Remove/install electric motor - AR08.10-P-0010MEV

ENGINE 780.009 in MODEL 451.391/491 

Fig 1: Identifying Electric Motor Remove/Install Components (1 Of 5)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Electric Motor Remove/Install Components (2 Of 5)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Electric Motor Remove/Install Components (3 Of 5)

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Fig 4: Identifying Electric Motor Remove/Install Components (4 Of 5)

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Fig 5: Identifying Electric Motor Remove/Install Components (5 Of 5)

Courtesy of MERCEDES-BENZ USA

	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
	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
	Note on high-voltage on-board electrical system		AH54.00-P-0010-01A
	Note on high-voltage battery		AH54.10-P-0006-01MEV
	Evaluation of high-voltage components		AH54.00-P-6500-01SXH
	Remove/install
1	Perform enable for the high voltage on-board electrical system		AR54.10-P-1160MEV
2	Disconnect ground line from 12 Volt battery		AR54.10-P-0003MCC
3	Lower and position rear drive module		AR01.00-P-3050MEV
4	Remove control arm	Only loosen left and right upper crossmember from frame-type integral support.	AR35.15-P-0200MCC
5	Remove external socket of communications control unit	Only if installed.	AR54.10-P-5108MEV
6	Drain coolant of drive electric motor (M5)		AR20.00-P-1143MEV
7	Drain transmission oil	Engine 780.009 in model 451.391/491 except code 494 (US version)	AR26.00-P-0200MCC
		Engine 780.009 in model 451.391/491 with code 494 (US version)	AR26.00-P-0200MCU
8	Remove left and right drive shafts	Engine 780.009 in model 451.391/491 except code 494 (US version)	AR35.30-P-0620MCC
		Engine 780.009 in model 451.391/491 with code 494 (US version)	AR35.30-P-0620MCU
9	Remove vacuum pump control unit		AR43.05-P-1323MEV
10	Remove coolant pump for electric motor and high voltage charger		AR20.10-P-1274MEV
11	Remove vacuum pump of brake booster		AR43.05-P-1320MEV
12	Remove radiator		AR20.20-P-3865MEV
13	Remove air supply ducting		AR20.20-P-6823MEV
14	Remove high voltage charger control unit		AR54.10-P-5106MEV
15	Remove high-voltage distributor control unit		AR54.10-P-1400MEV
16	Remove A/C compressor	Do not loosen refrigerant line on A/C compressor. Remove screw/bolts of A/C compressor and fix A/C compressor securely in position on electric motor drive (M5) at vehicle rear with cable tie.	AR83.55-P-5300MEV
17	Remove screw/bolts (7) from bracket of high-voltage distributor control unit and remove bracket of high-voltage distributor
18	Position major assembly-lifting platform under drive electric motor (M5) and transmission (2) and support using a suitable base (arrow A)
	000 588 03 62 00 Lifting platform		WS01.00-P-0091A
19	Remove screw/bolts (3) from engine support (5)	Screw/bolt, carrier for front engine mount to transmission	*BA22.10-P-1012-01M
20	Remove screw/bolt (4) from the torque support (6) and remove torque support (6) with engine support (5)	Screw/bolt, torque support to integral carrier	*BA22.10-P-1010-01M
21	Remove screw/bolts (8) from bearing of transmission mounting (10) on transmission (2)	Bolt, left transmission mount to transmission carrier	*BA26.00-P-1001-01E
22	Remove screw/bolt (21) and place check strap (20) to one side	Engine 780.009 in model 451.391/491 as of 9/25/10 with code 494 (US version) Screw/bolt, check strap to engine	*BA22.10-P-1015-01M
23	Remove screw/bolts (9) of engine mount (11) on right	Screw/bolt, right engine support to engine	*BA22.10-P-1014-01M
24	Remove screw/bolt (18) and place check strap (15) to one side	Engine 780.009 in model 451.391/491 as of 9/25/10 with code 494 (US version) Bolt, left transmission mount to transmission carrier	*BA26.00-P-1001-01E
25	Lower drive electric motor (M5) with transmission (2) carefully from vehicle.	During lowering and positioning ensure that no electrical lines and hoses get pinched. This can be damaged otherwise. Helper required.
26	Lift vehicle with the vehicle lift until the drive electric motor (M5) with the transmission (2) can be pulled forward under the vehicle
27	Loosen quick-release coupling of coolant feed hose (12) and coolant return hose (13) and remove coolant feed hose (12) and coolant return hose (13)	When replacing the electric motor drive (M5).
28	Remove screw/bolts (14) and remove transmission (2) from electric motor drive (M5)	When replacing the electric motor drive (M5). The screw/bolts (14) are of different design. Ensure that two different length Allen screws (at engine end) are screwed in again at the same point. Bolt, transmission to engine	*BA26.00-P-1002-01E
29	Install in the reverse order

ENGINE MOUNTS, ENGINE SUPPORTS

Number	Designation		ENGINE 780.009
BA22.10-P-1010-01M	Screw/bolt, torque support to integral carrier	Nm	115

ENGINE MOUNTS, ENGINE SUPPORTS

Number	Designation		ENGINE 780.009
BA22.10-P-1012-01M	Screw/bolt, carrier for front engine mount to transmission	Nm	23

ENGINE MOUNTS, ENGINE SUPPORTS

Number	Designation		ENGINE 780.009
BA22.10-P-1014-01M	Screw/bolt, right engine support to engine	Nm	56

ENGINE MOUNTS, ENGINE SUPPORTS

Number	Designation		ENGINE 780.009
BA22.10-P-1015-01M	Screw/bolt, check strap to engine	Nm	56

MANUAL TRANSMISSION COMPLETE

Number	Designation		Engine 780.009
BA26.00-P-1001-01E	Bolt, left transmission mount to transmission carrier	Nm	80

MANUAL TRANSMISSION COMPLETE

Number	Designation		Engine 780.009
BA26.00-P-1002-01E	Bolt, transmission to engine	Nm	23