Remove/install high-voltage distributor

AR54.10-P-1400LFM

Remove/install high-voltage distributor

02.12.2019

Model

222.173

Shown in removed condition

5

Bracket

10

Cable tie

6

Clips

17

Electrical plug connector for 3-phase high voltage line

7

High-voltage line

18

3-phase high-voltage line

8

High-voltage plug

F34/6

High-voltage distributor plate

9

Clips

Shown on removed engine

1

Bolts

2

Heat shield

3

Clips

Shown on removed engine

4

Nut

5

Bracket

6

Clips

7

High-voltage line

8

High-voltage plug

A9/5

Electric refrigerant compressor

Shown on removed engine except code 830 (Additional parts for China vehicles)

7

High-voltage line

9

Clamp

10

Cable tie

Shown on removed engine with code 830 (Additional parts for China vehicles)

7

High-voltage line

11

Bolts

12

Bracket

Shown on removed engine

13

Screw

14

Protective hoop

15

Screw

16

Screw

17

Electrical plug connector for 3-phase high voltage line

18

3-phase high-voltage 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

Move transmission into neutral position and release parking brake

2

Perform disable for the high-voltage on-board electrical system

AR54.10-P-1150LF

3

Secure vehicle on vehicle lift

AR00.60-P-0100CW

4

Remove left charge air pipe

AR09.41-P-8620LFA

5

Remove engine compartment paneling

AR61.20-P-1105LF

 Installation: Install lower engine compartment lining only after conducting the leak test.

6

Remove left catalytic converter

AR49.10-P-5502LF

7

Remove right catalytic converter

AR49.10-P-5503LF

8

Remove screw/bolts (1) and remove heat shield (2)

 Installation: Retract heat shield into clamps (3).

 Screw, high-voltage on-board electrical system electrical line heat shield to engine carrier heat shield

*BA22.10-P-1006-02A

9

Disconnect high-voltage plug (8) from electrical refrigerant compressor (A9/5) and seal off with protective cover

 Set of protective caps

*001589009100

10

Unscrew nut (4) and release bracket (5) from crankcase

 Nut, high voltage line for electrical refrigerant compressor to crankcase

*BA54.10-P-1004-03C

11

Unhook clamps (6) and thread out high voltage line (7) to the rear


Proceed with extreme caution here, in particular, when in the vicinity of sharp-edged component parts.
Do not crush or stretch the high voltage line (7).
Otherwise damage will occur.

12

Remove engine cross member with rear engine mount

AR22.10-P-1180LF

13

Release propeller shaft from transmission and secure on underbody

AR41.10-P-0050LF

14

Carefully lower the transmission


Do not crush or stretch any hoses or lines.
Otherwise damage will occur.

15.1

Cut through cable ties (10) and unhook clamps (9)

Model 222.173
except code 830 (China version)

 Installation: Replace cable ties (10).

15.2

Unscrew bolts (11) and release the brackets (12)

Model 222.173
with code 830 (China version)

16

Thread out high voltage line (7) and let it hang don at right next to the transmission


Proceed with extreme caution here, in particular, when in the vicinity of sharp-edged component parts.
Do not crush or stretch the high voltage line (7).
Otherwise damage will occur.

17

Unscrew bolt (13) and remove protection bar (14)

 Bolt, hoop guard to transmission

*BA08.10-P-1002-01F

18

Remove bolt (15)

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

*BA08.10-P-1003-01F

19

Release bolt (16) and disconnect electrical plug connector for 3-phase high voltage line (17)

 The bolt (16) and the electrical plug connector for the 3-phase high voltage line (17) cannot be separated.

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

*BA08.10-P-1001-01F

20

Seal the electrical plug connector for the 3-phase high voltage line (17) in a protective cover, thread it out and let it hang down at right next to transmission

 Set of protective caps

*001589029100

21

Install engine cross member with rear engine mount and tighten bolts lightly by hand

AR22.10-P-1180LF


Do not crush or stretch any hoses or lines.
Otherwise damage will occur.

22

Release power electronics and remove upwards with high voltage distributor plate (F34/6)

AR08.20-P-0011LF


Proceed with extreme caution here, in particular, when in the vicinity of sharp-edged component parts.
Do not crush or stretch the high voltage line (7) and the 3-phase high voltage line (18).
Otherwise damage will occur.

23

Remove high voltage distributor plate (F34/6) from power electronics

When replacing high voltage distributor plate (F34/6).

AR54.10-P-1400-01LFH

 Bolt, power distributor to power electronics

*BA08.20-P-1004-01E

 Set of protective covers

*001589039100

 Long wedge

*115589035900

24

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

25

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

 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

 Engine support (engine side)

Number

Designation

Engine 276

BA22.10-P-1006-02A

Screw, high-voltage on-board electrical system electrical line heat shield to engine carrier heat shield

Nm

9

 High-voltage distributor

Number

Designation

Model 222

BA54.10-P-1004-03C

Nut, high voltage line for electrical refrigerant compressor to crankcase

Nm

6