Remove/install high-voltage distributor

AR54.10-P-1400LF

Remove/install high-voltage distributor

02.12.2019

Model

222.004/057/104/157/163

Shown on engine 276.9

2a

Chafe protection

3a

Screw

28a

Connector for high-voltage on-board electrical system

2b

Bracket

4

Bracket

29

3-phase high-voltage lines

2c

Bracket

4a

Screw

29a

Connector for high-voltage on-board electrical system

2d

Bracket

20

High-voltage distributor

A9/5

Electric refrigerant compressor

3

Cover

28

Electric line

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

 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

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 avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

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

Remove left front cover from engine compartment

Model 222.057/157/163

3

Remove left charge air pipe

Model 222.163 with engine 276.8

AR09.41-P-8620LFA

4

Remove engine compartment paneling

AR61.20-P-1105LF

 Installation: Only install lower engine compartment paneling after leak test.

5

Release and disconnect plug for high-voltage on-board electrical system (28a) on electric refrigerant compressor (A9/5)

6

Pack plug for high-voltage on-board electrical system (28a) into protective cover

 Set of protective caps

*001589009100

7.1

Remove the diesel particulate filter

Model 222.004/104

AR49.10-P-5501OLF

7.2

Remove left and right catalytic converter

Model 222.057/157/163

AR49.10-P-5502LF

8

Support transmission with major assembly mount and remove rear engine crossmember with rear engine mount

Model 222.057/157/163 with engine 276

AR22.10-P-1180LF

Model 222.004/104 with engine 651

AR22.10-P-1180OLF



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B



000 588 10 62 00 Support plate

WS26.00-P-3309B

9

Mark flexible coupling relative to transmission output flange with color and remove bolts

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A



Drift for releasing the fitting sleeves in the flexible couplings

WF58.50-P-4110-01A

AR41.10-P-0040-01LF

 Flexible coupling to transmission or front propeller shaft

*BA41.10-P-1001-01J

10

Carefully lower transmission using major assembly mount


Do not crush or tension electrical line (28) and 3-phase high-voltage lines (29).
Otherwise the high voltage on-board electrical system may be damaged.

11.1

Remove holders (2b, 2c) of electric line (28) and let electric line (28) at left on transmission hang downwards

Model 222.004/104


Proceed with extreme caution when doing so, and avoid damaging the insulation on sharp-edged components.
Otherwise the high voltage on-board electrical system may be damaged.

11.2

Remove holders (2b, 2c, 2d) of electric line (28) and unhook electric line (28) in area of chafe protection (2a) from clamp and let it hang downwards at left on transmission

Model 222.057/157/163


Proceed with extreme caution when doing so, and avoid damaging the insulation on sharp-edged components.
Otherwise the high voltage on-board electrical system may be damaged.

12

Pack electric line (28) into protective cover

 Set of protective caps

*001589009100

13

Remove bolt (3a) and remove cover (3)

 Bolt, hoop guard to transmission

*BA08.10-P-1002-01F

14

Remove bolt (4a) from bracket (4)

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

*BA08.10-P-1003-01F

15

Remove connector for high-voltage on-board electrical system (29a) of 3-phase high-voltage lines (29) from electrical machine and place at right, next to transmission


Cover up the connector for high-voltage on-board electrical system (29a) and handle carefully.
Otherwise the high voltage on-board electrical system may be damaged.

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

*BA08.10-P-1001-01F

16

Pack plug for high-voltage on-board electrical system (29a) into protective cover

 Set of protective caps

*001589029100

17

Raise transmission using major assembly mount



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B



000 588 10 62 00 Support plate

WS26.00-P-3309B

18

Install rear engine crossmember and tighten bolts lightly by hand

Model 222.004/104 with engine 651

AR22.10-P-1180OLF

Model 222.057/157/163 with engine 276

AR22.10-P-1180LF


Do not crush or tension electrical line (28) and 3-phase high-voltage lines (29).
Otherwise the high voltage on-board electrical system may be damaged.

19

Remove power electronics

AR08.20-P-0011LF

20

Remove power electronics with high-voltage distributor (20) and 3-phase high-voltage lines (29) upwards


Proceed with extreme caution when doing so, and avoid damaging the insulation and shielding.
Otherwise the high voltage on-board electrical system may be damaged.

21

Remove high-voltage distributor (20) from power electronics

When replacing high-voltage distributor (20).

Model 222.163

AR54.10-P-1400-01LFH

Model 222.004/057/104/157

AR54.10-P-1400-01LF

 Model 222.004/057/104/157
with code ME04 (Mild hybrid drive)
Model 222.163
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

Install in the reverse order



Check

 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

23

Perform an engine test run and check engine for proper operation and leak tightness

24

Install lower engine compartment paneling

AR61.20-P-1105LF

 Electric motor

Number

Designation

Model 222

BA08.10-P-1001-01F

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

Nm

10

 Electric motor

Number

Designation

Model 222

BA08.10-P-1002-01F

Bolt, hoop guard to transmission

Nm

15

 Electric motor

Number

Designation

Model 222

BA08.10-P-1003-01F

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

Nm

20

 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

 Propeller shaft

Number

Designation

Model 222

BA41.10-P-1001-01J

Flexible coupling to transmission or front propeller shaft

Self-locking nut

Nm

68

Direct threaded connection

Stage 1

Nm

60

Stage 2

°

90