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Remove/install power electronics with power distributor - AR08.10-P-0011SXH

Engine 272.974 in model 221.095/195 

MODIFICATION NOTES

30.4.15 Check sealing ring and cover of interlock circuit (17) for deformation and damage and replace cover of interlock circuit (17) if necessary (contains an O-ring), added. Operation step 19  
30.4.15 Check sealing ring and cover for 3-phase line (19) for deformation and damage and replace cover for 3-phase line (19) if necessary (contains an O-ring), added. Operation step 21  
Fig 1: Identifying Power Electronics With Power Distributor Remove/Install Components (1 Of 3)
G10126520Courtesy of MERCEDES-BENZ USA
Fig 2: Identifying Power Electronics With Power Distributor Remove/Install Components (2 Of 3)
G10126521Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Power Electronics With Power Distributor Remove/Install Components (3 Of 3)
G10126522DANGERNOTESNOTESIMPORTANTREMOVINGINSTALLINGINSTALLATION NOTESIMPORTANTTORQUE SPECIFICATIONSPECIAL TOOLTORQUE SPECIFICATIONTORQUE SPECIFICATIONINSTALLATION IMPORTANTTORQUE SPECIFICATIONTORQUE SPECIFICATIONINSPECTTORQUE SPECIFICATIONINSPECTTORQUE SPECIFICATIONINSTALLATION IMPORTANTTORQUE SPECIFICATIONTORQUE SPECIFICATIONTORQUE SPECIFICATIONTORQUE SPECIFICATIONTORQUE SPECIFICATIONIMPORTANTINSTALLATION IMPORTANTNOTESNOTESIMPORTANTREFER TO SELF-DIAGNOSTIC SYSTEMSIMPORTANTINSPECTDANGERCourtesy of MERCEDES-BENZ USA
DANGER Risk of death  when touching components on vehicles with high-voltage on-board electrical system Do not touch components and open lines of the high-voltage on-board electrical system. Persons who wear electronic implants (e.g. cardiac pacemakers), must not  carry out any work on high-voltage on-board electrical systems. AS54.00-Z-0001-01A
NOTES Note on high-voltage on-board electrical system   AH54.00-P-0010-01A
NOTES Information on preventing damage to electronic components due to electrostatic discharge   AH54.00-P-0001-01A
IMPORTANT Evaluation of high-voltage components   AH54.00-P-6500-01SXH
REMOVINGINSTALLING Remove/install     
1 Perform enable for the high voltage on-board electrical system   AR54.10-P-1150SXH
2 Remove air filter housing   AR09.10-P-1150SX
3 Remove bracket (2b) for electrical line from high-voltage battery module to power distributor (1) from the bulkhead    
4 Remove screw/bolt (2a), remove high-voltage battery connector (2) from high-voltage battery module and detach INSTALLATION NOTES
Attach connector of electrical line vertically and centered on the high-voltage battery module and carefully screw in screw/bolt (2a).
Always observe tightening torque for screw/bolt (2s).
Damage will occur otherwise to the electrical line and high-voltage battery module.
IMPORTANT Close off connection fitting with protective cover.
Only use new or clean protective covers to cover the electrical connections.
TORQUE SPECIFICATION		  
Wiring harness to high-voltage battery *BA54.10-P-1036-01C 
SPECIAL TOOL Set of protective covers Fig 4
5 Lay electrical line of high-voltage battery module onto transmission    
6 Remove electrical connection for A/C compressor (3) of electrical line on electrical A/C compressor    
7 Remove power distributor (1) from transmission TORQUE SPECIFICATION Bolt, power electronics to intermediate housing *BA08.20-P-1001-01A 
TORQUE SPECIFICATION Bolt, automatic transmission to engine *BA27.40-P-1008-01A 
8 Remove right catalytic converter   AR49.10-P-7100SX
9 Remove screws/bolts (8a) and remove heat shield (8) under the right catalytic converter INSTALLATION IMPORTANT Check retaining clamp (8b) and replace if necessary.
Check that heat shield (8) is seated correctly in the retaining clamp (8b).		  
10 Unclip electrical wiring harness for alternator at heat shield (9)    
11 N129Remove screws/bolts (9a) and remove heat shield (9) between exhaust manifold and power electronics control unit (/1) together with bracket    
12 Drain off coolant   AR20.00-P-1142SX
13 Remove front coolant line (14) from power electronics control unit (N129/1), unclip out of lower bracket (15) on alternator and set aside    
14 Remove screws/bolts (12a) and remove coolant line (13) with fitting from power electronics control unit (N129/1) TORQUE SPECIFICATION Bolt, coolant connection fitting to power electronics *BA08.20-P-1005-01A 
15 Remove coolant line (13) from DC/DC converter    
16 Remove retaining clamp for coolant line (13) from front axle carrier and remove coolant line (13)    
17 Remove screw/bolts (16) and remove cap for interlock circuit (17) from power electronics control unit (N129/1) TORQUE SPECIFICATION Bolt, interlock circuit to cover for the 3-phase line *BA08.20-P-1007-01A 
INSPECT Check     
18 Check sealing ring and cover of interlock circuit (17) for deformation and damage and replace cover of interlock circuit (17) if necessary (contains an O-ring), added    
19 Remove screw/bolts (18) and remove cap for 3-phase line (19) from power electronics control unit (N129/1) TORQUE SPECIFICATION Bolt, cover for 3-phase line to power electronics *BA08.20-P-1008-01A 
INSPECT Check     
20 Check sealing ring and cover for 3-phase line (19) for deformation and damage and replace cover for 3-phase line (19) if necessary (contains an O-ring)    
21 Remove screw/bolts for 3-phase line (20) and disconnect 3-phase line of power electronics control unit (N129/1) on integrated starter alternator TORQUE SPECIFICATION Bolt, 3-phase line for power electronics to starter-alternator *BA08.20-P-1006-01A 
22 Remove ground line (10) from power electronics control unit (N129/1) INSTALLATION IMPORTANT Check ground line (10) for correct seating.  
TORQUE SPECIFICATION Bolt, ground line to power electronics *BA08.20-P-1004-01A 
23 Unclip electrical line of electrical A/C compressor from retaining clamp (4) on crankcase, remove retaining clamp (7) from transmission and lay electrical line on transmission TORQUE SPECIFICATION Bolt, automatic transmission to engine *BA27.40-P-1008-01A 
24 Unscrew nuts (22) for power electronics control unit (N129/1) at bracket TORQUE SPECIFICATION Bolt/nut, power electronics on bracket *BA08.20-P-1002-01A 
25 Unclip retaining clamp (5) on bracket and remove bracket from transmission TORQUE SPECIFICATION Bolt, automatic transmission to engine *BA27.40-P-1008-01A 
26 Remove bracket for the alternator wiring harness at engine support    
27 Remove screw/bolts (21) for power electronics control unit (N129/1) at intermediate housing (23) TORQUE SPECIFICATION Bolt, power electronics to intermediate housing *BA08.20-P-1001-01A 
28 Remove power electronics control unit (N129/1) from the front stud bolt and lay on front axle carrier IMPORTANT Lay the power electronics control unit (N129/1) in such a way that the electrical wiring harness of the power electronics control unit (N129/1) is accessible.  
29 Remove electrical wiring harness of power electronics control unit (N129/1) from oil pan (11) and crankcase INSTALLATION IMPORTANT Check electrical wiring harness to ensure it is in the correct factory installation position.  
30 Guide power electronics control unit (N129/1) to the rear and detach electrical connection (6) from power electronics control unit (N129/1) NOTES To disassemble the electrical connection (6) an assistant must secure the power electronics control unit (N129/1).
This can fall down otherwise and get damaged.		  
31 Remove power electronics control unit (N129/1) with power distributor (1) and electrical line downward and to the rear NOTES The electrical lines must not be removed from the power distributor (1) and power electronics control unit (N129/1).
Non-compliance leads to destruction of the power electronics control unit (N129/1) with power distributor (1).
IMPORTANT In the case of damage to the electrical lines, the power electronics control unit (N129/1) with power distributor (1) must be completely replaced.		  
32 Install in the reverse order    
33 Perform initial startup of power electronics control unit (N129/1) using diagnostic system    
REFER TO SELF-DIAGNOSTIC SYSTEMS     AD00.00-P-2000-04A
    IMPORTANT After completing the work, enclose initial startup log together with the power disable event log with the order folder.  
INSPECT Check     
34 Check engine cooling system for leaktightness   AR20.00-P-1010SX
DANGER 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
35 Carry out an engine test run and check engine for leaktightness and proper operation    
CONTROL UNITS

Number Designation Engine 272.974
BA08.20-P-1001-01A Bolt, power electronics to intermediate housing Nm 20
CONTROL UNITS

Number Designation Engine 272.974
BA08.20-P-1002-01A Bolt/nut, power electronics on bracket Nm 20
CONTROL UNITS

Number Designation Engine 272.974
BA08.20-P-1004-01A Bolt, ground line to power electronics Nm 15
CONTROL UNITS

Number Designation Engine 272.974
BA08.20-P-1005-01A Bolt, coolant connection fitting to power electronics Nm 5
CONTROL UNITS

Number Designation Engine 272.974
BA08.20-P-1006-01A Bolt, 3-phase line for power electronics to starter-alternator Nm 9
CONTROL UNITS

Number Designation Engine 272.974
BA08.20-P-1007-01A Bolt, interlock circuit to cover for the 3-phase line Nm 5
CONTROL UNITS

Number Designation Engine 272.974
BA08.20-P-1008-01A Bolt, cover for 3-phase line to power electronics Nm 9
HOUSING

Number Designation Transmission 722.9
BA27.40-P-1008-01A Bolt, automatic transmission to engine M10X40 Nm 38
M10X45 Nm 38
M10X90 Nm 38
M12 Nm -
BATTERY

Number Designation Model 221
BA54.10-P-1036-01C Wiring harness to high-voltage battery Nm 5
Fig 4: Identifying Set Of Protective Covers (001 589 01 91 00)
G07742161Courtesy of MERCEDES-BENZ USA
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