Remove/install high-voltage battery module

AR47.70-D-0001TE

Remove/install high-voltage battery module

08.01.2020

Engine

780.703 in model 910

Shown with code E4T (high-voltage battery (47 kWh))

2

Switchover valve

9

Right carrier

15

High-voltage plug

3

Coolant hoses

10

Left carrier

16

High-voltage plug

4

Coolant hose

11

Bolts

17

Electrical connectors

5

Coolant line

12

Bolts

18

High-voltage lines

6

Coolant hose

13

High-voltage lines

19

High-voltage plug

7

Heater auxiliary circuit

14

High-voltage plug

20

Ground cable

8

Coolant hose

Shown with code E4T (high-voltage battery (47 kWh))

1

High-voltage battery module

21

Bracket

23

Bracket

5

Coolant lines

22

Coolant hose lines

25

Bolts

18

High-voltage lines

Shown with code E4T (high-voltage battery (47 kWh))

1

High-voltage battery module

24

Supports

 Danger

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

 Warning

Risk of injury. Moving parts can pinch, crush or, in extreme cases even sever extremities.

No parts of the body or limbs should be within the operating area of mechanical components when moving components.

AS00.00-Z-0009-01A

 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

 Danger

Risk of fire/risk of explosion due to short circuit and escaping oxyhydrogen gas. Risk of (burn) injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte/mist, short circuit and arcing. Risk of poisoning caused by swallowing battery electrolyte or absorption of lead through the skin or body orifices. Risk of death due to voltage U >= 30 V AC and U >= 60 V DC.

No fires, sparks, open flames, or smoking. Wear acid-resistant gloves, clothing, and glasses. Pour battery acid only into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-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 battery

AH54.10-P-0001-01A



Remove

1

Lift vehicle with lifting platform.

AR00.60-D-1000-04TS

Topical note

Special instructions for lifting and supporting vehicle

AH00.60-N-0100-01TS


Lift vehicle as horizontally as possible.
Otherwise, problems may arise when assembly device is later placed on high-voltage battery module (1).

If necessary,



Adjust support plates of vehicle lift support arms accordingly.

2

Remove underfloor panels.

AR61.30-D-1001TS

3

Remove underfloor panelings from high-voltage battery module (1).

AR61.30-D-1002TE



Check

4

Wear personal protective equipment (arc-resistant jacket, face mask, electrical protective gloves, etc.).



Service Information: Personal protective equipment for working on high-voltage on-board electrical systems

SI54.10-P-0047A

5

Check hazard potential of high-voltage batteries of high-voltage battery module (1).

6

Check housing of high-voltage batteries of high-voltage battery module (1).

AR47.70-S-0002-01F

 Check the non-visible areas after removal of high-voltage battery module (1).

If there is a problem,



Contact the Market Performance Center (MPC) or general representative.

7

Take off personal protective equipment (arc-resistant jacket, face mask, electrical protective gloves, etc.).

8

Drain coolant of the auxiliary circuit.

AR08.50-D-0022TE

 Switchover valve (2) and coolant hoses (3) are already removed in the process.

9

Remove voltage of high-voltage on-board electrical system.

AR47.70-D-1000TE

10

Secure vehicle on vehicle lift.

AR00.60-D-0100-01TS

 Commercially available devices/tools
Tensioning strap

11

Remove protective plate.

AR61.40-D-1005TE

12

Remove coolant hose (4) from coolant line (5).

 Seal connections. Collect escaping coolant. Clamp is secured to coolant hose (4).

 Commercially available devices/tools
Collecting pan

 Set of protective covers

*001589019100

 Hose clamp pliers

*454589003700

13

Remove coolant hose (6) from heater auxiliary circuit (7).

 Seal connections. Collect escaping coolant. Clamp is secured to coolant hose (6).

 Commercially available devices/tools
Collecting pan

 Set of protective covers

*001589019100

 Hose clamp pliers

*454589003700

14

Remove coolant hoses (4, 6) from right carrier (9).

15

Disconnect electrical connector from switchover valve (2).

16

Remove coolant hose (7) with attached switchover valve (2) from right carrier (9).

17

Remove right carrier (9).

 To do this, remove screw/bolts (11).

18

Remove left carrier (10).

 To do so, remove screws/bolts (12).

19

Remove high-voltage lines (13) from bracket of underbody high-voltage power distributor.

20

Release and disconnect high-voltage plugs (14, 15, 16).

21

Remove electrical connectors (17) from bracket of underbody high-voltage power distributor.

 For this purpose, open cable ties.

22

Disconnect electrical connectors (17).

23

Remove high-voltage lines (18) from bracket of underbody high-voltage power distributor.

Engine 780.703 in model 910
with code E4T (High-voltage battery (47 kWh))

24

Release and disconnect high-voltage plug (19).

Engine 780.703 in model 910
with code E4T (High-voltage battery (47 kWh))

25

Cover high-voltage plug (19).

Engine 780.703 in model 910
with code E4T (High-voltage battery (47 kWh))

 Set of protective covers

*001589019100

26

Cover high-voltage connections on underbody high-voltage power distributor and high-voltage plugs (14, 15, 16).

 Set of protective covers

*001589019100

27

Remove coolant lines (5).

 For this purpose, remove nuts.

28

Remove bracket (21) of coolant hose lines (22) from high-voltage battery module (1).

Engine 780.703 in model 910
with code E4T (High-voltage battery (47 kWh))

 To do this, undo screw/bolt.

29

Remove coolant hose lines (22) from 4th high-voltage battery.

Engine 780.703 in model 910
with code E4T (High-voltage battery (47 kWh))

AR08.50-P-0018-01EQ

 Seal connections. Collect escaping coolant.

 Commercially available devices/tools
Collecting pan

 Set of protective caps

*001589009100

30

Remove brackets (23) from high-voltage battery module (1).

 For this purpose, remove nuts.

31

Position mounts (24) on high-voltage battery module (1).


Observe installation position of mounts (24) in relation to direction of travel (arrow).
An incorrect installation position results in damage to mounts (24) and high-voltage battery module (1).

 Choose suitable installation positions for even load distribution.
Mounts (24) are held in place at high-voltage battery module (1) magnetically.

 Set of mounts

*907588003100

32

Position assembly device under high-voltage battery module (1).



001 588 00 54 00 Assembly device

WS54.00-P-0086B

33

Lower vehicle using vehicle lift until mounts (24) rest on assembly device.

 Set of mounts

*907588003100



Check

34

Check positioning of high-voltage battery module (1) on assembly device.

 Depending on the position of the support arms of the vehicle lift used, observe positioning of assembly device.

If high-voltage battery module (1) is not positioned correctly on mounting plates of assembly device,



Lift vehicle, align moveable mounting plates of assembly device and position assembly device beneath high-voltage battery module (1) again.

35

Lower vehicle further until assembly device is completely deflected.


The red markings on assembly device must no longer be visible.
Otherwise, the thread of bolts (25) in the underbody may be damaged as a result of the weight of high-voltage battery module (1).

36

Remove screws (25).

37

Raise vehicle slightly.

 Engine 780.703 in model 910
except code E4T (High-voltage battery (47 kWh))
Ground line (20) must be accessible.

 Engine 780.703 in model 910
with code E4T (High-voltage battery (47 kWh))
Ground line (20) and high-voltage lines (18) above high-voltage battery module (1) must be accessible.

If, during lifting, high-voltage battery module (1) cannot get past support arms of vehicle lift,



Lift vehicle piece by piece and move assembly device as required.

38

Remove high-voltage lines (18) from high-voltage battery module (1).

Engine 780.703 in model 910
with code E4T (High-voltage battery (47 kWh))

39

Remove ground line (20).

 To do so, remove nut.

40

Fully lift vehicle using vehicle lift.

 High-voltage battery module (1) must be freely accessible.

If, during lifting, high-voltage battery module (1) cannot get past support arms of vehicle lift,



Lift vehicle piece by piece and move assembly device as required.



Check

41

Wear personal protective equipment (arc-resistant jacket, face mask, electrical protective gloves, etc.).

42

Check previously non-visible areas of housing of high-voltage batteries of high-voltage battery module (1).

If there is a problem,



Contact the MPC and/or general representative and store high-voltage battery module (1) in the specified container.

43

Take off personal protective equipment (arc-resistant jacket, face mask, electrical protective gloves, etc.).



Install

44

Position assembly device with high-voltage battery module (1) under vehicle.

45

Lower vehicle with vehicle lift.


Lower vehicle carefully.
Otherwise, high-voltage battery module (1) or adjacent component parts may be damaged.

 Aid of a helper required

 Engine 780.703 in model 910
except code E4T (High-voltage battery (47 kWh))
Ground line (20) must be accessible.

 Engine 780.703 in model 910
with code E4T (High-voltage battery (47 kWh))
Ground line (20) and high-voltage lines (18) must be accessible.

If during lowering, high-voltage battery module (1) cannot get past support arms of vehicle lift,



Lower vehicle piece by piece and move assembly device as required.

46

Attach high-voltage lines (18) to high-voltage battery module (1).

Engine 780.703 in model 910
with code E4T (High-voltage battery (47 kWh))

 Check retaining clips for damage.

If damage is present:



Replace damaged retaining clips.

47

Attach ground line (20).

Check ground lines for high-voltage on-board electrical system potential equalization

AR47.70-D-1020-01TE

 Check ground line (20).

 Nut, potential equalization ground line to body

*BA47.70-N-1006-02TE

 Nut, potential equalization ground line to high-voltage battery module

*BA47.70-N-1004-02TE

48

Lower vehicle using vehicle lift until high-voltage battery module (1) is resting on underbody.


Lower vehicle carefully.
Otherwise, high-voltage battery module (1) or adjacent component parts may be damaged.

If during lowering, high-voltage battery module (1) cannot get past support arms of vehicle lift,



Lower vehicle piece by piece and move assembly device as required.



Check

49

Check positioning of high-voltage battery module (1) relative to threads of bolts (25) in underbody.

If high-voltage battery module (1) is not positioned correctly,



Lift vehicle and reposition assembly device with high-voltage battery module (1).

50

Position bolts (25) and screw in slightly by hand.

51

Tighten bolts (25).

 Screw, high-voltage battery module to underbody

*BA47.70-N-1006-01TE

52

Lift vehicle and bring assembly device out of the working area.



001 588 00 54 00 Assembly device

WS54.00-P-0086B

53

Remove mounts (24).

 Set of mounts

*907588003100

54

Remove protective covers and attach coolant hose lines (22) to 4th high-voltage battery.

Engine 780.703 in model 910
with code E4T (High-voltage battery (47 kWh))

AR08.50-P-0018-01EQ

 Set of protective caps

*001589009100

55

Attach bracket (21) of coolant hose lines (22) to high-voltage battery module (1).

Engine 780.703 in model 910
with code E4T (High-voltage battery (47 kWh))

 To do this, screw in screw.

56

Attach brackets (23) to high-voltage battery module (1).

 For this purpose, attach nuts.

 M6

*BA00.10-N-1002-01A

57

Attach coolant lines (5).

 For this purpose, attach nuts.

 M6

*BA00.10-N-1002-01A

58

Remove protective covers from underbody high-voltage power distributor and high-voltage plugs (14, 15, 16).

 Set of protective covers

*001589019100

59

Remove protective covers from high-voltage plug (19).

Engine 780.703 in model 910
with code E4T (High-voltage battery (47 kWh))

 Set of protective covers

*001589019100

60

Install and lock high-voltage plug (19).

Engine 780.703 in model 910
with code E4T (High-voltage battery (47 kWh))

61

Attach high-voltage lines (18) to bracket of underbody high-voltage power distributor.

Engine 780.703 in model 910
with code E4T (High-voltage battery (47 kWh))

 Check retaining clips for damage.

If damage is present:



Replace damaged retaining clips.

62

Connect electrical connectors (17).

63

Attach electrical connectors (17) to bracket of underbody high-voltage power distributor.

 Replace cable tie. Check retaining clips for damage.

If damage is present:



Replace damaged retaining clips.

64

Attach and lock high-voltage plugs (14, 15, 16).

65

Attach high-voltage lines (13) to bracket of underbody high-voltage power distributor.

 Check retaining clips for damage.

If damage is present:



Replace damaged retaining clips.

66

Install left carrier (10).

 To do so, screw in bolts (12).

 Bolt, carrier to high-voltage battery module

*BA47.70-N-1008-01TE

 Bolt, carrier to underbody

*BA47.70-N-1009-01TE

67

Install right carrier (9).

 Screw in screw/bolts (11) to do this.

 Bolt, carrier to high-voltage battery module

*BA47.70-N-1008-01TE

 Bolt, carrier to underbody

*BA47.70-N-1009-01TE

68

Attach coolant hose (7) with attached switchover valve (2) to right carrier (9).

 Check retaining clips for damage.

If damage is present:



Replace damaged retaining clips.

69

Connect electrical connector from switchover valve (2).

70

Attach coolant hoses (4, 6) to right carrier (9).

 Check retaining clips for damage.

If damage is present:



Replace damaged retaining clips.

71

Remove protective covers and attach coolant hose (6) to heater auxiliary circuit (7).

 Set of protective covers

*001589019100

 Hose clamp pliers

*454589003700

72

Remove protective covers and attach coolant hose (4) to coolant line (5).

 Set of protective covers

*001589019100

 Hose clamp pliers

*454589003700

73

Install guard plate.

AR61.40-D-1005TE

74

Remove fuse of the vehicle.

AR00.60-D-0100-01TS

75

Pour in coolant for the auxiliary circuit and bleed auxiliary circuit.

AR08.50-D-0022TE

76

Install underfloor panelings on high-voltage battery module (1).

AR61.30-D-1002TE

77

Install underfloor paneling.

AR61.30-D-1001TS

 Headless screws/bolts: screws/bolts and nuts, coarse-pitch thread

Number

Designation

8.8

10.9

BA00.10-N-1002-01A

M6

Galvanized

Nm

9

13

Phosphated

Nm

9

12

 Headless screws/bolts: screws/bolts and nuts, coarse-pitch thread

Number

Designation

12.9

BA00.10-N-1002-01A

M6

Galvanized

Nm

16

Phosphated

Nm

14

 High-voltage on-board electrical system potential equalization ground lines

Number

Designation

Engine 780.703 in model 910

BA47.70-N-1004-02TE

Nut, potential equalization ground line to high-voltage battery module

Nm

16

 High-voltage battery

Number

Designation

Engine 780.703 in model 910

BA47.70-N-1006-01TE

Screw, high-voltage battery module to underbody

Nm

92

 High-voltage on-board electrical system potential equalization ground lines

Number

Designation

Engine 780.703 in model 910

BA47.70-N-1006-02TE

Nut, potential equalization ground line to body

Nm

16

 High-voltage battery

Number

Designation

Engine 780.703 in model 910

BA47.70-N-1008-01TE

Bolt, carrier to high-voltage battery module

Nm

51

 High-voltage battery

Number

Designation

Engine 780.703 in model 910

BA47.70-N-1009-01TE

Bolt, carrier to underbody

Nm

92