Retrofit electromagnetic viscous fan clutch

AN20.40-W-0004A

Retrofit electromagnetic viscous fan clutch

10.10.2016

Engine

541.9 in model 930, 932, 933, 934

with code M58 (Fan, increased output)

with code MZ3 (Electromagnetic viscous coupling for fan)

with code ZX1 (Common Powertrain Controller (CPC))

except code ML3 (High-speed fan drive with belt drive)

Engine

542.9 in model 930, 932, 934

with code M58 (Fan, increased output)

with code MZ3 (Electromagnetic viscous coupling for fan)

with code ZX1 (Common Powertrain Controller (CPC))

except code ML3 (High-speed fan drive with belt drive)

Modification notes

21.09.2016

Engine parameters updated.

Operation step 53

1

Coolant pipe (heater)

11

Fan wheel

20.1

Oil lines (only for code N55 (Transmission cooling))

2

Coolant hoses (heater)

12

Charge air distributor

20.2

Gear oil hoses (only for code N55(Transmission cooling))

3

Coolant hose (to coolant pump)

13

Coolant line

21

Coolant hose

4

Coolant hose (from engine)

14

Bracket

22

Boot

5

Coolant expansion reservoir

15

Bracket

23

Radiator mounting

6

Electrical connection

16

Bracket

24

Protective grille

7

Coolant hose

17

Bracket

25

Condenser

8

Coolant hose

18

Filler pipe

26

Cover

9

Radiator

19

Guide tube (oil dipstick)

B6

Coolant level switch

10

Fan shroud

20

Connection (only for code N55 (Transmission cooling))

Only vehicles with code H03 (Air conditioning in front end) or code H07 (AAC)

27

Low-pressure refrigerant line

28

High-pressure refrigerant line

29

Connection

30

Connection

31

Connection

32

Connection

33

Viscous fan clutch, BorgWarner

34

Screw/bolt

35

Electrical connection

36

Torque arm

37

Adapter

38

Belt pulley/vibration damper

33

Viscous fan clutch, BorgWarner

39

Viscous fan clutch, Behr

A

with code MO1 (Electromagnetic viscous fan clutch, Behr)

B

with code MZ3 (Electromagnetic viscous coupling for fan)

 Danger !

Risk of injury to skin and eyes due to handling of transmission oil. Health risk caused by swallowing transmission oil

Wear protective gloves, protective clothing and safety glasses.
Do not pour transmission oil into beverage bottles.

AS00.40-Z-0001-01A

 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

 Danger !

Risk of injury caused by body parts being pinched or crushed as cab is tilted

Ensure that no one is within the tilting range of the cab as it is being tilted. Always tilt the cab all the way to the end position and secure with the safety strut.

AS60.80-Z-0001-01A



Notes on tilting the cab

AH60.80-N-0003-01A



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A



Note on calculation of tightening torque when using insertion or socket tools with various effective lengths

AH00.00-P-0015-01CW



Remove

1

Switch off ignition

2

Remove cover on the rear panel of the cab

Only for vehicles with code F15 (MEGASPACE cab).

3

Remove soundproofing below the radiator (9)

4

Only drain coolant at the radiator



AR20.00-W-1142A

5

Open maintenance flap

6

Remove middle trim panel (26) over the bumper

7

Drain air conditioning system



Only for vehicles with code H03 (Air conditioning in front end) or with code H07 (AAC).

AR83.30-W-1760A

8

Remove coolant hoses (2) to heater heat exchanger

9.1

Remove sensor unit with hydraulic lines on cab

Vehicles with code GS3 ("Hydraulic" gearshift)



AR26.60-W-0012-01G

9.2

Tilt cab

Vehicles without code GS3 ("Hydraulic" gearshift).

10

Remove soundproofing on the left and right side of the engine

11

Disconnect electrical connection (6) from coolant level switch (B6)

12

Remove all coolant hoses (3, 4, 7, 8, 21) on the cooler side

13

Remove coolant expansion reservoir (5) on radiator (9)

14

Remove oil filler pipe (18) and oil dipstick guide tube (19) on radiator (9) and tie up on engine

15

Disconnect low-pressure refrigerant line (27) and high-pressure refrigerant line (28) at connections (31, 32)

Only for vehicles with code H03 (Air conditioning in front end) or with code H07 (AAC).

 When undoing the union nut, counterhold on fitting hexagon.

16

Remove screw/bolts at radiator mounting (23) on the right and left

17

Unfasten boot (22) from fan shroud (10)

18

Disconnect transmission oil hoses (20.2) from oil lines (20.1) at connections (20) and connect below on radiator (9)

Only on vehicles with code N55 (Transmission cooling).


Disconnect transmission oil hoses (20.2) at the connections (20) only.
If transmission oil hoses (20.2) are removed at the oil cooler, the oil cooler can be damaged.

 Collect feathering-out transmission oil and seal lines with stop plug.

19

Attach removal and installation tools onto radiator (9)



AR20.20-W-3865-08G

20

Remove radiator (9) with charge air cooler upwards

21

Remove fan shroud (10)

22

Disconnect electrical connection (35)

23

Remove screw/bolt (34) on the torque arm (36)

24

Remove fan wheel (11) with viscous fan clutch, BorgWarner (33) at adapter (37)

25

Remove adapter (37)

 The adapter (37) is no longer needed for further modification.



Install

26

Install new viscous fan clutch, co. Behr (39)

 Electromagnetic fan clutch on belt pulley for fan drive

*BA20.40-N-1017-01C

27

Tighten screw/bolt (34) on the torque arm (36)

 Bolt, support for electromagnetic fan clutch to coolant pump

*BA20.40-N-1010-01C

28

Connect electrical connection (35)

29

Install a new fan wheel (11)

 Bolt, fan to electromagnetic fan clutch

*BA20.40-N-1009-01C

30

Install fan shroud (10)

 Bolt, fan shroud to fan shroud bracket

*BA20.40-N-1016-01C

31

Insert cooler (9) with the charge air cooler

32

Remove removal and installation tools onto radiator (9)



AR20.20-W-3865-08G

33

Attach transmission hoses (20.2)

Only on vehicles with code N55 (Transmission cooling).

 Hose on transmission oil cooling line, vehicles with code GE3 (Mercedes PowerShift) or code GE7 (Mercedes PowerShift 2)Hose to transmission oil cooling line

*BA26.55-N-1004-01KL

 Hose on transmission oil cooling line, vehicles with code GS3("Hydraulic" gearshift) or code GS7 (Gear control II)Hose to transmission oil cooling line

*BA26.55-N-1007-01A

34

Push boot (22) over the fan shroud (10)

35

Tighten down screw/bolts at radiator mounting (23) on the right and left

36

Attach low-pressure refrigerant line (27) and high-pressure refrigerant line (28) with new sealing rings at connections (31, 32)

Only for vehicles with code H03 (Air conditioning in front end) or with code H07 (AAC).

 Union nut, refrigerant lines

*BA83.30-N-1009-01B

37

Attach filler pipe (18) and guide tube (19) on radiator (9)

38

Attach coolant expansion reservoir (5) to radiator (9)

39

Attach all coolant hoses (3, 4, 7, 8, 21) to the cooler side

40

Connect electrical connection (6) to coolant level switch (B6)

41

Attach soundproofing to the left and right side of the engine

42.1

Tilt back cab

Vehicles without code GS3 ("Hydraulic" gearshift).

42.2

Detach/attach shift control unit along with hydraulic lines at cab

Vehicles with code GS3 ("Hydraulic" gearshift)



AR26.60-W-0012-01G

 Bracket for lines to engine tunnelBracket for lines to engine tunnel

*BA26.60-N-1005-01KL

 Clamp bolt for gearshift leverClamp bolt for gearshift lever

*BA26.60-N-1006-01KL

 Sensor unit on engine tunnelSensor unit to engine tunnel

*BA26.60-N-1004-01KL

43

Attach coolant hoses (2) to heater heat exchanger

44

Charge air conditioning system



Only for vehicles with code H03 (Air conditioning in front end) or with code H07 (AAC).

AR83.30-W-1760A

45

Install middle trim panel (26) over the bumper

46

Pour in coolant



AR20.00-W-1142A

47

Close maintenance flap

48

Install soundproofing below the radiator (9)

49

Attach cover to rear panel of the cab

Only for vehicles with code F15 (MEGASPACE cab).

50

Connect diagnostic system and start XENTRY

51

Check software release in engine control (MR) control unit.

52

Perform download "MR1_35" in engine control (MR) control unit

Only for vehicles without code MU5 (Engine, V6, LA, 350 kW (476 hp), 1800 rpm) or Without Code MU6 (Engine, V8, LA, 375 kW (510 hp), 1800 rpm).
Only for MR software release less than 09.

 The process is completely menu-assisted under:
Trucks Category 
Automatic access using model series 
Special functions  
MR download 
Select MR1_35

53

Perform download "MR1_40" in engine control (MR) control unit

Only for vehicles with code MU5 (Engine, V6, LA, 350 kW (476 hp), 1800 rpm) or with code MU6 (Engine, V8, LA, 375 kW (510 hp), 1800 rpm).
Only for software release less than 24.

 The process is completely menu-assisted under:
Trucks Category 
Automatic access using model series 
Special functions  
MR download 
Select MR1_40

54

Change fan control parameter in drive control (FR) control unit

 The process is completely menu-assisted under:
Control unit adaptations 
Parameterization 
Engine parameters 
070.000 Fan control 
Select model 11

55

Check viscous fan clutch, Behr (39)

 The process is completely menu-assisted under:
MR control unit 
Actuations 
Behr or BorgWarner fan clutch (Vistronik) test

56

Perform a quick test

 There must be no fault codes in the control units being updated. If necessary, process any fault codes in other control units, subject to separate repair order.

57

End XENTRY and remove diagnostic system

Update Vehicle Documentation (VeDoc)

58

Replace the previous code MZ3 (Electromagnetic viscous fan coupling) by the new code MO1 (Electromagnetic viscous fan coupling, Behr).

59

Replace number of SAA (SAA) Z 505.154/09 by Z 505.154/17

 Fan, fan clutch

Number

Designation

ENGINE 541.9, 542.9 with CODE MO1/MZ3

BA20.40-N-1009-01C

Bolt, fan to electromagnetic fan clutch

Nm

25

 Fan, fan clutch

Number

Designation

ENGINE 541.9, 542.9 with CODE MO1/MZ3

BA20.40-N-1010-01C

Bolt, support for electromagnetic fan clutch to coolant pump

Nm

50

 Fan, fan clutch

Number

Designation

ENGINE 541.9, 542.9 with CODE MO1/MZ3

BA20.40-N-1016-01C

Bolt, fan shroud to fan shroud bracket

Nm

15

 Fan, fan clutch

Number

Designation

ENGINE 541.9, 542.9 with CODE MO1/MZ3

BA20.40-N-1017-01C

Electromagnetic fan clutch on belt pulley for fan drive

Nm

30

 Transmission oil cooling, oil pump

Number

Designation

Transmission 715.515/525

BA26.55-N-1004-01KL

Hose to transmission oil cooling line

Nm

60

 Transmission oil cooling, oil pump

Number

Designation

TRANSMISSION 715.500 /507/510/513/517 /520/527/540/561 /567/568

BA26.55-N-1007-01A

Hose to transmission oil cooling line

Nm

60

 Shift

Number

Designation

Transmission 715.500/507/510/513/520/540

BA26.60-N-1004-01KL

Sensor unit to engine tunnel

Nm

30

 Shift

Number

Designation

Transmission 715.500/507/510/513/520/540

BA26.60-N-1005-01KL

Bracket for lines to engine tunnel

Nm

20

 Shift

Number

Designation

Transmission 715.500/507/510/513/520/540

BA26.60-N-1006-01KL

Clamp bolt for gearshift lever

Nm

20

 Air conditioning

Number

Designation

Model 930, 932, 933, 934 with code H01, H03, H07, H09

BA83.30-N-1009-01B

Union nut, refrigerant lines

Size 19

Nm

16

Size 27

Nm

30

Size 32

Nm

40

Parts ordering note

Part no.

Designation

Quantity

A 541 200 19 22

Viscous fan clutch, Behr

1

A 541 205 01 06

Fan wheel

1

N 910105 008005

Screw/bolt M8x25

6