Remove/install front module · ar8830d1064sd · Mercedes-Benz WIS

AR88.30-D-1064SD

Remove/install front module

18.11.2019

Model	900
Model	906 with engine 271.951, 272.979, 646.984/985/986/989/990, 651.955/956/957

D88.30-1187-09

Shown on model 906 with engine 646

1	Front module	5	Engine hood cable	9	Circuit
2	Air cleaner housing	6	Engine hood catch	10	Spray nozzle hose
3	Air intake pipe	7	Spray nozzle hose	11	Charge air hose
4	Air duct insert	8	Spray nozzle	12	Charge air cooler

D88.30-1188-09

Shown on model 906 with engine 646

1	Front module	16	Air duct insert	19	Screw
13	Fender	17	Screw	20	Washer
14	Marking	18	Bracket	21	Bolts
15	Screw

Shown on model 906 with engine 642 and transmission 722.9 with automatic transmission oil cooler integrated into the cooler

24	Upper return line
25	Rear return line
27	Front feed line
28	Rear feed line
29	Front return line

D27.55-1119-12

Shown on model 906 with engine 651 and transmission 722.9

25	Rear return line
27	Front feed line
28	Rear feed line
29	Front return line

D27.55-1120-12

 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
 Warning	Risk of burns and scalding when handling hot fluids and components they come into contact with. Risk of injury to skin and eyes when handling hot fluids.	Wear protective gloves, protective clothing and safety glasses, if necessary. Pour hot fluids in suitable containers only.	AS00.00-Z-0033-01A
	Notes on automatic transmission	Model 906 with engine 651.955/956 with transmission 722.6 Model 906 with engine 651.955/956 with transmission 722.9 Model 906.1/2/6/7 with engine 271.951 with transmission 722.6 Model 906.1/2/6/7 with engine 272.979 with transmission 722.6 Model 906.1/2/6/7 with engine 646.984/985/986/989/990 with transmission 722.6 Model 906.1/2/6/7 with engine 646.984/985/986/989/990 with transmission 722.9	AH27.19-P-0001-01NKB
 	Remove/install
1	Discharge air conditioning system.	Model 900.633/65 with code HK4 (Rear air conditioning, reinforced) except code HH9 (Air conditioner, automatic heater control) Model 906 with engine 271.951, 272.979, 646.984/985/986/989/990, 651.955/956/957 with code HK4 (Rear air conditioning, reinforced) with code ZL3 (National version for Latin America)	AR83.30-D-1760WE
		Model 900 with code HH9 (Air conditioner, automatic heater control) except code HK4 (Rear air conditioning, reinforced) Model 906 with engine 271.951, 272.979, 646.984/985/986/989/990, 651.955/956/957 with code H08 (Roof-mounted air conditioning system, reinforced) with code HH9 (Air conditioner, automatic heater control) except code HH7 (Roof-mounted air conditioning system, basic) except code HK4 (Rear air conditioning, reinforced) Model 906 with engine 271.951, 272.979, 646.984/985/986/989/990, 651.955/956/957 with code HH7 (Roof-mounted air conditioning system, basic) with code HH9 (Air conditioner, automatic heater control) except code H08 (Roof-mounted air conditioning system, reinforced) except code HK4 (Rear air conditioning, reinforced) Model 906 with engine 271.951, 272.979, 646.984/985/986/989/990, 651.955/956/957 with code HH9 (Air conditioner, automatic heater control) except code H08 (Roof-mounted air conditioning system, reinforced) except code HH7 (Roof-mounted air conditioning system, basic) except code HK4 (Rear air conditioning, reinforced) except code HX1 (Refrigerant R-1234yf)	AR83.30-D-1760D
2	Remove transmitter key.
3	Remove front bumper.	Model 906 with code XM0 (Facelift) or with code XM5 (Facelift Latin America)	AR88.20-D-2000M
		Model 900, model 906 except code XM0 (Facelift) except code XM5 (Facelift Latin America) except code ZX8 (Dodge brand scope) except code ZX9 (Freightliner (FTL) brand scope)	AR88.20-D-2000SD
		MODEL 906 with CODE ZX8 (Dodge brand scope) or with CODE ZX9 (Freightliner (FTL) brand scope)	AR88.20-D-2000SE
4	Remove air duct inserts (4).
5	Remove air intake pipe (3).
6	Pull air filter housing (2) out of supports on front module (1) (arrows).	Model 900, model 906 except with engine 271.951
7	Drain off coolant.		AR20.00-D-1140SD
 Danger	Risk of death when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC)	Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines.	AS00.00-Z-0035-01A
 Danger	Risk of explosion/risk of fire caused by highly flammable materials in the vicinity of damaged xenon bulbs. Risk of injury caused by UV light, hot components on xenon headlamps and glass splinters produced by bursting xenon bulbs. Risk of poisoning caused by inhalation of mercury vapors and by swallowing of/skin contact with toxic salts and mercury compounds.	Do not touch parts conducting high voltage. Persons with active electronic implants (e.g. cardiac pacemakers) must never work on xenon headlamps. Switch off the entire lighting system. Wear insulated safety shoes, safety glasses and protective gloves. Remove highly inflammable materials from the danger zone. Ensure sufficient ventilation in the working area.	AS82.10-Z-0001-01A
8	Disconnect electrical lines to remove front module (1).		AR88.30-D-1064-02SD
9	Unhook engine hood release cable (5) from engine hood catch (6) and lay down to side.
10	Disconnect coolant hoses from cooler.		AR20.20-D-3865-09SD
		 M61	*BA00.10-N-1002-04A
11	Disconnect charge air hose (11) from charge air cooler (12).	Model 900, model 906 with engine 651	AR09.41-D-1311-01WE
		 Model 906 with engine 646Clamp, charge air hose to charge air cooler/throttle valve actuator	*BA09.41-N-1010-01M
12	Immediately plug connections with clean protective covers.	 Set of protective caps	*001589029100
13	Disconnect refrigerant lines from condenser.	Model 900, 906 with code HH9 (Semiautomatic controlled air conditioning, TEMPMATIC)
	Compressor oils (specification 362.0)		BB00.40-P-0362-00A
		 Installation: Replace sealing rings and coat with compressor oil.
		 Nut, refrigerant lines to condenser	*BA83.30-N-1005-01F
14	Immediately plug connections with clean stop plug.	Model 900, 906 with code HH9 (Semiautomatic controlled air conditioning, TEMPMATIC)
		 Record plug	*129589009100
 Warning	Risk of injury to skin or eyes from hydraulic fluid spraying out under pressure.Risk of poisoning from swallowing hydraulic fluid.	Depressurize hydraulic system completely before starting any work on it. Wear protective clothing and safety glasses.	AS00.00-Z-0013-01A
15	Disconnect hydraulic lines from radiator of power steering.	Model 900, 906 up to 02.12.11	AR46.25-D-3020-01SD
		Model 900, 906 as of 02.12.11	AR46.25-D-3020-01SE
		 Record plug	*129589009100
		 Hand pump	*210589007100
16.1	Disconnect upper return line (24) from cooler.	Model 906 with engine 271.951 with transmission 722.684 Model 906 with engine 272.979 with transmission 722.685 Model 906 with engine 646.984/985/986/989/990 with transmission 722.684 Model 906 with engine 651.955/956/957 with transmission 722.686
			AR27.55-D-0100-01US
		 Record plug	*129589009100
16.2	Disconnect front feed line (27) from rear feed line (28).	Model 906 with engine 651.955/956/957 with transmission 722.908
			AR27.10-D-0501-03WE
		 Record plug	*129589009100
17.1	Disconnect rear return line (25) from cooler.	Model 906 with engine 271.951 with transmission 722.684 Model 906 with engine 272.979 with transmission 722.685 Model 906 with engine 646.984/985/986/989/990 with transmission 722.684 Model 906 with engine 651.955/956/957 with transmission 722.686
			AR27.55-D-0100-01US
		 Record plug	*129589009100
17.2	Disconnect front return line (29) from rear return line (25).	Model 906 with engine 651.955/956/957 with transmission 722.908
			AR27.10-D-0501-03WE
		 Record plug	*129589009100
18	Clamp off spray nozzle hose (10) with clamp (9).	Model 900 with code F46 (headlamp cleaning system), model 906 with code F46 (headlamp cleaning system) except code XM0 (facelift) except code XM5 (Latin America facelift)
		 Clamp	*000589403700
19.1	Disconnect spray nozzle hose (7) from spray nozzles (8).	Model 900 with code F46 (headlamp cleaning system), model 906 with code F46 (headlamp cleaning system) except code XM0 (facelift) except code XM5 (Latin America facelift)
		 Installation: Check sealing rings for damage and replace if necessary.
19.2	Unclip spray nozzles (8) from headlamps.	Model 906 with code F46 (headlamp cleaning system) with code XM0 (facelift), model 906 with code F46 (headlamp cleaning system) with code XM5 (Latin America facelift)
20	Immediately plug connections with clean stop plug.	Model 900 with code F46 (headlamp cleaning system), model 906 with code F46 (headlamp cleaning system) except code XM0 (facelift) except code XM5 (Latin America facelift)
		 Record plug	*129589009100
21	Remove screws (17) on both sides.	 Bolt, module carrier to upper and lower A-pillar inner section	*BA88.00-N-1002-01B
22.1	Unscrew bolts (19) and unclip bracket (18) from fender (13).	Model 900, model 906 except code XM0 (Facelift) except code XM5 (Facelift Latin America)
22.2	Unscrew bolts on fender (13) from front module (1).	Model 906 with engine 271.951, 651.955/956 with code XM0 (Facelift) or with code XM5 (Latin America facelift)
23	Insert washers (20) between front module (1) and longitudinal member.	 Washer	*906589003100
24	Install marking (14) on fenders (13) to indicate installation position of front module (1).	Model 900, model 906 except code XM0 (Facelift) except code XM5 (Facelift Latin America)
25	Remove headlamps.		AR82.10-D-4730H
26	Remove screws (15) on both sides.	 M61	*BA00.10-N-1002-04A
27	Remove screw/bolts (21) .	 Bolt, module carrier to longitudinal member bracket	*BA88.00-N-1003-01B
28	Fold air duct insert (16) toward inside.
29	Lift out front module (1) with aid of helper.	 Installation: Position front module (1) on vehicle so that bolt holes for bolts (15) in front module (1) are centered in relation to the threaded holes of fender (13).
30	Install assembly device on front module (1).		AR88.30-D-1064-01SD
		 Assembly device	*639589026200
		 Mounting plates	*906589026200
31	Install in the reverse order
32	Charge power-steering pump and bleed.		AR46.30-S-0010S
33	Check oil level in automatic transmission and correct if necessary.	Model 906 with engine 271.951 with transmission 722.6 Model 906 with engine 272.979 with transmission 722.6 Model 906 with engine 646.984/985/986/989/990 with transmission 722.6 Model 906 with engine 646.984/985/986/989/990 with transmission 722.9 Model 906 with engine 651.955/956 with transmission 722.9 Model 906 with engine 651.955/956/957 with transmission 722.6
		Model 906 with engine 646.984/985/986/989/990 with transmission 722.9 Transmission without guide tube for oil dipstickModel 906 with engine 651.955/956 with transmission 722.9Transmission without guide tube for oil dipstick	AR27.00-D-0270WE
		Model 906 with engine 272.979 with transmission 722.68 Model 906 with engine 646.984/985/986/989/990 with transmission 722.68 Model 906 with engine 651.955/956/957 with transmission 722.68 Model 906.1/2/6/7 with engine 271.951 with transmission 722.68	AR27.00-D-0270-01A
		Model 906 with engine 646.984/985/986/989/990 with transmission 722.9 Transmission with guide tube for oil dipstickModel 906 with engine 651.955/956 with transmission 722.9Transmission with guide tube for oil dipstick	AR27.00-D-0101WE
		 Model 906 with engine 271.951 with transmission 722.684 Model 906 with engine 272.979 with transmission 722.685 Model 906 with engine 646.984/985/986/989/990 with transmission 722.684 Model 906 with engine 651.955/956/957 with transmission 722.686Automatic transmission fluid ATF	*BF27.00-N-1001-01A
		 Funnel	*126589126300
		 Model 906 with engine 271.951 with transmission 722.6 Model 906 with engine 272.979 with transmission 722.6 Model 906 with engine 646.984/985/986/989/990 with transmission 722.6 Model 906 with engine 651.955/956/957 with transmission 722.6 Dipstick	*140589152100
		 Hand pump	*210589007100
34	Check feed lines (27, 28) or return lines (24, 25, 29) for leakage when engine is running.	Model 906 with engine 271.951 with transmission 722.6 Model 906 with engine 272.979 with transmission 722.6 Model 906 with engine 646.984/985/986/989/990 with transmission 722.6 Model 906 with engine 651.955/956/957 with transmission 722.6 Model 906 with engine 651.955/956/957 with transmission 722.9
35	Check headlamp adjustment and correct if necessary.
		Model 900 Model 906 with engine 271.951, 272.979, 646.984/985/986/989/990, 651.955/956/957 except code LG0 (Bi-xenon headlamps) except code LG1 (Bi-xenon headlamps with cornering function)	AP82.10-D-8260A
		Model 906 with engine 271.951, 272.979, 646.984/985/986/989/990, 651.955/956/957 with code LG0 (Bi-xenon headlamps) with code LG1 (Bi-xenon headlamps with cornering function)	AP82.10-D-8260B

 Metric bolts and nuts as per MBN 10 105, 10 143

Number	Designation		8.8	10.9
BA00.10-N-1002-04A	M61	Nm	9	13

 Charge air pipe/charge air cooling

Number	Designation		Engine 646 in model 906
BA09.41-N-1010-01M	Clamp, charge air hose to charge air cooler/throttle valve actuator	Nm	5,5

 Air conditioning

Number	Designation		Model 900 with code HH9	Model 906, 909 with code HH9
BA83.30-N-1005-01F	Nut, refrigerant lines to condenser	Nm	6	6

 Lock crossmember

Number	Designation			Model 900	Model 906
BA88.00-N-1002-01B	Bolt, module carrier to upper and lower A-pillar inner section	M8	Nm	10	10

 Lock crossmember

Number	Designation			Model 900	Model 906
BA88.00-N-1003-01B	Bolt, module carrier to longitudinal member bracket	M8	Nm	20	20

 Automatic transmission

Number	Designation				Transmission 722.683/684/685/686
BF27.00-N-1001-01A	Automatic transmission fluid ATF	Filling capacity - complete refill		Liter	7,1
		Filling capacity - oil change		Liter	7,1
		Filling capacity, transmission oil change	with torque converter	Liter	7,1
		Filling capacity, transmission oil change	without torque converter	Liter	5,5
			Sheet		-
			Sheet		BB00.40-P-0236-14A
			Sheet		-
			Sheet		-
			Sheet		-

140 589 15 21 00

Dipstick

210 589 00 71 00

Hand pump

639 589 02 62 00

Assembly device

129 589 00 91 00

Record plug

000 589 40 37 00

Clamp

906 589 02 62 00

Mounting plates

126 589 12 63 00

Funnel

906 589 00 31 00

Washer

001 589 02 91 00

Set of protective caps

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