Remove/install high-voltage power distributor in engine compartment

AR47.70-D-0003TE

Remove/install high-voltage power distributor in engine compartment

28.11.2019

Engine

780.703 in model 910

Modification notes

12.07.2019

Work procedure updated

Whole document.

28.08.2019

Basic data added

Operation step 4

28.11.2019

Work procedure and image displays revised

The whole document

1

High-voltage power distributor

2

High-voltage lines

3

Bracket

4

High-voltage connection

5

High-voltage connection

6

High-voltage connection

7

High-voltage connection

8

Electrical connector

9

Electrical connector

10

Electrical line

11

Screw

12

Jump-start connection point

13

Vacuum line

14

Electrical line

1

High-voltage power distributor

18

High-voltage connection

21

Electrical connector

15

High-voltage lines

19

Bracket

22

Ground cable

16

High-voltage connection

20

High-voltage connection

23

Nuts

17

High-voltage connection

 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

 

Remove/install

1

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

AR47.70-D-1000TE

2

Detach ground line of on-board electrical system battery.

AR54.10-D-0029TS

3

Remove high-voltage lines (2) from bracket (3).

 Installation: Check retaining clips for damage.

 Clip remover

*452589016300

If damage exists,



Replace damaged retaining clips.

4

Release and disconnect the high-voltage plug(4).

5

Release and disconnect high-voltage plug (5).

6

Disconnect high-voltage plug (6).

AR47.70-S-0005-01F

 Safety screw, locking element to DC current charge-connection unit high-voltage plug

*BA47.70-N-1005-07TE

7

Release and disconnect high-voltage plug (7).

 WIS Service Media
wsm://04_ 201800_30

8

Disconnect electrical connectors (8, 9).

9

Remove electric line (10) at DC current charge-connection unit and place to one side.

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

AR47.70-D-1020-01TE

 Installation: Check electric line (10).

 Screw, potential equalization ground line/protective ground conductor to DC current charge-connection unit

*BA47.70-N-1009-02TE

10

Cover high-voltage connections with suitable protective covers.

 Set of protective covers

*001589019100

11

Remove screw (11).

 Bolt, refrigerant line to bracket

*BA83.30-N-1003-01TS

12

Remove jump-start connection point (12) at bracket (3).

 Release and remove jump-start connection point (12) for this purpose.

13

Remove vacuum line (13) from bracket (3).

AR43.10-D-0355TE

 Vacuum line (13) remains on vacuum pump and brake booster.

14

Remove electric line (14) from bracket (3).

 Installation: Check retaining clips for damage.

 Clip remover

*452589016300

If damage exists,



Replace retaining clip.

15

Remove the bracket (3).

 Screw, strain-relief clamp bracket to DC current charge-connection unit

*BA47.70-N-1003-07TE

16

Remove high-voltage lines (15) from bracket (19).

 Installation: Check retaining clips for damage.

 Clip remover

*452589016300

If damage exists,



Replace damaged retaining clips.

17

Release and disconnect high-voltage plug (16).

 WIS Service Media
wsm://04_ 201800_30

18

Release and disconnect high-voltage plug (17).

 WIS Service Media
wsm://04_ 201800_30

19

Release and disconnect high-voltage plug (18).

 WIS Service Media
wsm://04_ 201800_30

20

Remove bracket (19) from high-voltage power distributor (1).

 To do this, unscrew screws.

 Bolt, holder to high-voltage power distributor/holder

*BA47.70-N-1006-03TE

21

Remove high-voltage plug (20) from high-voltage power distributor (1).

AR47.70-S-0005-01F

 Safety screw, locking element to high-voltage power distributor high-voltage plug

*BA47.70-N-1001-03TE

22

Cover high-voltage connections with suitable protective covers.

 Set of protective covers

*001589019100

23

Disconnect electrical connector (21).

24

Remove ground line (22) from high-voltage power distributor (1).

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

AR47.70-D-1020-01TE

 Installation: Check ground line (22).

 Screw, potential equalization ground line to high-voltage power distributor in engine compartment

*BA47.70-N-1001-02TE

 Nut, potential equalization ground line to high-voltage components holder in engine compartment

*BA47.70-N-1008-02TE

25

Remove bracket (19).

 Remove the remaining high-voltage lines on bracket (19) for this purpose.

 Installation: Check retaining clips for damage.

 Clip remover

*452589016300

If damage exists,



Replace damaged retaining clips.

26

Remove nuts (23).

 Nut, high-voltage power distributor in engine compartment to supporting frame

*BA47.70-N-1002-03TE

27

Remove high-voltage power distributor (1).


Carefully remove and insert high-voltage power distributor (1).
High-voltage power distributor (1) and/or adjacent component parts can otherwise be damaged.

28

Install in the reverse order.

29

Perform commissioning of high-voltage power distributor (1) with vehicle diagnosis system.

If high-voltage power distributor (1) will be replaced.



Connect/disconnect diagnostic unit

AD00.00-D-2000-06TS

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

Number

Designation

Engine 780.703 in model 910

BA47.70-N-1001-02TE

Screw, potential equalization ground line to high-voltage power distributor in engine compartment

Nm

16

 High-voltage power distributor

Number

Designation

Engine 780.703 in model 910

BA47.70-N-1001-03TE

Safety screw, locking element to high-voltage power distributor high-voltage plug

Nm

4

 High-voltage power distributor

Number

Designation

Engine 780.703 in model 910

BA47.70-N-1002-03TE

Nut, high-voltage power distributor in engine compartment to supporting frame

Nm

20

 Direct current charge connection unit

Number

Designation

Engine 780.703 in model 910

BA47.70-N-1003-07TE

Screw, strain-relief clamp bracket to DC current charge-connection unit

Nm

8

 Direct current charge connection unit

Number

Designation

Engine 780.703 in model 910

BA47.70-N-1005-07TE

Safety screw, locking element to DC current charge-connection unit high-voltage plug

Nm

4

 High-voltage power distributor

Number

Designation

Engine 780.703 in model 910

BA47.70-N-1006-03TE

Bolt, holder to high-voltage power distributor/holder

Nm

8

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

Number

Designation

Engine 780.703 in model 910

BA47.70-N-1008-02TE

Nut, potential equalization ground line to high-voltage components holder in engine compartment

Nm

16

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

Number

Designation

Engine 780.703 in model 910

BA47.70-N-1009-02TE

Screw, potential equalization ground line/protective ground conductor to DC current charge-connection unit

Nm

7

 Air conditioning

Number

Designation

Model 910 with engine 780.703

BA83.30-N-1003-01TS

Bolt, refrigerant line to bracket

Nm

6