Remove/install high-voltage distributor

AR54.10-P-1400LW

Remove/install high-voltage distributor

02.12.2019

Model

205.012/047/147/212/247

Modification notes

12.05.2016

Tightening torque - added

Bolt/nut, power distributor to power electronics

AR54.10-P-1400-01LW

12.09.2017

Nut, upper struts to firewall

Model 205

BA62.30-P-1002-02K

Shown on model 205.012

1

Vacuum line

2

Grommet

3

Electric lines

4

Bracket

5

Screw

6

Refrigerant compressor electrical connection

7

Bracket

8

Screw

A9/5

Electric refrigerant compressor

Model 205.047/147/247

23

Interlock switch

25

Fuse cover

26

Screw

Model 205.047/147/247

27

Screw

28

High-voltage plug

Shown on model 205.012

6

Refrigerant compressor electrical connection

16

Screw

10

High-voltage battery module high-voltage plug

17

3-phase high-voltage lines high-voltage plug

11

Reinforcement

18

Screw

12

High-voltage battery module electrical lines

19

Bracket

13

Cover

20

Screw

14

Screw

21

Electrical connector

15

3-phase high-voltage electrical lines

Shown on model 205.012

3

Electric lines

15

3-phase high-voltage electrical lines

6

Refrigerant compressor electrical connection

17

3-phase high-voltage lines high-voltage plug

7

Bracket

19

Bracket

10

High-voltage battery module high-voltage plug

22

High-voltage distributor

12

High-voltage battery module electrical lines

 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 disable for the high-voltage on-board electrical system

AR54.10-P-1150LW

2

Remove the right engine compartment cover

3

Detach lower engine compartment paneling

AR61.20-P-1105LW

4

Remove high-voltage distributor (22) and seal power electronics control unit with a protective cover

AR54.10-P-1400-01LW

 Screw/bolt/nut, power distributor to power electronics

*BA08.20-P-1001-01G

 Nut, upper struts to firewall

*BA62.30-P-1002-02K

 Screw/bolt, upper struts to suspension strut tower mounting bracket

*BA62.30-P-1001-02K

 Cover

*000589029800

 Set of protective covers

*001589039100

5

Remove vacuum line (1)

6

Extend grommet (2) upwards

7

Detach electrical cables (3) from the engine compartment partition wall

8

Remove screw/bolt (5)

Model 205.012/212

9

Disconnect refrigerant compressor electrical connection (6) from A/C compressor (A9/5)

10.1

Remove catalytic converter

Model 205.047/147/247

AR49.10-P-5500LW

10.2

Remove the diesel particulate filter

Model 205.012/212

AR49.10-P-5501LWB

11

Remove bracket (4)

Model 205.012/212

12

remove screw/bolt (8)

13

Unhook bracket (7)

14

Remove left underfloor paneling

AR61.30-P-1001LW

15

Expose refrigerant compressor electrical connection (6) from below


Proceed with extreme caution when doing so, and avoid damaging the insulation on sharp-edged components.
Otherwise the high voltage on-board electrical system may be damaged.

16

Remove reinforcement (11)

 Bolt, rear reinforcement to frame floor assembly

*BA61.10-P-1004-01L

17

Detach high-voltage battery module high-voltage plug (10) from the high voltage plug connection of the high-voltage battery

Model 205.012/212

AR08.00-P-0101-01LFH


Always observe the work instructions and notes listed in the linked description.
Otherwise, there may be damage to high-voltage battery module high-voltage plug (10) and contact problems and consequently damage to the high voltage on-board electrical system.

 Safety screw, lock to high-voltage on-board electrical system high-voltage plug

*BA54.10-P-1006-02F

18

Unscrew bolt (26) of interlock switch (23)

Model 205.047/147/247

19

Open fuse cover (25)

Model 205.047/147/247

20

Remove bolt (27) and disconnect high-voltage connector (28) from electrical lines for high-voltage battery module (12)

Model 205.047/147/247

 Screw/bolt, separating point of electrical line

*BA54.10-P-1021-02F

21

Unscrew bolt from bracket of electrical lines for high-voltage battery module (12) on frame floor assembly

Model 205.047/147/247
with code ME06 (Hybrid drive 60 kW variant (incl. plugin))

 Screw/bolt, bracket for electrical line upstream of separating point to body

*BA54.10-P-1020-02F

22

Unscrew bolt from bracket of electrical lines for high-voltage battery module (12) on transmission

 Model 205.012/047/147/212/247 with transmission 724.2Screw/bolt, bracket for electrical lines to transmission housing

*BA27.10-P-1027-04G

23

Unclip high-voltage battery module electrical lines (12) along the body to the transmission

24

Detach drive shaft flexible coupling from the transmission

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A



Drift for releasing the fitting sleeves in the flexible couplings

WF58.50-P-4110-01A

AR41.10-P-0040-01LW

 Model 205.012/047/147/212/247Flex disk or joint flange at transmission/rear axle differential or propeller shaft

*BA41.10-P-1001-01L

25

Remove engine cross member at rear

AR22.10-P-4360LWB

26

Lower transmission until cover (13) is accessible



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B



000 588 10 62 00 Support plate

WS26.00-P-3309B


Do not crush or tension refrigerant compressor electrical connection (6), high-voltage battery module electrical lines (12) and 3-phase high-voltage electrical lines (15).
Otherwise the high voltage on-board electrical system may be damaged.

27

Remove bolt (14) and remove cover (13)

 Bolt, hoop guard to transmission

*BA08.10-P-1002-01F

28

Remove bolt (18) on bracket (19)

 Bolt, 3-phase high-voltage line to electrical machine housing

*BA08.10-P-1003-01F

29

Unscrew bolt (16) from 3-phase high-voltage lines high-voltage plug (17)

 Bolt, 3-phase high-voltage line coupling connector to electrical machine housing

*BA08.10-P-1001-01F

30

Remove 3-phase high-voltage lines high-voltage plug (17) and allow it and 3-phase high-voltage electrical lines (15) to hang down to the right of the transmission


Cover 3-phase high-voltage lines high-voltage plug (17) and handle carefully.
Otherwise the high voltage on-board electrical system may be damaged.

31

Remove screw (20)

32

Allow high-voltage battery module electrical lines (12) and refrigerant compressor electrical connection (6) to hang down to the right of the transmission

33

Raise transmission



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B



000 588 10 62 00 Support plate

WS26.00-P-3309B


Do not crush or tension refrigerant compressor electrical connection (6), high-voltage battery module electrical lines (12) and 3-phase high-voltage electrical lines (15).
Otherwise the high voltage on-board electrical system may be damaged.

34

Install engine cross member at rear

AR22.10-P-4360LWB

35

Detach heat shield from over electrical connector (21) on transmission

 Model 205.012/047/147/212/247 with transmission 724.2Bolt, heat shield to sprag

*BA27.10-P-1013-04G

36

Separate electric plug connection (21) at transmission

37

Remove high-voltage distributor (22), electrical line for A/C compressor (6), electrical lines for high-voltage battery module (12) and electrical lines for 3-phase high voltage (15) upwards through the engine compartment


Proceed with extreme caution when doing so, and avoid damaging the insulation and shielding.
Otherwise the high voltage on-board electrical system may be damaged.

38

Install in the reverse order



Check

 Warning

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

39

Carry out an engine test run

 Electric motor

Number

Designation

Model 205
with code ME05 (Hybrid drive 85 kW-94 kW variant (incl. plug-in))

Model 205.0/2
with code ME04 (Mild hybrid drive)

BA08.10-P-1001-01F

Bolt, 3-phase high-voltage line coupling connector to electrical machine housing

Nm

10

10

 Electric motor

Number

Designation

Model 205
with code ME06 (Hybrid drive 60 kW variant (incl. plugin))

BA08.10-P-1001-01F

Bolt, 3-phase high-voltage line coupling connector to electrical machine housing

Nm

10

 Electric motor

Number

Designation

Model 205
with code ME05 (Hybrid drive 85 kW-94 kW variant (incl. plug-in))

Model 205.0/2
with code ME04 (Mild hybrid drive)

BA08.10-P-1002-01F

Bolt, hoop guard to transmission

Nm

9

15

 Electric motor

Number

Designation

Model 205
with code ME06 (Hybrid drive 60 kW variant (incl. plugin))

BA08.10-P-1002-01F

Bolt, hoop guard to transmission

Nm

15

 Electric motor

Number

Designation

Model 205
with code ME05 (Hybrid drive 85 kW-94 kW variant (incl. plug-in))

Model 205.0/2
with code ME04 (Mild hybrid drive)

BA08.10-P-1003-01F

Bolt, 3-phase high-voltage line to electrical machine housing

Nm

-

16

 Electric motor

Number

Designation

Model 205
with code ME06 (Hybrid drive 60 kW variant (incl. plugin))

BA08.10-P-1003-01F

Bolt, 3-phase high-voltage line to electrical machine housing

Nm

16

 Control units

Number

Designation

Model 205.0/2
with code ME04 (Mild hybrid drive)

Model 205.0/2
with code ME05 (Hybrid drive 85 kW-94 kW variant (incl. plug-in))

BA08.20-P-1001-01G

Screw/bolt/nut, power distributor to power electronics

M5

Nm

6

-

M8

Nm

6

-

 Control units

Number

Designation

Model 205.0/1/2
with code ME06 (Hybrid drive 60 kW variant (incl. plugin))

BA08.20-P-1001-01G

Screw/bolt/nut, power distributor to power electronics

M5

Nm

6

M8

Nm

6

 Automatic transmission complete

Number

Designation

Transmission 724.2

BA27.10-P-1013-04G

Bolt, heat shield to sprag

Nm

9

 Automatic transmission complete

Number

Designation

Transmission 724.2

BA27.10-P-1027-04G

Screw/bolt, bracket for electrical lines to transmission housing

M8

Nm

20

 Propeller shaft

Number

Designation

Model 205

BA41.10-P-1001-01L

Flex disk or joint flange at transmission/rear axle differential or propeller shaft

Self-locking nut

Nm

68

Direct threaded connection

Stage 1

Nm

60

Stage 2

°

90

 High-voltage battery

Number

Designation

Model 205.012/212

BA54.10-P-1006-02F

Safety screw, lock to high-voltage on-board electrical system high-voltage plug

Nm

4

 High-voltage battery

Number

Designation

Model 205.047/147/247

BA54.10-P-1020-02F

Screw/bolt, bracket for electrical line upstream of separating point to body

M8

Nm

20

 High-voltage battery

Number

Designation

Model 205.047/147/247

BA54.10-P-1021-02F

Screw/bolt, separating point of electrical line

M5

Nm

6

 Frame floor assembly

Number

Designation

Model 205

BA61.10-P-1004-01L

Bolt, rear reinforcement to frame floor assembly

Nm

23

 Frond end with front reinforcement

Number

Designation

Model 205

BA62.30-P-1001-02K

Screw/bolt, upper struts to suspension strut tower mounting bracket

Stage 1

Nm

50

Stage 2

Nm

-

Stage 3

Loosen

°

-

Stage 4

Nm

-

 Frond end with front reinforcement

Number

Designation

Model 205

BA62.30-P-1002-02K

Nut, upper struts to firewall

Nm

35