Remove/install rear-wheel drive module

AR01.00-P-3060MEX

Remove/install rear-wheel drive module

21.11.2019

Engine

780.993 in model 451.390/392/490/492

Modification notes

28.09.2015

Screw/bolt, high-voltage connector to high-voltage battery

Model 451.390/392/490/492 except code 908 (On-board charger 22 kW)

BA54.10-P-1006-01H

28.09.2015

Screw/bolt, high-voltage connector to high-voltage battery

Model 451.390/392/490/492 with code 908 (On-board charger 22 kW)

BA54.10-P-1006-01H

1

Right luggage compartment lining

4

Electrical connector

6

Cable grommet

3

Electrical connector

5

Electrical connectors

X26

Interior/engine connector

7

Rear end CBS

8

Catch hook

9

Nut

10

Ground lines

11

Screw

12

High-voltage connector

13

Quick-connect coupling

14

Vent line

G5

High-voltage battery

W11/5

Engine body ground connection

15

Coolant hose

18

Clamp

21

Clean air distributor

16

Coolant hose

19

Temperature sensor housing

22

Screw

17

Coolant hose

20

Clamp

23

Screw

24

Major assembly lifting platform

25

Shim

 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 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

 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

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

Topical note

Notes on battery

AH54.10-P-0001-01A

 

Remove/install

1

Connect Star Diagnosis and enable high voltage on-board electrical system



AD00.00-P-2000-04MCC

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

 Installation: Put the high-voltage on-board electrical system into operation.

2

Remove right luggage compartment lining (1)

AR68.30-P-4800MEV

3

Remove interior flap above engine

AR88.40-P-1100-03MCC

4

Release and disconnect electrical connections (3, 4 and 5)

5

Unlock and disconnect electrical connection of interior engine (X26)

6

Push out cable boot (6) in the direction engine compartment

7

Pull through wiring harness in the direction engine compartment

8

Remove refrigerant lines on A/C compressor in engine compartment and place to one side

AR83.30-P-7810MEX

 Disconnect refrigerant pressure line at connecting point in engine compartment.

9

Remove lines for charger feed socket in engine compartment and place to one side

AR54.10-P-5109MEX

10

Remove high-voltage distributor electrical line at PTC HB in engine compartment and place to one side

AR54.10-P-1402MEV

11

Remove electric motor charging cable to 12 Volt battery in engine compartment and place to one side

AR54.10-P-5107MEX

12

Remove wire for selector lever lock in engine compartment and place to one side

AR26.60-P-1000MEX

13

Remove fender liner in fender

AR88.10-P-1400MCC

14

Disconnect brake booster vacuum line from vacuum pump

AR43.10-P-0355MEX

15

Raise vehicle with vehicle lift

16

Remove underfloor paneling

 Commercially available devices: cordless drill/driver, cordless drilling machine

17

Secure vehicle on vehicle lift

AR00.60-P-0100MCC

18

Lower vehicle with vehicle lift

19

Unhook CBS rear end (7) at the catch hook (8)

20

Unscrew nut (9) from engine-body ground connection (W11/5) and remove ground lines (10)

21

Raise vehicle with vehicle lift

22

Remove screw/bolt (11) and disconnect high voltage connector (12) from the high-voltage battery (G5)

 Screw/bolt (11) serves as the removal and pulling in device and is integrated in the high-voltage connector.

 Screw/bolt, high-voltage connector to high-voltage battery

*BA54.10-P-1006-01H

23

Pull protective cover over the connector for the high voltage connector (12) on the high-voltage battery (G5)


Protect the connection for the high voltage connector (12) on the high-voltage battery (G5) against dirt and moisture.
Otherwise, consequential damage may occur on the high voltage on-board electrical system.

 Protective cover must be ordered separately.

24

Pull protective cover over high-voltage connector (12)


Protect high-voltage connector (12) against dirt and moisture.
Otherwise, consequential damage may occur on the high voltage on-board electrical system.

 Set of protective caps

*001589029100

25

Disconnect quick-connect coupling (13) and remove vent line (14) from the high-voltage battery (G5)

26

Pull protective cover over the connection for the vent line (14) on the high-voltage battery (G5)


Protect the connection for the vent line (14) on the high-voltage battery (G5) against dirt and moisture.
Otherwise, consequential damage may occur on the high voltage on-board electrical system.

 Protective cover must be ordered separately.

27

Pull protective cover over the quick-connect coupling (13) on the vent line (14)


Protect the vent line (14) against dirt and moisture.
Otherwise, consequential damage may occur on the high voltage on-board electrical system.

 Set of protective caps

*001589029100

28

Remove rear axle rpm sensor

AR42.30-P-0714MCC

 Remove rear axle rpm sensor up to the electrical connection at the rear left.

29

Remove brake hoses on rear axle

AR42.10-P-0023MCC

 Remove brake hoses only on axle tube.

30

Clamp off coolant hoses (16, 17) on the temperature sensor housing (19) with clamps

 Clamp

*000589543700

31

Release clamp (18) with hose clamp pliers and slide towards rear on coolant hose (16)

 Hose clamp pliers

*003589033700

32

Detach coolant hose (16) from the temperature sensor housing (19)

 Collect escaping coolant in a suitable container and seal the temperature sensor housing (19) using suitable stop plugs.

 Installation: Check clamp (18) and coolant hose (16) for damage, replace if necessary.

33

Clamp off coolant hose (15) on clean air distributor (21) with clamp

 Clamp

*000589543700

34

Release clamp (20) with hose clamp pliers and slide towards rear on coolant hose (15)

 Hose clamp pliers

*003589033700

35

Detach coolant hose (15) from clean air distributor (21)

 Collect escaping coolant in a suitable container and seal the clean air distributor (21) using suitable stop plugs.

 Installation: Check clamp (20) and coolant hose (15) for damage, replace if necessary.

36

Position major assembly lifting platform (24) and up to the end stop on the rear ends of the axle tube



000 588 03 62 00 Lifting platform

WS01.00-P-0091A

 The major assembly lifting platform (24) must be positioned in such a way that the screw/bolts (22, 23) remain accessible.

37

Attach a suitable base (25) in the front area of the axle tube

 The base (25) must be selected in such a way that the axle tube fully lies in the front area.

38

Unscrew screws (22, 23)

 Screw/bolt, integral carrier to body

*BA35.10-P-1001-01F

39

Lower rear drive module carefully

AR42.20-P-0570MEX



000 588 03 62 00 Lifting platform

WS01.00-P-0091A


Ensure that no lines and hose are pinched and that sufficient clearance exists to the components remaining in the vehicle.
Damage can occur otherwise to lines, hoses and to components remaining in the vehicle.

 The parking brake must be released completely to release the pull rod of the parking brake.

 Installation: Introduce pull rod for the parking brake in the pilot bushing and press on seal.

 Helper required.

40

Install in the reverse order

41

Bleed cooling system with Star Diagnosis



AD00.00-P-2000-04MCC

AR20.00-P-1142-06MEX

 Filling device

*450589206300

 Pressure pump

*450589072100

42

Check cooling system for leak tightness

AR20.00-P-1010MCC

43

Check function of the parking brake

44

Perform wheel alignment check

Engine 780.993 in model 451.390/392/490/492without recording the vehicle level

AR40.20-P-0200MCC

Engine 780.993 in model 451.390/392/490/492with recording the vehicle level

AR40.20-P-0200MCE

 Depending on the workshop equipment select between the measurement variant with recording the vehicle level or without recording the vehicle level.

 Rear axle carrier

Number

Designation

Model 451.3/4

BA35.10-P-1001-01F

Screw/bolt, integral carrier to body

Nm

125

 Battery

Number

Designation

Model 451.390/392/490/492
except code 908 (On-board charger 22kW)

Model 451.390/392/490/492
with code 908 (On-board charger 22kW)

BA54.10-P-1006-01H

Screw/bolt, high-voltage connector to high-voltage battery

Nm

5,5

5,5