Remove/install radiator unit

AR20.20-W-3871H

Remove/install radiator unit

20.8.15

Engine

470.9, 471.9, 473.9 in model 963, 964

1

Radiator

5

Refrigerant line (only for code D6F(A/C) or code D6G (AAC))

9

Retaining plate

2

Charge air cooler

6

Retaining plate

28

Bracket (only for code M7K (Radiator shutters))

3

Protective grille (only for code M7I (Insect screen, in front of cooling system))

7

Refrigerant line (only for code D6F(A/C) or code D6G (AAC))

29

Bracket (only for code M7K (Radiator shutters))

4

Refrigerant line (only for code D6F(A/C) or code D6G (AAC))

8

Filler neck

2

Charge air cooler

10

Condenser (only for code D6F(A/C) or code D6G (AAC))

4

Refrigerant line (only for code D6F(A/C) or code D6G (AAC))

11

Strut

1

Radiator

14

Charge air hose (black)

20

Coolant hose

2

Charge air cooler

15

Clamp

21

Fan

4

Refrigerant line (only for code D6F(A/C) or code D6G (AAC))

16

Coolant hose

22

Bracket with coolant line

5

Refrigerant line (only for code D6F(A/C) or code D6G (AAC))

17

Oil/coolant module

23

Securing clamp

12

Filler pipe

18

Coolant hose

24

Sealing ring

13

Plug connection

19

Bracket with coolant line

1

Radiator

25

Coolant hose

26

Sealing ring

27

Securing clamp

 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

 Danger !

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. 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



Notes on tilting the cab

AH60.80-N-0003-01A



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A



Notes on avoiding damage through contamination and foreign objects

AH00.00-N-5000-01H



Notes on coolant

AH20.00-N-2080-01A

 

Remove/install

1

Switch off ignition

2

Open maintenance flap

3

Remove bumper center section

Only for vehicles with code D6F (A/C) or code D6G (AAC).

AR88.20-W-2003A

4

Remove bracket (28, 29)

Only for model 963 with code M7K (Radiator shutters).

5

Remove upper radiator shutters

Only for model 963 with code M7K (Radiator shutters).

AR20.20-W-3881-01H

6

Remove clamps for refrigerant line (4) on protective grille (3) and charge air cooler (2) to the upper right

Only for vehicles with code D6F (A/C) or code D6G (AAC) and code M7I (Insect screen, in front of cooling system).

7

Remove clamps for refrigerant line (5) on the RH retaining plate (6)

Only for vehicles with code D6F (A/C) or code D6G (AAC).

8

Remove clamp for refrigerant line (7) on protective grille (3) on the upper left

Only for vehicles with code D6F (A/C) or code D6G (AAC) and code M7I (Insect screen, in front of cooling system).

9

Remove protective grille (3)

Only for vehicles with code M7I (Insect screen, in front of cooling system).

10

Remove RH retaining plate (6) on charge air cooler (2)

Only for vehicles with code D6F (A/C) or code D6G (AAC).

11

Remove LH retaining plate (9) on charge air cooler (2) and place oil filler neck (8) to one side with the refrigerant line (7)

Only for vehicles with code D6F (A/C) or code D6G (AAC).

12

Remove condenser (10) on the charge air cooler (2) and tie up with a cable tie to the strut (11)

Only for vehicles with code D6F (A/C) or code D6G (AAC).

 Do not separate refrigerant lines (4, 5, 7).

13

Remove plug-in nuts from the charge air cooler (2)

14

Tilt cab

 Installation: Only tilt back cab after the leak test.

15

Remove soundproofing

16

Remove fan (21)

Engine 470.9, 471.9 with code M8A (Air intake, from the front)

AR20.40-W-5614HA

Engine 470.9, 471.9, 473.9 without code M8A (Air intake, from the front)

AR20.40-W-5614H

17

Remove clamps for refrigerant lines (4, 5) on engine radiator (1) on the right and unclip on the retaining clamp

Only for vehicles with code D6F (A/C) or code D6G (AAC).

18

Remove bracket with coolant line (22) on engine radiator at the (1) upper right and lay to the front

19

Remove charge air hose (black) (14)

 Installation: Check clamps (15); replace if necessary.

 Clamp, charge air hose to charge air pipe and charge air cooler

*BA09.41-N-1010-01P

20

Unlock and remove coolant hose (16) on oil/coolant module (17)

 Installation: Check sealing ring (24) in the coolant hose (16); replace sealing ring (24) or coolant hose (16) if necessary. Coat sealing ring (24) with lubricant. Click safety clamp (23) into place on the coolant hose (16).

Lubricant, rubber assembly 1 l

*BR00.45-Z-1010-06A

21

Remove coolant hose (20)

22

Remove bracket with coolant line (19) on engine radiator (1) at the upper left and lay with coolant hose (16) to the front

23

Unlock coolant hose (18) on the engine radiator (1), remove and lay to the rear to the engine

24

Remove filler pipe (12) on engine radiator (1)

25

Disconnect filler pipe (12) at plug coupling (13)

 Installation: Check sealing ring, replace if necessary.

26

Unlock and remove coolant hose (25) below on engine radiator (1)

 Installation: Check sealing ring (26) in the coolant hose (25); replace sealing ring (26) or coolant hose (25) if necessary. Coat sealing ring (26) with lubricant. Click safety clamp (27) into place on the coolant hose (25).

Lubricant, rubber assembly 1 l

*BR00.45-Z-1010-06A

27

Remove radiator unit

AR20.20-W-3865-05H

 Bolt, bracket for engine radiator to engine radiator main bearing, top

*BA20.20-N-1002-02A

 Bolt, retainer wedge to engine radiator bearing, bottom

*BA20.20-N-1003-02A

Lubricant, rubber assembly 1 l

*BR00.45-Z-1010-06A

28

Attach lifting device for the radiator unit

AR20.20-W-3865-12H

 Lifting device

*963589006200

29

Pull out radiator unit upwards

Check both radiator bearings on vehicle frame for damage; replace if necessary:



Replace radiator bearings.

30

Remove charge air cooler (2) and fan shroud from engine radiator (1)

Only if engine radiator (1), the charge air cooler (2) or the fan shroud are renewed.

31

Install in the reverse order

32

Start engine and perform an engine test run

 Allow engine to run at a higher rotational speed.

33

Check area around the radiator unit for leaktightness and stop engine

 Visual inspection.

 Charge air pipe/charge air cooling

Number

Designation

Engine 470.9

Engine 471.9

BA09.41-N-1010-01P

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

Nm

7,5

7,5

 Charge air pipe/charge air cooling

Number

Designation

Engine 473.9

BA09.41-N-1010-01P

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

Nm

7,5

 Engine radiator, coolant hoses, lines

Number

Designation

Engine 470.9, 471.9

Engine 473.9

BA20.20-N-1002-02A

Bolt, bracket for engine radiator to engine radiator main bearing, top

Nm

51

51

 Engine radiator, coolant hoses, lines

Number

Designation

Engine 470.9, 471.9

Engine 473.9

BA20.20-N-1003-02A

Bolt, retainer wedge to engine radiator bearing, bottom

Nm

20

20

Repair materials

Number

Designation

Order number

BR00.45-Z-1010-06A

Lubricant, rubber assembly 1 l

A 000 989 03 67