Remove/install heat exchanger of high-voltage battery cooling system in engine compartment

AR08.50-P-0300EQ

Remove/install heat exchanger of high-voltage battery cooling system in engine compartment

03.12.2019

Model

293

2

Nuts

5

High-voltage connection

3

Screw

6

High-voltage connection

4

Bracket

1

Heat exchanger

12

Electrical connector

7

Nut

13

Screw

8

Low pressure pipe

14

Bracket

9

Nut

16

Coolant hose

10

High pressure pipe

17

Coolant hose

11

Electrical connector

 Danger

Risk of fire due to ignition of R1234yf refrigerant on hot components. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with escaped R1234yf refrigerant and when working on pressurized parts. Risk of explosion due to formation of ignitable refrigerant/air mixtures

Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated rooms. Carry out repair work on the air conditioning system circuit only after the system has been evacuated.

AS83.00-Z-0007-01A

 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 poisoning caused by inhaling overheated refrigerant vapors from an air conditioning system containing R134a. Risk of injury to skin and eyes caused by contact with liquid R134a refrigerant and when working on pressurized parts

Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated rooms. Carry out repair work on the air conditioning system circuit only after the system has been evacuated.

AS83.00-Z-0006-01A

 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

Protect air conditioning circuit and components from moisture when carrying out repair work

AH83.30-N-0005-01A

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

Notes on handling refrigerant R1234yf

AH83.30-P-0003-02A

Notes on handling refrigerant R134a

AH83.30-N-0003-01A

 

Remove/install

1

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

AR47.70-P-1000EQ

2

Discharge air conditioning system.

AR83.30-P-1760EQ

3

Remove rear underfloor paneling.

AR61.30-P-1001EQ

4

Remove front crossmember from the high-voltage battery.

AR61.10-P-0001LWR

5

Remove nuts (2).

6

Remove screw (3) and remove bracket (4).

7

Disconnect high-voltage plugs (5, 6) from the high-voltage battery and seal connections with protective covers.

AR47.70-P-0005-01EQ


Ensure utmost care and cleanliness.
Otherwise, damage to the high voltage components may occur.

 Set of protective covers

*001589019100

8

Remove nut (7), remove low-pressure line (8), and seal openings with suitable stop plugs.

 Installation: Replace sealing ring.

 Nut, refrigerant line to heat exchanger of high-voltage battery cooling system

*BA83.30-P-1008-01V

 Record plug

*129589009100

9

Remove nut (9), remove high-pressure line (10), and seal openings with suitable stop plugs.

 Installation: Replace sealing ring.

 Nut, refrigerant line to heat exchanger of high-voltage battery cooling system

*BA83.30-P-1008-01V

 Record plug

*129589009100

10

Disconnect electrical connectors (11, 12).

11

Remove screws (13) and remove heat exchanger (1) from the bracket (14) until the coolant hoses (16, 17) are accessible.

 Screw, heat exchanger to holder

*BA83.30-P-1010-01V

12

Clamp off coolant hoses (16, 17) at a suitable point.

 Clamp

*000589543700

13

Release coolant hoses (16, 17), detach, and seal openings with suitable stop plugs.

AR08.50-P-0018-01EQ

 Catch escaping coolant with a suitable container.

 Record plug

*129589009100

14

Remove heat exchanger (1).

15

Install in the reverse order.



Check

16

Correct coolant level.



AP08.50-P-2053A

17

Perform venting routine with diagnostic device.



AD00.00-P-2000-06FR

18

Check/correct coolant level.



AP08.50-P-2053A

 Air conditioning

Number

Designation

Model 293

BA83.30-P-1008-01V

Nut, refrigerant line to heat exchanger of high-voltage battery cooling system

Nm

12

 Air conditioning

Number

Designation

Model 293

BA83.30-P-1010-01V

Screw, heat exchanger to holder

Nm

8