Remove/install radiator unit

AR20.20-W-3871O

Remove/install radiator unit

29.11.2017

Engine

460.9 in model 963, 964

Shown on vehicle with code D6F (A/C)

1

Engine radiator

4

Charge air cooler

7

Filling line (upper part)

2

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

5

Protective grille (only with code D6F (A/C) or code D6G (AAC) or code M7I (Insect screen, in front of cooling system))

8

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

3

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

6

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

Shown on vehicle with code D6F(A/C)

1

Engine radiator

12

Coolant hose

19

Coolant hose

2

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

13

T-piece

20

Charge air hose (red)

7

Filling line (upper part)

14

Bracket

21

Vent line

8

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

15

Vent line

22

Coolant line

9

Filling line (lower part)

16

Coolant hose

23

Sealing ring

10

Fan shroud

17

Bracket

24

Securing clamp

11

Charge air hose (black)

18

Bracket

29

Coolant line

1

Engine radiator

23

Sealing ring

24

Securing clamp

25

Coolant hose

26

Seal mount

1

Engine radiator

10

Fan shroud

28

Bolts

4

Charge air cooler

27

Bolts

 Warning

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

 Warning

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

 Warning

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

Topical note

Notes and information for working on engine cooling

AH20.00-N-0001-01B

 

Remove/install

1

Switch off ignition

2

Open maintenance flap

3

Remove bumper center section

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

AR88.20-W-2003A

4

Remove the filling line (7) at the front from the engine radiator (1)

5

Remove clamps (5) for refrigerant lines (2, 3) on the protective grille (5)

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

6

Remove clamp for refrigerant line (2) in the top right on the charge air cooler (4)

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

7

Remove protective grille (5)

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

8

Remove the condenser (6) on the charge air cooler (4) and attach it at the front

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

 Do not disconnect refrigerant lines (2, 3, 8).
Attach the condenser (6) in such a way that it is not damaged when the cab is tilted.

9

Remove all plug-in nuts from the charge air cooler (4)

10

Tilt cab

11

Remove soundproofing from frame on the left and right

12

Drain off coolant

AR20.00-W-1142O

13

Remove the filling line (7) at the side from the engine radiator (1)

14

Remove the filling line (7) from the filling line (9)

 Installation: Check the sealing ring, replace if necessary.

15

Remove charge air hose (11)

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

*BA09.41-N-1002-01OA

16

Disconnect the coolant hose (12) from the T-piece (13) and attach it to the engine

17

Detach the bracket (14) from the engine radiator (1) and attach it to the cab

18

Disconnect the vent line (15) on the engine radiator (1) and expose it as far as the bracket (17)

19

Disconnect the vent line (21) from the coolant line (22) and from the bracket (17) and remove it

20

Detach the bracket (17) from the bracket (18) and attach it to the cab with the vent line (15)

 Do not kink the vent line (15).

21

Remove the coolant hose (16) from the bracket (18)

22

Remove the bracket (18) from the engine radiator (1)

23

Expose the coolant line (29) as far as the engine and attach it to the engine with the bracket (18)

24

Remove coolant hose (19)

 Installation: Check the sealing rings (23) in the quick-release fasteners of the coolant hose (19); if necessary, replace the sealing rings (23) and/or coolant hose (19). Coat the sealing rings (23) with lubricant. Click safety clamps (24) into place on the coolant hose (19).

Lubricant, rubber assembly 1 l

*BR00.45-Z-1010-06A

25

Remove charge air hose (20)

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

*BA09.41-N-1002-01OA

26

Remove the bracket of the refrigerant lines (2, 8) on the right on the engine radiator (1)

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

 Installation: Do not tighten the refrigerant lines (2, 8) until the condenser (6) has been attached.
Do not disconnect the refrigerant lines (2, 8).

27

Remove the bracket seals (26) on the left and right of the cab

28

Remove coolant hose (25) from engine radiator (1)

 Installation: Check the sealing ring (23) in the quick-release fastener of the coolant hose (25); if necessary, replace the sealing ring (23) and coolant hose (25). Coat the sealing ring (23) with lubricant. Click safety clamp (24) into place on the coolant hose (25).

Lubricant, rubber assembly 1 l

*BR00.45-Z-1010-06A

29

Attach lifting device for the radiator unit

AR20.20-W-3865-12O

 The engine radiator (1) and the charge air cooler (4) are removed together as a radiator unit.

 Lifting device

*963589006200

30

Unscrew screws/bolts (27) on the left and right of the engine radiator main bearings at the top

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

*BA20.20-N-1002-02O

31

Unscrew screws/bolts (28) on the left and right on the engine radiator bearings at the bottom

 Bolt, holder engine radiator mount at bottom to radiator

*BA20.20-N-1007-02O

32

Pull the radiator unit out upwards

 The engine radiator (1) and the charge air cooler (4) are removed together as a radiator unit.

 Installation: Check both engine radiator main bearings at the top and bottom for damage; replace if necessary.

33

Remove charge air cooler (4) and fan shroud (10) from engine radiator (1)

Only when replacing the engine radiator (1), the charge air cooler (4) or the fan shroud (10).

34

Install in the reverse order

 Charge air pipe/charge air cooling

Number

Designation

Engine 460.9 in model 963, 964

BA09.41-N-1002-01OA

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

Nm

6

 Engine radiator, coolant hoses and lines

Number

Designation

Engine 460.9 in model 963, 964

BA20.20-N-1002-02O

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

Nm

51

 Engine radiator, coolant hoses and lines

Number

Designation

Engine 460.9 in model 963, 964

BA20.20-N-1007-02O

Bolt, holder engine radiator mount at bottom to radiator

Nm

18

Repair materials

Number

Designation

Order number

BR00.45-Z-1010-06A

Lubricant, rubber assembly 1 l

A 000 989 03 67