Remove/install radiator

AR20.20-W-3865B

Remove/install radiator

4.12.09

10.7.05

Work procedure completely revised.

 

Remove/install



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

1

Switch off ignition

2

Detach trim panel on cab rear wall

 Only for vehicles with code (F15) Cab with MEGASPACE.

3

Remove soundproofing below the radiator (6)

 Danger!

Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by 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

4

Drain coolant

 Only drain coolant at radiator (6)

AR20.00-W-1142A



Notes on coolant

AH20.00-N-2080-01A

5

Open maintenance flap

6

Remove middle fascia section over bumper

7

Discharge air conditioning system

 Only on vehicles with code (H03) Air conditioning in front end.

AR83.30-W-1760A



Protect air conditioning circuit and components from moisture when carrying out repair work

AH83.30-N-0005-01A



Notes on handling R134a refrigerant

AH83.30-N-0003-01A

8

Remove coolant hoses (3) to heater heat exchanger

 Danger!

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

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

AS60.80-Z-0001-01A

9.1

Remove sensor unit with hydraulic lines on cab

On vehicles with code (GS3) "Hydraulic" gearshift.

AR26.60-W-0012-01G



*BA26.60-N-1025-01D



*BA26.60-N-1026-01D



*BA26.60-N-1030-01D



Notes on tilting the cab

AH60.80-N-0003-01A

 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

9.2

Tilt cab

On vehicles without code (GS3) "Hydraulic" gearshift.



Notes on tilting the cab

AH60.80-N-0003-01A

10

Detach air filter housing over engine

 Only on vehicles with box-shaped air filter.

11

Remove soundproofing on the left and right side of the engine

12

Detach shift rod (1) at relay lever, push together and tie up on cab

 Only on vehicles with code (GS1) "Manual" gearshift.

13

Detach coolant level switch connector (8) on coolant level switch (B6)

14

Remove red charge air hose (10) and black charge air hose (11)

 Installation: The red charge air hose (10) and the black charge air hose (11) must not be interchanged.



*BA09.41-N-1006-01C

15

Remove all coolant hoses (4, 5, 9, 12, 16)

16

Detach coolant expansion reservoir (7) on radiator (6)

17

Remove oil dipstick guide tube (15) and oil filler pipe (14) on radiator (6) and tie up on engine

18

Disconnect low pressure refrigerant line (26) and high pressure refrigerant line (27) at connecting points (30, 31)

 Only on vehicles with code (H03) Air conditioning in front end.

When undoing union nuts, counterhold on fitting hexagon.

19

Unscrew bolts at the radiator mounting (18) on right and left

20

Disconnect low pressure refrigerant line (26) and high pressure refrigerant line (27) at connecting points (28, 29)

 Only on vehicles with code (H03) Air conditioning in front end.

When undoing union nuts, counterhold on fitting hexagon.

21

Disconnect transmission oil lines (17.2) at connecting points (17) to transmission oil lines (17.1)

 Only on vehicles with code (N55) Transmission oil cooling.

 Only detach transmission oil hoses (17.2) at connecting points (17). If the transmission oil hoses (17.2) are removed at the oil cooler, the oil cooler can be damaged.

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

22

Tie transmission oil hoses (17.2) below onto radiator (6)

 Only on vehicles with code (N55) Transmission oil cooling.

23

Attach removal and installation tools onto radiator (6)

AR20.20-W-3865-08G

24

Lift out radiator (6) with charge air cooler (19) upwards

 Installation: When installing radiator (6) ensure that protective grille (20) is not tilted on vehicle frame.

25

Install in the reverse order

26

Inspect transmission oil level

 Only on vehicles with code (N55) Transmission oil cooling.

Observe set oil quality in the maintenance system or Specifications for Operating Fluids.



*BA26.40-N-1011-01D

Number

Designation

Engine
541.9

Engine
542.9

BA09.41-N-1006-01C

Clamp, charge air hose to charge air housing/charge air pipe and charge air cooler

Nm

7.5

7.5

Number

Designation

Transmission 715.500/507/
510/513/517/
520/527/540

BA26.40-N-1011-01D

Oil filler screw/oil check screw on transmission housing

Nm

60

Number

Designation

Transmission 715.500/507/510/513/520/540
with code GS3 without code IY2

BA26.60-N-1025-01D

Nut and bolt, shift control unit to center tunnel

Nm

30

BA26.60-N-1026-01D

Bolt, HPS line bracket to center tunnel

Nm

20

BA26.60-N-1030-01D

Clamp bolt for gearshift lever

Nm

20