Remove/Install Pyrofuse Electrical Connector - AR54.15-P-1100LF

Model 222

MODIFICATION NOTES

25.09.2017	Operation step validity changed.	Operation steps 1, 3, 15 and 17.
25.09.2017	Operation steps added.	Operation steps 5 and 14.
25.09.2017	Repair materials added.	Operation step 10.

Shown On Model 222 With Code ME04 (Mild hybrid drive)

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

Shown On Model 222 With Code ME04 (Mild hybrid drive)

Courtesy of MERCEDES-BENZ USA

	Risk of injury. Moving parts can pinch, crush or, in extreme cases even sever extremities.	No parts of the body or limbs should be within the operating area of mechanical components when moving components.	AS00.00-Z-0009-01A
	Risk of explosion from explosive gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury through burns to skin and eyes from battery acid or when handling damaged lead-acid batteries	No fires, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and glasses. Only pour battery acid into suitable and appropriately marked containers.	AS54.10-Z-0001-01A
Topical note	Notes on battery		AH54.10-P-0001-01A
	Notes on HANDS-FREE ACCESS		AH80.61-P-0001-01A
	Remove
1	Remove partition trim (7)	Model 222 (except 222.077/176/177/178/179/187/188) with engine 176 except code 811 (Advanced sound system) except code B01 (48V technology) except code ME04 (Mild hybrid drive) Model 222 (except 222.077/176/177/178/179/187/188) with code B01 (48V technology) Model 222 (except 222.077/176/177/178/179/187/188) with code ME04 (Mild hybrid drive) Model 222.077/177/178/179/187/188 Model 222.176 except code Z07 (Top protection)	AR68.30-P-4600LF
2	Disconnect ground line (9) from the on-board electrical system battery (G1)		AR54.10-P-0003LF
3	Detach positive terminal cover (10) from on-board electrical system battery (G1)
4	Using a diode test lamp, check on-board electrical system for voltage between positive line of on-board electrical system battery (G1) and disconnected ground line (9)	If the diode test lamp lights up, the on-board electrical system is still active because of a defect in the electrical system. ↓ Disconnect ground line of ECO start/stop function additional battery. Model 222 (except 222.077/176/177/178/179/187/188/980), 222.173 except code B01 (48V technology) except code Z07 (Top protection)	AR54.10-P-0007LF
		Model 222 with code Z07 (Top protection)	AR54.10-P-0007LFS
		Cover the positive line. There is a risk of short circuit otherwise. After completing the required operations, repair the electrical system.
5	Release locking pin (1) or (11)
6.1	Detach pyrofuse plug (2) from pyrotechnical separator (K88)	Model 222 except code ME04 (Mild hybrid drive)
6.2	Detach high-voltage pyrofuse plug (12) from high-voltage pyrofuse	Model 222 with code ME04 (Mild hybrid drive) The high-voltage pyrofuse is on the underside of the rear pre-fuse box (F33).
7	Create access to wiring harness of pyrofuse plug (2) or high-voltage pyrofuse plug (12)
8	Remove insulation (3) from wiring harness of pyrofuse plug (2) or high-voltage pyrofuse plug (12) to behind the damaged area and cut off wiring harness
	Install
	Risk of injury caused by burns to skin and eyes, risk of poisoning caused by inhaling fumes during soldering.	Wear protective gloves, protective clothing and safety glasses. Ensure that the work area is adequately ventilated. Secure power supply cables. Avoid sources of fire in working area.	AS00.19-Z-0002-01A
9	Cut repair wiring harness (4) to same size as old part and connect to wiring harness of pyrofuse plug (2) or high-voltage pyrofuse plug (12) using end sleeve (5)		AR00.19-P-0100-09A
Topical note	Notes on soldering		AH00.19-P-1000-10A
	Notes on soft soldering		AH00.19-P-1000-07A
	000 588 00 84 00 Heat gun	Observe color coding of cables of repair wiring harness (4) and wiring harness of pyrofuse plug (2) or high-voltage pyrofuse plug (12).	WS54.00-P-0049B
		Wiring harness repair kit, basic	Fig 4
		Welding bead catcher	Fig 1
		Wire stripper	Fig 5
		Reflector	Fig 6
		Adapter	Fig 3
		New passenger car wiring harness repair kit	Fig 2
10	Wrap fabric tape around repair area (6)		AR00.19-P-0100-08A
		Adhesive fabric tape	*BR00.45-Z-1062-02A
11.1	Route electrical wiring harness of pyrofuse plug (2) to on-board electrical system battery (G1)	Model 222 except code ME04 (Mild hybrid drive) Ensure that the pyrofuse plug (2) wiring harness is routed correctly. Otherwise the wiring harness of the pyrofuse plug (2) can be damaged by chafing or crushing.
11.2	Route electrical wiring harness of high-voltage pyrofuse plug (12) to rear pre-fuse box (F33)	Model 222 with code ME04 (Mild hybrid drive) Make sure that the wiring harness of the high-voltage pyrofuse connector (12) is routed correctly. Otherwise the wiring harness of the high-voltage pyrofuse plug (12) can be damaged by chafing or crushing.
12	Fix electrical wiring harness of pyrofuse plug (2) or high-voltage pyrofuse plug (12) in place along wiring harnesses on vehicle using cable ties
13.1	Connect pyrofuse plug (2) at pyrotechnical separator (K88)	Model 222 except code ME04 (Mild hybrid drive)
13.2	Connect high-voltage pyrofuse plug (12) at pyrotechnical separator (K88)	Model 222 with code ME04 (Mild hybrid drive)
14	Lock locking pin (1) or (11)
15	Attach positive terminal cover (10) to on-board electrical system battery (G1)
16	Connect ground line (9) to on-board electrical system battery (G1)		AR54.10-P-0003LF
17	Install partition trim (7)	Model 222 (except 222.077/176/177/178/179/187/188) with engine 176 except code 811 (Advanced sound system) except code B01 (48V technology) except code ME04 (Mild hybrid drive) Model 222 (except 222.077/176/177/178/179/187/188) with code B01 (48V technology) Model 222 (except 222.077/176/177/178/179/187/188) with code ME04 (Mild hybrid drive) Model 222.077/177/178/179/187/188 Model 222.176 except code Z07 (Top protection)	AR68.30-P-4600LF