Remove/install retaining frame for high-voltage system components

AR54.21-S-5000EV

Remove/install retaining frame for high-voltage system components

03.12.2019

Model

639.603/703 with engine 780.994

with code MA0 (E-CELL 60 kW)

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

1

Electrical connectors

4

Electrical connector

7

Electrical connector

2

Equipotential bonding line for charging mode control unit

5

Retaining frame for high-voltage system components

N83/2

Charging operation control unit 1 and 2

3

Screw

6

Major assembly carrier

Shown on MODEL 639.6 up to FIN 745075

5

Retaining frame for high-voltage system components

14

Fitting (MODEL 639.6 up to VIN 745075, MODEL 639.7 up to VIN 717332)

22

Charge wiring harness

8

Screw

15

Clamp (MODEL 639.6 up to VIN 745075, MODEL 639.7 up to VIN 717332)

23

High-voltage distributor module carrier plate

9

Equipotential bonding line for charging mode control unit

16

Coolant hose (MODEL 639.6 up to VIN 745075, MODEL 639.7 up to VIN 717332)

24

Water collector

10

Electrical connector

17

Radiator (MODEL 639.6 up to VIN 745075, MODEL 639.7 up to VIN 717332)

N33/9

PTC heater booster

11

Electrical connectors

18

Coolant hose (MODEL 639.6 up to VIN 745075, MODEL 639.7 up to VIN 717332)

N33/9x1

PTC heater booster electrical connector

12

Mounting clip

19

Clamp (MODEL 639.6 up to VIN 745075, MODEL 639.7 up to VIN 717332)

N116

High-voltage distributor module

13

Coolant hose

21

Expansion reservoir

Shown on MODEL 639.6 up to FIN 745075

2

Equipotential bonding line for charging mode control unit

25

Electric line

28

Coolant hose

5

Retaining frame for high-voltage system components

26

Equipotential bonding line for electric motor

N83/2

Charging operation control unit 1 and 2

23

High-voltage distributor module carrier plate

27

Clip

MODEL 639.6 as of VIN 745076, MODEL 639.7 as of VIN 717333

28

Coolant hose

29

Clip

30

Distributor

31

Clip

32

Coolant hose

N83/2

Charging operation control unit 1 and 2

 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

 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

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

 

Remove/install

1

Open engine hood and secure against falling down

2

Carry out disconnection of high-voltage system

AR54.10-S-1160EV

 Installation: Conduct initial startup of the high voltage system only after checking the equipotential bonding lines to the other high-voltage components.

3

Drain coolant of the low-temperature cooling circuit

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

AR20.00-S-1140EV

4

Drain coolant of battery cooling circuit

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

AR20.00-S-1140EW

5

Remove front bumper

AR88.20-S-2000S

6

Remove water shield

AR61.30-S-0010EV

7

Disconnect electrical connector (7) at DC/DC converter control unit

AR54.00-S-0050-01EY

 Cover electrical connections with  protective covers.

 Set of protective caps

*001589009100

8

Remove charging mode control unit (SCCU)

AR54.10-S-5108EV

9

Detach retaining frame for high-voltage system components (5) from major assembly carrier (6)

AR54.21-S-5000-02EV

 Nut, retaining frame to major assembly carrier

*BA54.21-N-1007-01B

10

Release and disconnect electrical connection (4)

 Cover electrical connections with  protective covers.

 Set of protective covers

*001589019100

11

Release and disconnect electrical connectors (1) using suitable screwdriver

 Cover electrical connections with  protective covers.

 Set of protective covers

*001589019100

 Set of protective caps

*001589009100

12

Remove bolt (3) securing equipotential bonding line for charging mode control unit (2)

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

*BA54.21-N-1006-01B

13

Release and disconnect electrical connector (10)

 Cover electrical connections with  protective covers.

 Set of protective covers

*001589019100

14

Release and disconnect electrical connectors (11) using suitable screwdriver

 Cover electrical connections with  protective covers.

 Set of protective caps

*001589009100

 Set of protective covers

*001589019100

15

Unclip retaining clips (12) from coolant hoses (13)

16

Remove bolt (8) securing equipotential bonding line for charging mode control unit (9)

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

*BA54.21-N-1006-01B

17

Release clamp (15) on coolant hose (16)

TYP 639.603 ## bis 745075, 639.703 ## bis 717332 mit MOTOR 780.994
mit CODE MA0 (E-CELL 60 kW)

 Hose clamp pliers

*003589033700

18

Detach coolant hose (16) at fitting (14)

TYP 639.603 ## bis 745075, 639.703 ## bis 717332 mit MOTOR 780.994
mit CODE MA0 (E-CELL 60 kW)

 Seal connections.

19

Loosen clamp (19) on coolant hose (18)

TYP 639.603 ## bis 745075, 639.703 ## bis 717332 mit MOTOR 780.994
mit CODE MA0 (E-CELL 60 kW)

 Hose clamp pliers

*003589033700

20

Detach coolant hose (18) at cooler (17)

TYP 639.603 ## bis 745075, 639.703 ## bis 717332 mit MOTOR 780.994
mit CODE MA0 (E-CELL 60 kW)

 Seal connections.

21

Detach expansion reservoir (21) and place to one side with hydraulic hose still attached

AR46.25-S-1000-02EV

 Do not disconnect hydraulic hose.

22

Disconnect PTC heater booster electrical connector (N33/9x1)

AR54.00-S-0050-01EW

 Cover electrical connections with  protective covers.

 Set of protective covers

*001589019100

23

Detach PTC heater booster (N33/9) from retaining frame for high-voltage system components (5) and tie to one side with coolant hoses still attached

AR83.70-S-8001-01EV

 Bolt, PTC heater booster to retaining frame for high-voltage components

*BA83.70-N-1001-02A

24

Detach charge wiring harness (22) at water collector (24), at retaining frame for high-voltage system components (5) and at high-voltage distributor module carrier plate (23) and guide out of engine compartment

 Installation: Replace cable tie.
Check clamp for fastening of charge wiring harness (22) at water collector (24) for damage, replace if necessary.

25

Remove air/water duct (24)

AR83.25-S-1402S

26

Remove high-voltage distributor module (N116) and set down at left on front module

AR54.10-S-1400-01EV

 Nut, high-voltage distributor module to high-voltage distributor module carrier plate

*BA54.10-N-1001-03A

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

*BA54.10-N-1004-03A

 Set of protective caps

*001589029100

 Set of protective caps

*001589009100

 Unlocking tool

*245589006300

27

Detach electrical lines (25) from retaining frame for high-voltage system components (5)

AR54.21-S-5000-01EV

28

Detach equipotential bonding line for charging mode control unit (2) and equipotential bonding line for electric motor (26) from retaining frame for high-voltage system components (5)

29.1

Loosen clamp (27) on coolant hose (28) and detach coolant hose (28)

TYP 639.603 ## bis 745075, 639.703 ## bis 717332 mit MOTOR 780.994
mit CODE MA0 (E-CELL 60 kW)
When replacing the retaining frame for high-voltage system components (5).

 Hose clamp pliers

*003589033700

29.2

Loosen clamp (29) on coolant hose (28) and detach coolant hose (28) from distributor (30)

TYP 639.603 ## ab 745076, 639.703 ## ab 717333 mit MOTOR 780.994
mit CODE MA0 (E-CELL 60 kW)
When reusing retaining frame for high-voltage system components (5).

 Hose clamp pliers

*003589033700

30

Loosen clamp (31) on coolant hose (32) and detach coolant hose (32) from distributor (arrow A)

TYP 639.603 ## ab 745076, 639.703 ## ab 717332 mit MOTOR 780.994
mit CODE MA0 (E-CELL 60 kW)

 Hose clamp pliers

*003589033700

31

Lift out retaining frame for high-voltage system components (5) with aid of a second person


Do not press retaining frame for high-voltage system components (5) against radiator unit when lifting out.
The radiator unit can otherwise be damaged.

32

Remove high-voltage distributor module carrier plate (23) from retaining frame for high-voltage system components (5)

When replacing the retaining frame for high-voltage system components (5).

 Screw/bolt, high-voltage distributor module carrier plate to retaining frame for high-voltage components

*BA54.10-N-1005-03A

33

Detach charging mode 1 and 2 control unit (N83/2) from retaining frame for high-voltage system components (5) and remove

When replacing the retaining frame for high-voltage system components (5).

 Screw/bolt, charging mode 1 and 2 control unit to retaining frame

*BA54.21-N-1005-01B

34

Install in the reverse order

35

Check potential equalization lines

AR54.18-S-0101-02EV

 Before initial startup of the high-voltage system, a visual inspection of the potential equalization lines and their connections at the high-voltage components must be performed.
If necessary tighten the bolts or nuts of equipotential bonding lines.

 Bolt, potential equalization line to electric motor

*BA08.10-N-1001-01A

 Nut, electric motor potential equalization to body

*BA08.10-N-1002-01A

 Nut, potential equalization line to battery management system

*BA54.10-N-1002-02A

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

*BA54.10-N-1004-03A

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

*BA54.21-N-1002-01B

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

*BA54.21-N-1006-01B

 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

 High-voltage distributor

Number

Designation

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

BA54.10-N-1001-03A

Nut, high-voltage distributor module to high-voltage distributor module carrier plate

M6

Nm

6

 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

 High-voltage distributor

Number

Designation

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

BA54.10-N-1005-03A

Screw/bolt, high-voltage distributor module carrier plate to retaining frame for high-voltage components

M6

Nm

4,5

 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-1005-01B

Screw/bolt, charging mode 1 and 2 control unit to retaining frame

M6

Nm

6

 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

 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-1007-01B

Nut, retaining frame to major assembly carrier

M8

Nm

25

 Heater booster unit

Number

Designation

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

BA83.70-N-1001-02A

Bolt, PTC heater booster to retaining frame for high-voltage components

M5

Nm

6

M6

Nm

9