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

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ENGINE 276.9 in MODEL 212.095/195 

Fig 1: Power Electronics With Power Distributor Remove/Install Components (1 Of 4)
G09974711Courtesy of MERCEDES-BENZ USA
Fig 2: Power Electronics With Power Distributor Remove/Install Components (2 Of 4)
G09974712Courtesy of MERCEDES-BENZ USA
Fig 3: Power Electronics With Power Distributor Remove/Install Components (3 Of 4)
G09974713Courtesy of MERCEDES-BENZ USA
Fig 4: Power Electronics With Power Distributor Remove/Install Components (4 Of 4)
G09974714DANGERDANGERDANGERNOTESNOTESNOTESNOTESREMOVINGINSTALLINGIMPORTANTINSTALLATION IMPORTANTINSTALLATION IMPORTANTNOTESTORQUE SPECIFICATIONTORQUE SPECIFICATIONTORQUE SPECIFICATIONTORQUE SPECIFICATIONIMPORTANTIMPORTANTTORQUE SPECIFICATIONIMPORTANTINSTALLATION IMPORTANTINSTALLATION IMPORTANTTORQUE SPECIFICATIONINSTALLATION NOTESINSTALLATION IMPORTANTTORQUE SPECIFICATIONIMPORTANTINSTALLATION IMPORTANTSPECIAL TOOLSPECIAL TOOLTORQUE SPECIFICATIONNOTESIMPORTANTINSTALLATION IMPORTANTTORQUE SPECIFICATIONNOTESINSTALLATION IMPORTANTSPECIAL TOOLDANGERCourtesy 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
DANGER Risk of injury  to skin and eyes suffering scalding from contact with hot coolant spray. Risk of poisoning  from swallowing coolant. Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.		 AS20.00-Z-0001-01A
DANGER Risk of death  caused by vehicle slipping or toppling off of the lifting platform. Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. AS00.00-Z-0010-01A
NOTES Evaluation of high-voltage components   AH54.00-P-6500-01SXH
NOTES Note on high-voltage battery   AH54.10-P-0006-01MEV
NOTES Note on the -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
REMOVINGINSTALLING Remove/install     
1 Mark drive shaft and remove from transmission IMPORTANT Flexible coupling remains on propeller shaft.
INSTALLATION IMPORTANT Check Hardy coupling for damage, replace as indicated. Install new self-locking nuts.
Restore works side installation position based on the marking.		 AR41.10-P-0050EW
2 Perform enable for the high voltage on-board electrical system INSTALLATION IMPORTANT When replacing the power electronics control unit (N129/1) the interior and engine wiring harness electrical connection (X26) must be contacted before commissioning of the high-voltage on-board electrical system and subsequent commissioning of the power electronics control unit (N129/1) with Star Diagnosis. AR54.10-P-1150EH
3 Remove ground line on on-board electrical system battery   AR54.10-P-0003EW
NOTES Notes on battery   AH54.10-P-0001-01A
4 Remove air filter housing with intake air duct TORQUE SPECIFICATION Bolt, air filter to air intake pipe support brace *BA09.10-P-1002-01M 
TORQUE SPECIFICATION Bolt, air filter to cylinder head cover *BA09.10-P-1001-01M 
5 Unclip coolant expansion reservoir (12) from major assembly partition wall    
6 Remove seal (13) in the area of the high-voltage line (3)    
7 Remove guides (6) for the high-voltage line (3) from suspension strut tower    
8 Remove retaining clamp (14) from bracket for the high-voltage line (3)    
9 Remove bracket (9) for the high-voltage line (4) from electrical A/C compressor (A9/5)    
10 Detach high voltage plug (7) from electrical A/C compressor (A9/5)    
11 Secure vehicle on the vehicle lift   AR00.60-P-0100EWS
12 Remove engine compartment paneling   AR61.20-P-1105EW
13 Remove shield (15)    
14 Remove both bracket (8) for the high-voltage line (4) from the oil pan and high-voltage line (4) TORQUE SPECIFICATION Bolt, bracket for high-voltage electrical line to oil pan *BA54.10-P-1005-02C 
15 Drain coolant   AR20.00-P-1142EL
16 Remove right catalytic converter   AR49.10-P-7100EL
17 Remove heat shield (16)    
18 Remove retaining clamps (17, 18) for 3-phase high-voltage line (5)    
19 Support transmission with transmission platform and transmission jack Transmission platform
Transmission jack		  
20 Remove rear engine crossmember on undercarriage   AR22.10-P-1180CW
21 Lower transmission until the protective hoop (19) is accessible    
22 Remove screw/bolt (20) and remove protective hoop (19) to the rear TORQUE SPECIFICATION Bolt, safety bar to electric machine housing *BA08.10-P-1002-01E 
23 Remove bolt (21) from bracket (10)    
24 Remove screw/bolt (22) and take high voltage plug (11) off high-voltage connection IMPORTANT Handle the high voltage plug carefully; cover if necessary.
The shielding on the high voltage plug (11) can be damaged otherwise.
IMPORTANT The screw/bolt (22) serves as a removal and pulling in aid and is integrated in the high voltage plug (11).		  
TORQUE SPECIFICATION Bolt, connector for 3-phase high-voltage line to electric machine housing *BA08.10-P-1001-01E 
25 Raise transmission up to attachment of the engine crossmember on undercarriage    
26 Attach rear engine crossmember to vehicle frame IMPORTANT Screw in the engine crossmember screw/bolts on the vehicle frame all the way; do not tighten using a torque.  
27 Remove electrical line circuit 30 (24) from power electronics control unit (N129/1) INSTALLATION IMPORTANT Ensure contact surfaces are absolutely clean.
Contact problems and therefore damage to the high-voltage system can occur otherwise.
INSTALLATION IMPORTANT Ensure correct seating of the electrical line circuit 30 (24)		  
TORQUE SPECIFICATION
ENGINE ALL in MODEL 212.0/1		 *BA08.20-P-1003-01D 
28 Release and disconnect electrical connection (25) on power electronics control unit (N129/1)    
29 Remove electrical line potential equalization (26) from power electronics control unit (N129/1) INSTALLATION NOTES Ensure contact surfaces are absolutely clean.
Contact problems and therefore damage to the high-voltage system can occur otherwise.
INSTALLATION IMPORTANT Ensure correct seating of the electrical line potential equalization (26)		  
TORQUE SPECIFICATION
ENGINE ALL in MODEL 212.0/1		 *BA08.20-P-1004-01D 
30 Remove coolant lines from coolant connection (27, 28) IMPORTANT Catch escaping coolant and close off openings.
INSTALLATION IMPORTANT Check clamps and coolant hoses for damage; replace if necessary.
SPECIAL TOOL Hose clamp pliers Fig 7		  
SPECIAL TOOL Record plug Figure
31 Unclip electrical wiring harness (29) from power electronics control unit (N129/1)    
32 Remove screw/bolts (30) TORQUE SPECIFICATION
ENGINE ALL in MODEL 212.0/1		 *BA08.20-P-1001-01D 
33 Remove power electronics control unit (N129/1) with power distributor (2), high-voltage lines (3, 4) and 3-phase high-voltage line (5) upwards NOTES Take note during taking off and insertion of power electronics control unit (N129/1) on the high-voltage lines (3, 4) and the 3-phase high-voltage line (5).
These components can be damaged otherwise.
IMPORTANT Helper required.		  
  When replacing the power distributor (2) or the power electronics control unit (N129/1)     
34 Remove retaining clamp (23) from power electronics control unit (N129/1)    
35 Remove screw/bolts (32, 33, 34) INSTALLATION IMPORTANT Tighten screw/bolts (32, 33, 34) in the reverse sequence of the numbering.  
TORQUE SPECIFICATION
ENGINE ALL in MODEL 212.0/1		 *BA08.20-P-1002-01D 
36 Evenly lift off and take off power distributor (2) using two long wedge (31) NOTES The power distributor (2) must be removed/installed evenly with tilting. Tilting of the power distributor (2) to the power electronics control unit (N129/1) can otherwise lead to damage to the contacting on the power electronics control unit (N129/1).
INSTALLATION IMPORTANT Push the power distributor (2) onto the power electronics control unit (N129/1) carefully and evenly, until the screw/bolts (32, 33, 34) can be placed on. Then use the screw/bolts (32, 33, 34) to pull the power distributor (2) evenly onto the power electronics control unit (N129/1).		  
SPECIAL TOOL Long wedge Figure
37 Install in the reverse order    
38 Check cooling system for leaktightness   AR20.00-P-1010EL
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
39 Carry out an engine test run and check engine for leaktightness and proper operation    
ELECTRIC MOTOR

Number Designation ENGINE 276, 651 in MODEL 212
BA08.10-P-1001-01E Bolt, connector for 3-phase high-voltage line to electric machine housing Nm 10
ELECTRIC MOTOR

Number Designation ENGINE 276, 651 in MODEL 212
BA08.10-P-1002-01E Bolt, safety bar to electric machine housing Nm 15
CONTROL UNITS

Number Designation ENGINE 156, 157, 271, 272, 273, 274, 276, 278, 642, 651 in MODEL 212
BA08.20-P-1001-01D Bolt, power electronics to timing case/major assembly carrier Nm 20
CONTROL UNITS

Number Designation ENGINE 156, 157, 271, 272, 273, 274, 276, 278, 642, 651 in MODEL 212
BA08.20-P-1002-01D Bolt, power distributor to power electronics Nm 5
CONTROL UNITS

Number Designation ENGINE 156, 157, 271, 272, 273, 274, 276, 278, 642, 651 in MODEL 212
BA08.20-P-1003-01D Nut, electrical line circuit 30 to power electronics M8 Nm 14
CONTROL UNITS

Number Designation ENGINE 156, 157, 271, 272, 273, 274, 276, 278, 642, 651 in MODEL 212
BA08.20-P-1004-01D Bolt, electrical line for equipotential bonding to power electronics/major assembly carrier M8 Nm 16
AIR FILTER

Number Designation ENGINE 276.9
BA09.10-P-1001-01M Bolt, air filter to cylinder head cover Nm 9
AIR FILTER

Number Designation ENGINE 276.9
BA09.10-P-1002-01M Bolt, air filter to air intake pipe support brace Nm 9
HIGH-VOLTAGE BATTERY

Number Designation MODEL 212
BA54.10-P-1005-02C Bolt, bracket for high-voltage electrical line to oil pan Nm 11
Fig 5: Identifying Long Wedge (115 589 03 59 00)
G09974715Courtesy of MERCEDES-BENZ USA
Fig 6: Identifying Record Plug (129 589 00 91 00)
G09974716Courtesy of MERCEDES-BENZ USA
Fig 7: Identifying Hose Clamp Pliers (003 589 03 37 00)
G09974717Courtesy of MERCEDES-BENZ USA
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