Remove/install electric motor

AR08.10-P-0010MEV

Remove/install electric motor

26.11.2019

Engine

780.009 in model 451.391/491

2

Transmission

8

Bolts

M5

Electric drive motor

7

Bolts

10

Mount for transmission mounting

15

Check strap (as of 25.09.10 with CODE 494 (USA version))

18

Screw

20

Check strap (as of 25.09.10 with CODE 494 (USA version))

21

Screw

3

Bolts

5

Engine support

9

Bolts

4

Screw

6

Torque support

11

Engine mount

2

Transmission

12

Coolant feed hose

13

Coolant return flow hose

14

Bolts

M5

Electric drive motor

 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

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

Perform enable for the high voltage on-board electrical system

AR54.10-P-1160MEV

2

Disconnect ground line from 12 Volt battery

AR54.10-P-0003MCC

3

Lower and position rear drive module

AR01.00-P-3050MEV

4

Remove control arm

AR35.15-P-0200MCC

 Only loosen left and right upper crossmember from frame-type integral support.

5

Remove external socket of communications control unit

Only if installed.

AR54.10-P-5108MEV

6

Drain coolant of drive electric motor (M5)

AR20.00-P-1143MEV

7

Drain transmission oil

Engine 780.009 in model 451.391/491
except code 494 (US version)

AR26.00-P-0200MCC

Engine 780.009 in model 451.391/491
with code 494 (US version)

AR26.00-P-0200MCU

8

Remove left and right drive shafts

Engine 780.009 in model 451.391/491
except code 494 (US version)

AR35.30-P-0620MCC

Engine 780.009 in model 451.391/491
with code 494 (US version)

AR35.30-P-0620MCU

9

Remove vacuum pump control unit

AR43.05-P-1323MEV

10

Remove coolant pump for electric motor and high voltage charger

AR20.10-P-1274MEV

11

Remove vacuum pump of brake booster

AR43.05-P-1320MEV

12

Remove radiator

AR20.20-P-3865MEV

13

Remove air supply ducting

AR20.20-P-6823MEV

14

Remove high voltage charger control unit

AR54.10-P-5106MEV

15

Remove high-voltage distributor control unit

AR54.10-P-1400MEV

16

Remove A/C compressor

AR83.55-P-5300MEV

 Do not loosen refrigerant line on A/C compressor. Remove screw/bolts of A/C compressor and fix A/C compressor securely in position on electric motor drive (M5) at vehicle rear with cable tie.

17

Remove screw/bolts (7) from bracket of high-voltage distributor control unit and remove bracket of high-voltage distributor

18

Position major assembly-lifting platform under drive electric motor (M5) and transmission (2) and support using a suitable base (arrow A)



000 588 03 62 00 Lifting platform

WS01.00-P-0091A

19

Remove screw/bolts (3) from engine support (5)

 Screw/bolt, carrier for front engine mount to transmission

*BA22.10-P-1012-01M

20

Remove screw/bolt (4) from the torque support (6) and remove torque support (6) with engine support (5)

 Screw/bolt, torque support to integral carrier

*BA22.10-P-1010-01M

21

Remove screw/bolts (8) from bearing of transmission mounting (10) on transmission (2)

 Bolt, left transmission mount to transmission carrier

*BA26.00-P-1001-01E

22

Remove screw/bolt (21) and place check strap (20) to one side

Engine 780.009 in model 451.391/491 as of 9/25/10
with code 494 (US version)

 Screw/bolt, check strap to engine

*BA22.10-P-1015-01M

23

Remove screw/bolts (9) of engine mount (11) on right

 Screw/bolt, right engine support to engine

*BA22.10-P-1014-01M

24

Remove screw (18) and place check strap (15) to one side

Engine 780.009 in model 451.391/491 as of 9/25/10
with code 494 (US version)

 Bolt, left transmission mount to transmission carrier

*BA26.00-P-1001-01E

25

Lower drive electric motor (M5) with transmission (2) carefully from veh.


During lowering and positioning ensure that no electrical lines and hoses get pinched.
This can be damaged otherwise.

 Helper required.

26

Lift vehicle with the vehicle lift until the drive electric motor (M5) with the transmission (2) can be pulled forward under the vehicle

27

Loosen quick-release coupling of coolant feed hose (12) and coolant return hose (13) and remove coolant feed hose (12) and coolant return hose (13)

When replacing the electric motor drive (M5).

28

Remove screw/bolts (14) and remove transmission (2) from electric motor drive (M5)

When replacing the electric motor drive (M5).

 The screw/bolts (14) are of different design. Ensure that two different length Allen screws (at engine end) are screwed in again at the same point.

 Bolt/nut, transmission to engine

*BA26.00-P-1002-01E

29

Install in the reverse order

 Engine mounts, engine supports

Number

Designation

ENGINE 780.009

BA22.10-P-1010-01M

Screw/bolt, torque support to integral carrier

Nm

115

 Engine mounts, engine supports

Number

Designation

ENGINE 780.009

BA22.10-P-1012-01M

Screw/bolt, carrier for front engine mount to transmission

Nm

23

 Engine mounts, engine supports

Number

Designation

ENGINE 780.009

BA22.10-P-1014-01M

Screw/bolt, right engine support to engine

Nm

56

 Engine mounts, engine supports

Number

Designation

ENGINE 780.009

BA22.10-P-1015-01M

Screw/bolt, check strap to engine

Nm

56

 Manual transmission, complete

Number

Designation

Engine 780.009 in model 451.39/49

BA26.00-P-1001-01E

Bolt, left transmission mount to transmission carrier

Nm

80

 Manual transmission, complete

Number

Designation

Engine 780.009 in model 451.39/49

BA26.00-P-1002-01E

Bolt/nut, transmission to engine

Nm

23