Remove/install high-voltage line between high-voltage distributor and PTC heaterbooster

AR54.10-P-1402MEV

Remove/install high-voltage line between high-voltage distributor and PTC heaterbooster

02.12.2019

Model

451.390/392/490/492 with engine 780.993

Model

451.391/491 with engine 780.009

MODEL 451.391/491

1

High-voltage line

R23

High-voltage PTC heater

N116/5

PDU high-voltage distributor control unit

2

Cable grommet

Model 451.390/392/490/492

1

High-voltage line

R23

High-voltage PTC heater

N116/5

PDU high-voltage distributor control unit

2

Cable grommet

 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

Notes on battery

AH54.10-P-0001-01A

 

Remove/install

1

Remove vehicle key and mains plug

2.1

Carry out disconnection of high-voltage system

Model 451.391/491 with engine 780.009

AR54.10-P-1160MEV

2.2

Connect Star Diagnosis and disconnect HV system

Model 451.390/392/490/492 with engine 780.993



AD00.00-P-2000-04MCC

 Print out power disable event log and add to the vehicle file.

 Installation: Activate high-voltage system.

3

Remove floor covering

Model 451.390/392/490/492 with engine 780.993
except code 494 (US version)
Model 451.391/491 with engine 780.009
except code 494 (US version)

AR68.20-P-2040MCC

Model 451.390/392/490/492 with engine 780.993
with code 494 (US version)
Model 451.391/491 with engine 780.009
with code 494 (US version)

AR68.20-P-2040MCU

4

Remove footrest on the passenger-side

MODEL 451.39#/49#1#

AR68.30-P-1340MCC

MODEL 451.39#/49# 2#

AR68.30-P-1340MCE

5

Remove interior flap above engine

AR88.40-P-1100-03MCC

6

Disconnect high-voltage connector of high-voltage line (1) from PDU high-voltage distributor control unit (N116/5)

7

Pull protective covers over high-voltage connector on line side and component side


Protect the high-voltage connector against dirt and moisture.
Consequential damage can occur on the high voltage system otherwise.

 Set of protective caps

*001589009100

8

Create access to high-voltage line (1) as far as rear-end floor

 Replace cable tie.

9

Remove cable grommet (2) from rear-end floor

10

Remove adhesive tape from indicated area (arrow A) and pull high-voltage line (1) inward into vehicle through cable grommet (2)


If damaged, replace cable boot (2).
Otherwise, penetrating humidity could result in damages.

 Installation: Replace adhesive tape in indicated area (arrow A).

11

Create access to high-voltage line (1) along entire length in vehicle

 Replace cable tie.

12

Disconnect high-voltage connector of high-voltage line (1) from high-voltage PTC heater (R23)

13

Pull protective covers over high-voltage connector on line side and component side


Protect the high-voltage connector against dirt and moisture.
Consequential damage can occur on the high voltage system otherwise.

 Set of protective caps

*001589009100

14

Remove high-voltage line (1) from vehicle

15

Install in the reverse order