6125010 Removing and installing high-voltage battery unit Overview of Activities Additional Information Prel ary Work 1. Remove flap in luggage compartment trim panel on. 2. Disconnect high-voltage system from power 3. Check that no voltage is applied 4 Remove underbody paneling 5. Remove expansion valve 6 Disconnecting the high-votage line 7 Removing the luggage compartment wel seal {8 Removing the luggage compartment floor tim pane! 9 Removing oddnents tray 40 Removing the loading edge tim 41 Romove storage tray 42 Remove luggage compartment wheel arch tim panel on let 43 Removing the letthand support 14 Removing ight luggage compartment wheel arch trim panel 48 Removing oddments tray forthe Mobiliy Sat 46 Removing ight support 17 Disconnectng signal connector 418 Loosening the high-voltage battery unt screw connection 419 Loosening the equipotential bonding screw Main Work 20 Remove high-vollage batery unit 21 Install high-votage battery unt Postprocesses 22 Tightening high-volage battery unit screw connection 23 Tightening equipotential bonding screw 24 Connecting signal connectors 25 nsaling the lett support 26 Install luggage compartment wheel arch trim panel at eft 27 stall the oddments tray forthe Mobilty SetInstaling right support Instalng the luggage compartment whee! arch trim panel onthe right Instaling storage tray Instaling loading edge trim Instaling oddments tray Instaling the luggage compartment floor trim panel 28 2 30 am 32 3 34 lnstaling gasket for luggage compartment well 35. Install high-voltage battery unit 36 Install expansion valve 37 Instaling the underbody paneling 38 Activate high-voltage system ‘39, Install the fap in the right luggage compartment trim panel 40 Fin the eoetoing a General information Pcs ZAZA) sorte tm ‘The high-voltage system operates on the basis of hazardous, electrical voltage and high currents Danger to life through electric shock! ‘+All wok onthe highseltage system may orly be cared out by specially trained and techrcally experienced personnel, ‘+ For addtional information see: 61 00. Safety information on handing hybrid vehicles | | + For atonal information see: 625. Repair information fr ighaeltage betty unit PRELIMINARY WORK ‘4-Remove flap in luggage compartment trim panel on right + Carflly remove the tap (1) rom the sce tim pan R51 01899 2-Disconnect high-voltage system from power Prerequisite ‘The battery chargers are cisconnected. “Tailgate is open. Ignition is switched oftVehicle has gone to sloop (rest stato) FReoe keno) ‘The high-ltage safety dsconnect cannat be fuly disconnected, + Pl out the unlocking mechanism (1) (Once the unlocking mechanism has bean puled out it is possible to dsconnect the highvoltage ‘senice disconnect (2) until the bore hole on the connector becomes accessible, ‘The labeling OFF is sible onthe highcltage senice disconnect + Inset the shackle lock (1) into the exposed bore hole (2) onthe igh-ltage senice disconnect @anclock it + Store the shackle lock key in a safe place. 3-Check that no voltage is applied Prerequisite A DANGER Danger to life in the high-voltage system. "Danger tof tthe disconnection from power cannot be verted! 1 + Moko sure tat the Chock Canto] mostago "Hah ltgesyslamdeacato is depaya in th instant ctr bulo commencing Wark + Lock he hcl and tock it wih Mghretage bari tape ithe scomocon fom paw: caro be cleat vere {Carta Tecvica! Supp in al cases whee the dscornecton fom power srk ley ered | + Acotiad quite eactcion 1000 V DC must ny the dscomecon fam paver wth measur doves / meas pocades. Ct FRoe enc) \With the ignition off and the highswotage senice disconnect isconnacted, the Check Control massage "High voltage system faulty” is esplayed by default, Chock + Switch onthe ignition and chock the dscomection fom power inthe instrument cluster (Kou. desired stato‘+The Check Control message "Hgtroltage system deactheted” must be displayed. Result > Ifthe disconnection from power cannot be clearly verifed in the KOMBI, commencement of work is prohibited. Danger tolifet Measure + Before work begins, a qualfed,cetifed electrician ust vey tat the system has been sdscomected fom the power supply 1000 V DC using appropriate measuring devices and ‘measuring procedures. “The 12.V battery may not be disconnected unil the "Highroltage system deactivated” Check \Cortrol message is displayed inthe instnenert cluster (KOM). Ifthe disconnection from power cannot be verified with certainty, contact Technical ‘Support Furthermore, the vehicle must be made inaccessible and blocked off with high-voltage barrier tape. ‘4-Remove underbody panelling + Loosen screws on underbody paneling R51 02139 '5-Remove expansion valve » Hane 1g refrigerant lines + Seal all components and lines in reigerant circu as well as retum delivery parts immediately after disassembling with the special tool 0 494 179 (32 4 270). to prevent any ingress of ieee moisture or foign bade. + Loosen the nut (1) and remove the AIC cable, + Disconnect signal connector (2) on expansion vale + Loosen serews (1) on expansion ve (2) ‘+ Remove the expansion vale (2)+ Loosen the screw (1) fr tension rte, + Disconnacthighaltage connector (2). eZ EAS + Loosen screws (1). + Remeve the ngage compatent flo vim panel (1)10-Removing the loading edge trim + Remove te clip (1). + Remove the loading edge trim (2). + Loosen nuts (1) + Remave storage tray (2) + Remove the cover (1). + Loosen clip @) + Disconnect connector for power socket. 43-Removing the left-hand support TEE oo+ Undo and remove screw on lashing eye (1). ‘+ Detach the clips (2) and guide out the wheel arch trim panel (3). + Remove addments tray (1). ‘+ Remove support (1). + Discomect signal connector (1).= es iby i > if) 48-Loosening the high-voltage battery unit screw connection + Loosen nuts (1) + Loosen serovs 2). + Undo equipotent bonding screw (1) MAIN WORK 20-Remove high-voltage battery unit ‘+ Mount special tocl 2.284 952 and special tool 2:360:086 on workshop crano 2220 718. 61 02185 + Altach special tol 2360 086 to higheitage battery Unit and lock.Grito nes Heavy component. Heavy components can lead to Injury or damage ‘+ Remove and install heay components with the aid of another personvather parsons. + Lit igh-wltage battery unit (1). + Using the spindle (2), change the angle of the special too! 2360 086 so that the highltage battery unit canbe guided completely out ofthe luggage compartment, oa Heavy component. Heavy components can lead to injury or damage |) + Remove and install eawy components wih the aid of another personfather persons. + Using the spinle 2), change the angle of the special too! 2 360.086 so thatthe highsltage battery unit can be guided completly into of the luggage compartment + Caretly tower the high-wetage battery unit (1). ‘+ Unlock special to 2 360 086 on Figh-oltage battery uit and carefily remove special too! 2220718 trom luggage compartment + Tighten down screws (2). High voltage battery unit to body g Hexagon sere Renew screw Tigtering tore Nm he ‘Are of tation 100 + Tefen nuts (1). High voltage battery unit to body, side g M0 at Tetering tore 55 Nm 23-Tightening equipotential bonding screwEquipotential bonding in high-voltage system. Danger to life ifthe equipotential bonding screw connection is not correct! + Observe the safety reairements for the equipeential banding screw connection, ‘+ Clean contact faces and have then checked by a second person, ‘+ Tighten the screws for equiptentil bonding tothe specifed torque; havea second person check the torque | + Carect execution of these tasks must be documented in the vehicle records by both persons. + Tighter equipotertil bonding screw (1). Potential compensation to high-veltago battery unit 3 Maxt6 Tightening tore 49Nn + Connect he signal connector (1). + insert suppot (). 26-Install luggage compartment wheel arch trim panel at left + Connect the connector forthe power socket, + Insert the wheal arch im panel (3) and secure the clips (2) + Tighten the screw onthe lashing eye 1) Lashing eye to body 3 49Nn 10+ Secure the clip Q) + Attach the cover (1) + Insert domes tray (1) + Insert suppat (2 *+ Inset the whee arch trim panel (3) and secure the cps (2) + Tighten the screw on the lashing oye (1. 3 Lashing eye to body 19.Nm "130-Installing storage tray + ser storage tray (2 + Tihten nuts (1. stray Plastic rut Tightening tore + Inset loading exge tim (2). + Clp in cps (), + Insert odements tay (1) + Inset the luggage compartment floor rim panel (1) 34Installing gasket for luggage compartment well 35 Nm‘Seal high-voltage battery unit to vehicle underboay Ey Mexi2 Renew screw. Tightening tore Nm Gout aincs Heavy component. Heavy components can lead to injury or damage. ‘+ Remove and install heay components with the aid of another pesonvather persons. “+ Using the spinle 2), change the angle of the special too! 2:360:086 so that the highanltage battery unit can be guided completly into of the luggage compartment. + Carelly lower the high-weltage battery unit (1). ‘+ Unlock special tol 2 360 086 on righ-oltage battery uit and carefily remove special tool 2.220718 trom luggage compartment ‘36-Install expansion valve » Handling refrigerant lines + Seal all components and lines in refigerant circuit as well as retum delay parts immodiately after disassembling with the special tool 0 494 179 (32 1 270), to prevent any ingress of ican mastue or orig bodes. ‘+ Renew the sealing rings with the special tool 0 496 714 (00 9 030). Parts: Sean ing «Renate gue sees sr spec to 2298 05 Parts ude soos ‘+ Correctly position the expansion valves (2). + Tefen sre, Expanon va to highvoltage bat unit a MS Tightening torque 5,5 Nm 13,‘+ Renew the sealing rings with the special tool 0 496 714 (00 9 030). Parts Sean ing «Rene the gue sees sr spec to 2298 05 Parts Guido soos + Poson the reigernt in cnet and ttn the rt 1) + orrect he comectr (the expansion ae and ock Faigrant tines to expansion valve a We Tenn 37-Installing the underbody panelling + “Tighten the screws on the underbody paneling R51 02139 38-Activate high-voltage system ‘+ Remove the shackle lock (1). a \\ + Inset the screwetver into the opering 1) and simultaneously press the lock (2) downwards in the direction of the avon, ‘+ Push the bush (8) together + Fuly pres inthe lock (1) tolock it 14‘39-Install the flap in the right luggage compartment trim panel + Carell insert th fap (1), R51 01899 ‘40-Filling the air conditioning Prerequisite ‘Serco funtion must be active The engine s switched of Heating and air conditioning system i switched of. The refigeant circuit is evacuated and tit. Vehicle must be positioned on the round, Refrigerant circuit under high pressure. Danger of injury! + Note and fellow safety information on container. 1 + Avaid contact with refigorant; woar safety goggles and protective dows. ‘+ For more information see: 64 50 Handing refigerant and 6450 Notes on repair work on air contoning i TECHNICAL INFORMATION Filing arsed vehicle wil esut in insuficient ling lev, + For the amount of retigerant ol drawn off and noted, deterine the new amaunt of refigerant cil that has tobe filed adtonally, i requir, + Check if the loss of refigerant is below the approved oss. ‘Approved loss of refrigerant [No.of years since the last fling ot [iz [23 [34 [as ‘Approved oss [9] 90 [se [so |s120 [s150 the loss is less then the approved loss, there is no lek. The refigerant ol will not be topped ‘up. Orly refigerant wl be tapped un, » The approved loss of refrigerant has been exceeded + Determine the amount of refigerant ol to be topped up. When the actual oss of efigerant oi exceeds the approved loss (e.g, due to leaks), refigerant ‘ll may have tobe topped up in aston tothe refigerant. 15> When replacing components in the refrigerant amount of refrigerant oil ‘Top up quantity refrigerant oil [No.of years since the ast fling | Loss ofreigerant[a}_| Tap up quantity refigerant il of <120 ° 4 120-150 10 a > 150 2 12 <= 180) 0 12 180-210 10 12 > 210) 2 23 < 240 ° 23 240-270 10 23 > 270 2 34 = 300) 0 34 300-330 10 a4 > 390) 2 45 < 360) 10 45 > 360 2 circuit: Determine the +f components inthe reigrant circuit have been replaced crease the amount of efigerant oi ‘additionally with te flowing amounts. Part exchange of with stow | with sudden leak leak ‘Ar condtining compressor a * Exeporator 10m 36m ‘Ar conditioning condenser without integrated desiccant | 20 mi 35m Insert ‘Ar conditioning condenser with integrated desiccant | 40 mi 5m insert Desiccant insert/tyer flask 20m Eta for each replaced refigerant ne 10m 351m er replaced salty pressure sviten Omi Omi per replaced seal Omi Omi “Ai conkitioning compresser: see acktional information 6452 Changing the ll forthe air ‘conditioning compressor Inthe event ofa slow leak components were replaced due to ‘a minor leak (e.g. aban crack) Inthe event ofa sudion leak, components were replaced due toa major leak (ag, alin break ‘caused by an accident) + Top up determined amount ofrefigorat al into the rofigerant circuit + Fl the amount of refigerant according to the type plate onthe reigerant circu 16‘+ Disconnect the high pressure line and low pressure ine on the vehicle + Dain the high pressure line and low pressure line ———— + Ces to sealing cap ofthe conan loc nock = Ne mam Capacity, refrigerant Rt4a Cc Reacase 17 7409