt, high-voltage connector to high-voltage distributor

Nm

4