Retrofit electromagnetic viscous fan clutch

AN20.40-W-0004C

Retrofit electromagnetic viscous fan clutch

10.10.2016

Engine

541.9 in model 930, 932, 933, 934

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

with code MZ3 (Electromagnetic viscous coupling for fan)

with code ZX1 (Common Powertrain Controller (CPC))

Engine

542.9 in model 930, 932, 934

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

with code MZ3 (Electromagnetic viscous coupling for fan)

with code ZX1 (Common Powertrain Controller (CPC))

Modification notes

21.09.2016

Engine parameters updated.

Operation step 53

1

Coolant pipe (heater)

9

Coolant hose

16.1

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

2

Coolant hoses (heater)

10

Charge air distributor

16.2

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

3

Coolant expansion reservoir

11

Coolant pipe

17

Radiator mounting

4

Coolant hose (from engine)

12

Fan

18

Charge air cooler

5

Coolant hose (to coolant pump)

13

Guide tube (oil dipstick)

19

Protective grille

6

Radiator

14

Filler pipe (engine oil)

20

Condenser

7

Coolant hose

15

Coolant hose

21

Cover

8

Electrical connection

16

Connection (only for code N55 (Transmission cooling))

B6

Coolant level switch

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

26

Low-pressure refrigerant line

27

High-pressure refrigerant line

28

Connection

29

Connection

30

Connection

31

Connection

32

Viscous fan clutch, BorgWarner

33

Viscous fan clutch, Behr

34

Electrical connection

35

Torque arm

36

Adapter with freewheel bearing

A

with code MZ3 (Electromagnetic viscous coupling for fan)

B

with code MO1 (Electromagnetic viscous fan clutch, Behr)

 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 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

 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



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 on the radiator (6)

4

Drain coolant at radiator (6)



AR20.00-W-1142A

5

Open maintenance flap

6

Remove middle trim panel (21) over the bumper

7

Drain air conditioning system



Only for vehicles with code H03 (Air conditioning in front end) or 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 (8) from coolant level switch (B6)

12

Remove all coolant hoses (4, 5, 7, 9, 15) on the cooler side

13

Remove coolant expansion reservoir (3) on radiator (6)

14

Remove oil filler pipe (14) and oil dipstick guide tube (13) on radiator (6) and tie up on engine

15

Disconnect low-pressure refrigerant line (26) and high-pressure refrigerant line (27) at connections (28, 29)

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 (17) on the right and left

17

Disconnect transmission oil hoses (16.1) from oil lines (16.2) at connections (16) and connect below on radiator (6)

Only on vehicles with code N55 (Transmission cooling).


Disconnect transmission oil hoses (16.1) at the connections (16) only.
If transmission oil hoses (16.1) are removed at the oil cooler, the oil cooler can be damaged.

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

18

Attach removal and installation tools onto radiator (6)



AR20.20-W-3865-08G

19

Remove radiator (6) with charge air cooler (18) upwards

20

Disconnect electrical connection (34)

21

Remove torque arm (35) on engine

22

Slacken fan poly-V belt (12) and remove from the belt pulley of the coolant pump

23

Remove viscous fan clutch, BorgWarner (32) on adapter with freewheel bearing (36)

24

Lift out fan (12) with viscous fan clutch, BorgWarner (32)

25

Remove adapter with freewheel bearing (36)



Install

26

Install new adapter with freewheel bearing (36)

 Intermediate piece with freewheel bearing on vibration damper

*BA20.40-N-1011-01C

27

Fit on fan poly-V belt (12)



Damage profiles for a poly-V belt

AP13.22-D-1351-01A



Routing diagram for poly-V belt

AR13.22-W-3902-02A

28

Remove viscous fan clutch, Behr (33) on adapter with freewheel bearing (36)

 Electromagnetic fan clutch on adapter

*BA20.40-N-1007-01C

29

Attach torque arm (35) to engine

 Bolt, support for electromagnetic fan clutch to coolant pump

*BA20.40-N-1010-01C

30

Attach electrical connection (34) for fan clutch

31

Attach fan (12)

 Bolt, fan to viscous fan clutch

*BA20.40-N-1002-01C

32

Insert cooler (6) with the charge air cooler (18)

33

Remove removal and installation tools on radiator (6)



AR20.20-W-3865-08G

34

Attach transmission hoses (16.1)

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

35

Tighten down screw/bolts at radiator mounting (17) on the right and left

36

Attach low-pressure refrigerant line (26) and high-pressure refrigerant line (27) with new sealing rings at connections (28, 29)

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 (14) and guide tube (13) on radiator (6)

38

Attach coolant expansion reservoir (3) to radiator (6)

39

Attach all coolant hoses (4, 5, 7, 9, 15) to the cooler side

40

Connect electrical connection (8) 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

 Clamp bolt for gearshift lever

*BA26.60-N-1006-01KL

 Bracket for lines to engine tunnel

*BA26.60-N-1005-01KL

 Sensor 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 code H07 (AAC).



AR83.30-W-1760A

45

Install middle trim panel (21) over the bumper

46

Pour in coolant



AR20.00-W-1142A

47

Close maintenance flap

48

Attach soundproofing below on the radiator (6)

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.
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.
Only for MR 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 10

55

Check viscous fan clutch, Behr (33)

Perform the check on a warm engine; perform a second check if necessary.

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

56

Perform a final 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 505.154/14 by Z 505.154/19

 For the viscose fan clutch, Behr (33).

60

Replace number of SAA (SAA) Z 505.169/03 by Z 505.169/04


For the adapter with freewheel bearing (36).

61

Replace number of SAA (SAA) Z 505.154/15 by Z 505.154/19

 For the fan (12).

 Fan, fan clutch

Number

Designation

ENGINE 541.9, 542.9 with CODE ML3

ENGINE 541.9, 542.9 with CODE MO1/MZ3

BA20.40-N-1002-01C

Bolt, fan to viscous fan clutch

Nm

30

–

 Fan, fan clutch

Number

Designation

ENGINE 541.9, 542.9 with CODE ML3

ENGINE 541.9, 542.9 with CODE MO1/MZ3

BA20.40-N-1007-01C

Electromagnetic fan clutch on adapter

Nm

–

50

 Fan, fan clutch

Number

Designation

ENGINE 541.9, 542.9 with CODE ML3

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 ML3

ENGINE 541.9, 542.9 with CODE MO1/MZ3

BA20.40-N-1011-01C

Intermediate piece with freewheel bearing on vibration damper

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

Transmission 715.515/525

BA26.60-N-1004-01KL

Sensor unit to engine tunnel

Nm

30

30

 Shift

Number

Designation

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

Transmission 715.515/525

BA26.60-N-1005-01KL

Bracket for lines to engine tunnel

Nm

20

20

 Shift

Number

Designation

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

Transmission 715.515/525

BA26.60-N-1006-01KL

Clamp bolt for gearshift lever

Nm

20

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 542 200 10 22

Viscous fan clutch, Behr

1

A 542 030 02 94

Adapter with freewheel bearing

1

A 003 205 49 06

Fan

1

N 910112 010001

Nuts (fan clutch on adapter with freewheel bearing)

3

N 910105 008005

Screw/bolts M8x25 (adapter with freewheel bearing on vibration damper)

6

N 910105 008012

Screw/bolt M8x30 (fan on fan clutch)

6