LEMON Manuals: Even more car manuals for everyone
Home >> Mercedes Benz >> 2012 >> S63 >> Repair and Diagnosis >> Electrical >> Body Electrical >> Electrical System, Equipment & Instructions - 221 Chassis - 4 Of 9 >> Retrofitting & Conversion >> Retrofit additional battery - AN54.10-P-0002I

Retrofit additional battery - AN54.10-P-0002I

MODEL 220 customer service solution 

Fig 1: Retrofitting Additional Battery
G10127736Courtesy of MERCEDES-BENZ USA
REMOVING Remove     
DANGER Risk of explosion  caused by escaping oxyhydrogen gas. Risk of injury  caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte (contains diluted sulfuric acid) or metal spatter due to short circuit. Risk of burn injuries  caused by short circuit. Risk of poisoning  caused by swallowing battery electrolyte (contains diluted sulfuric acid) or absorption of lead over the skin or orifices No fire, sparks, open flames or smoking. Wear acid-resistant gloves and clothing and safety glasses with side guards.
Do not place any conductive objects on the battery and avoid any short circuit from battery positive to ground.
Only fill liquid battery electrolyte (diluted sulfuric acid) into suitable and appropriately marked containers.		 AS54.10-Z-0001-01A
NOTES Notes on battery All models AH54.10-P-0001-01A
1 Remove battery NOTES Do not connect a quiescent current retention device.
IMPORTANT Part discontinued.		  
REFER TO TESTING & REPAIR     AR54.10-P-0005I
REFER TO FORMS Dispose of battery All models OS54.10-P-0001-01Z
2 Remove trim in trunk IMPORTANT Trim of trunk floor and right side paneling.  
REFER TO TESTING & REPAIR     AR68.30-P-4600M
3 Remove ground line IMPORTANT Part discontinued.  
4 Remove rear bumper    
REFER TO TESTING & REPAIR     AR88.20-P-2200M
5 Remove inner fender from rear fender IMPORTANT Passenger side.  
DANGER Risk of death  caused by high voltage used for electric welding. Risk of explosion  caused by welding in the area of highly inflammable materials. Risk of injury  caused by welding spatter and UV light while welding. Risk of poisoning  caused by inhaling welding fumes. Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the hazard area. Use air extractor system. AS00.00-Z-0007-01A
6 Prepare retrofit of battery frame   AN54.10-P-0002-01I
    COMMERCIALLY AVAILABLE TOOLS Round wire brush, braided, Ø 70 mm dia.
COMMERCIALLY AVAILABLE TOOLS Jumbotherm K-25-R flat nozzle hot air gun with integrated scraper
COMMERCIALLY AVAILABLE TOOLS Replacement scraper for Jumbotherm K-25-R hot air blower
Inert gas welder
Drill (electric/pneumatic)
Angle grinder (electric/pneumatic)
Wet/dry vacuum cleaner
Tarp (fire-resistant)		  
NOTES Measures for preventing damage to vehicles or components when performing electric welding work All models AH00.00-N-0005-01A
7 Supplement standard underfloor protection with MB permanent underbody sealant    
REFER TO TESTING & REPAIR     AR97.20-P-0500-03A
    SATA-UBE underbody protection spray gun for 1 kg one-way screw-top can Airless unit  
8 Cut out trim in luggage compartment   AN68.30-P-0002-01I
INSTALLING Install     
9 Install trim panel in luggage compartment IMPORTANT Right side paneling.  
REFER TO TESTING & REPAIR     AR68.30-P-4600M
10 Modify battery   AN54.10-P-0002-02I
  Install battery (G1) NOTES Do not connect lines. New part.  
REFER TO TESTING & REPAIR     AR54.10-P-0005I
11 Retrofit circuit breaker   AN54.10-P-0002-03I
TORQUE SPECIFICATION Adapter on positive battery terminal *BA54.10-P-1003-01C 
12 Install additional battery (G1/1) NOTES New part.
IMPORTANT Fix additional battery in place with battery bracket and bolts M8 x 16 on battery frame.		  
13 Connect positive line of additional battery (G1/1)    
14 Connect ground line of additional battery (G1/1)    
15 Install gas line IMPORTANT Cut length of approx. 300mm. Connect additional battery (G1/1) with battery (G1).  
16 Switch on circuit breaker    
17 Affix information plate IMPORTANT Prepare information plate: "Operate circuit breaker when working on the batteries. In case of need always replace both batteries at the same time Only install batteries with the same capacity. Affix information plate in a clearly visible position.  
18 Install trim panel in luggage compartment IMPORTANT Trunk floor trim.
New part.
At the customer request cut out the removed part in the area of the battery frame.		  
REFER TO TESTING & REPAIR     AR68.30-P-4600M
19 Install battery lining IMPORTANT New part.  
20 Install rear bumper    
REFER TO TESTING & REPAIR     AR88.20-P-2200M
21 Install inner fender in rear fender    
22 Carry out normalization    
23 Read out fault memory and erase IMPORTANT STAR Diagnosis tool.  
BATTERY

Number Designation Model 220
BA54.10-P-1003-01C Adapter on positive battery terminal Nm 20
PARTS ORDERING NOTES

Part no. Designation Quantity
HKW 220 820 L 023 Battery frame 1
HKW 078 022 A 008 Battery bracket 1
HKW 220 821 L 004 Bracket for additional parts 1
HKW 220 690 L 000 Battery cover 1
A 220 440 04 30 Positive line (additional battery on 1st battery) 1
A 220 540 00 41 Ground line (additional battery and 1st battery) 2
A 220 540 01 41 Ground line (circuit breaker to body) 1
A 000 541 00 72 Nut (adapter on battery positive pole) 1
A 001 546 09 44 Battery clamp 1
A 000 545 76 08 Circuit breaker 1
N 910 105 006 033 Bolt M6 x 20 3
N 910 105 006 002 Bolt M6 x 12 2
N 910 105 008 041 Screw M8 x 16 2
N 910 143 006 001 Screw M6 x 16 4
N 913 023 006 001 Nut M6 8
A 003 994 17 45 Box nutM6 1
A 005 541 10 01 Absorbent glass mat battery 2
A 002 997 24 86 Plug 1
A 024 997 49 82 Hose (approx. 300 mm) 1
A 000 990 38 72 Distributor fitting 2
HKW 220 680 L 017 Trunk floor paneling 1
scientia non olet · About LEMON Manuals