Remove/install front module

AR88.30-D-1064SE

Remove/install front module

18.11.2019

Model

906 with engine 642.896/898/992/993

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

1

Front module

16

Air duct insert

20

Refrigerant line separating point

13

Fender

17

Screw

21

Nut

14

Marking

18

Bracket

22

Washer

15

Screw

19

Screw

23

Bolts

Shown on model 906 with transmission 722.9 with oil cooler automatic transmission integrated in the radiator

24

Upper return line

25

Rear return line

27

Front feed line

28

Rear feed line

29

Front return line

Shown on model 906 with transmission 722.9 without oil cooler automatic transmission integrated in the radiator

25

Rear return line

27

Front feed line

28

Rear feed line

29

Front return line

 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 642.896 with transmission 722.9
Model 906 with engine 642.898 with transmission 722.9
Model 906 with engine 642.993 with transmission 722.9
Model 906.1/2/6/7 with engine 642.896 with transmission 722.6
Model 906.1/2/6/7 with engine 642.898 with transmission 722.6
Model 906.1/2/6/7 with engine 642.992 with transmission 722.6
Model 906.1/2/6/7 with engine 642.993 with transmission 722.6

AH27.19-P-0001-01NKB

 

Remove/install

1

Drain air conditioning system

Model 906 with engine 642.896/898/992/993
with code HK4 (Rear air conditioning, reinforced)
with code ZL3 (National version for Latin America)

AR83.30-D-1760WE

Model 906 with engine 642.896/898/992/993
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 642.896/898/992/993
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 642.896/898/992/993
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 engine 642.896/898
with code XM0 (Facelift)
Model 906 with engine 642.896/898
with code XM5 (Facelift Latin America)

AR88.20-D-2000M

Model 906 with engine 642.896/898
except code XM0 (Facelift)
except code XM5 (Facelift Latin America)
except code ZX8 (Dodge execution)
except code ZX9 (Freightliner execution)

AR88.20-D-2000SD

Model 906 with engine 642.896/898/992/993
with code ZX8 (Dodge execution)
except code XM0 (Facelift)
except code XM5 (Facelift Latin America)
Model 906 with engine 642.896/898/992/993
with code ZX9 (Freightliner execution)
except code XM0 (Facelift)
except code XM5 (Facelift Latin America)

AR88.20-D-2000SE

4

Remove air duct inserts (4)

5

Remove air intake pipe (3)

6

Pull air filter housing (2) out of mounts on front module (1) (arrows)

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)

AR09.41-D-8619M

12

Unscrew nut (21) from refrigerant line separating point (20)

Model 906 with engine 642.896/898/992/993
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 642.896/898/992/993
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 642.896/898/992/993
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)
Model 906 with engine 642.896/898/992/993
with code HK4 (Rear air conditioning, reinforced)
with code ZL3 (National version for Latin America)

 Nut, refrigerant lines to expansion valve

*BA83.30-N-1001-01F

13

Disconnect refrigerant lines from condenser

Model 906 with engine 642.896/898/992/993
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 642.896/898/992/993
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 642.896/898/992/993
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)
Model 906 with engine 642.896/898/992/993
with code HK4 (Rear air conditioning, reinforced)
with code ZL3 (National version for Latin America)



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 906 with engine 642.896/898/992/993
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 642.896/898/992/993
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 642.896/898/992/993
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)
Model 906 with engine 642.896/898/992/993
with code HK4 (Rear air conditioning, reinforced)
with code ZL3 (National version for Latin America)

 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 906 as of 12/2/11 with engine 642.896/898/992/993

AR46.25-D-3020-01SE

Model 906 up to 12/2/11 with engine 642.896/898/992/993

AR46.25-D-3020-01SD

 Record plug

*129589009100

 Hand pump

*210589007100

16

Disconnect upper return line (24) from cooler

Model 906 with engine 642.896 with transmission 722.902
with automatic transmission cooler integrated into coolerModel 906 with engine 642.896/898/992/993 with transmission 722.683
Model 906 with engine 642.898 with transmission 722.902
with automatic transmission cooler integrated into coolerModel 906 with engine 642.898 with transmission 722.908
with automatic transmission cooler integrated into coolerModel 906 with engine 642.993 with transmission 722.908with automatic transmission cooler integrated into cooler

AR27.55-D-0100-01US

 Record plug

*129589009100

17.1

Disconnect rear return line (25) from cooler

Model 906 with engine 642.896 with transmission 722.902
with automatic transmission cooler integrated into coolerModel 906 with engine 642.896/898/992/993 with transmission 722.683
Model 906 with engine 642.898 with transmission 722.902
with automatic transmission cooler integrated into coolerModel 906 with engine 642.898 with transmission 722.908
with automatic transmission cooler integrated into coolerModel 906 with engine 642.993 with transmission 722.908with automatic transmission cooler integrated into cooler

AR27.55-D-0100-01US

 Record plug

*129589009100

17.2

Disconnect front return line (29) from rear return line (25)

Model 906 with engine 642.896 with transmission 722.902
without automatic transmission cooler integrated into coolerModel 906 with engine 642.898 with transmission 722.902
without automatic transmission cooler integrated into coolerModel 906 with engine 642.898 with transmission 722.908
without automatic transmission cooler integrated into coolerModel 906 with engine 642.993 with transmission 722.908without automatic transmission cooler integrated into cooler

AR27.10-D-0501-03WE

 Record plug

*129589009100

18

Disconnect front return line (29) from upper return line (24)

Model 906 with engine 642.896 with transmission 722.902
with automatic transmission cooler integrated into coolerModel 906 with engine 642.898 with transmission 722.902
with automatic transmission cooler integrated into coolerModel 906 with engine 642.898 with transmission 722.908
with automatic transmission cooler integrated into coolerModel 906 with engine 642.993 with transmission 722.908with automatic transmission cooler integrated into cooler

AR27.10-D-0501-03WE

 Record plug

*129589009100

19

Disconnect front feed line (27) from rear feed line (28)

Model 906 with engine 642.896 with transmission 722.902
Model 906 with engine 642.898 with transmission 722.902
Model 906 with engine 642.898 with transmission 722.908
Model 906 with engine 642.993 with transmission 722.908

AR27.10-D-0501-03WE

 Record plug

*129589009100

20

Clamp off spray nozzle hose (10) with clamp (9)

Model 906 with engine 642.896/898/992/993
with code F46 (Headlamp washing system)

 Clamp

*000589403700

21.1

Disconnect spray nozzle hose (7) from spray nozzles (8)

Model 906 with engine 642.896/898/992/993
with code F46 (Headlamp washing system)
except code XM0 (Facelift)
except code XM5 (Facelift Latin America)

 Installation: Check sealing rings for damage; replace if necessary.

21.2

Unclip spray nozzles (8) from headlamps

Model 906 with engine 642.896/898/992/993
with code F46 (Headlamp washing system)
with code XM0 (Facelift)
Model 906 with engine 642.896/898/992/993
with code F46 (Headlamp washing system)
with code XM5 (Facelift Latin America)

22

Immediately plug connections with clean stop plug

Model 906 with engine 642.896/898/992/993
with code F46 (Headlamp washing system)
except code XM0 (Facelift)
except code XM5 (Facelift Latin America)

 Record plug

*129589009100

23

Unscrew bolts (19) on left and right side of vehicle

 Bolt, module carrier to upper and lower A-pillar inner section

*BA88.00-N-1002-01B

24

Unscrew bolts (17) on left and right side of vehicle and unclip bracket (18) on fender (13)

25

Insert subbases (22) on left and right side of vehicle between front module (1) and longitudinal member

 Washer

*906589003100

26

Mark (14) fenders (13) on both sides to indicate installation position of front module (1)

Model 906 with engine 642.896/898/992/993
except code XM0 (Facelift)
except code XM5 (Facelift Latin America)

27

Unscrew bolts (15) on left and right side of vehicle

 M61

*BA00.10-N-1002-04A

28

Unscrew bolts (23) on left and right side of vehicle

 Bolt, module carrier to longitudinal member bracket

*BA88.00-N-1003-01B

29

Fold air duct insert (16) toward inside

30

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). A uniform gap should be present between the fenders (13) and lamp units, if required, align lamp units in relation to fenders (13).

31

Install assembly device on front module (1)

AR88.30-D-1064-01SD

 Assembly device

*639589026200

 Mounting plates

*906589026200

32

Install in the reverse order

33

Fill power steering pump and bleed

AR46.30-S-0010S

34

Check oil level in A/T and correct if necessary

Model 906 with engine 642.896 with transmission 722.9
Transmission without guide tube for oil dipstickModel 906 with engine 642.898 with transmission 722.9
Transmission without guide tube for oil dipstickModel 906 with engine 642.993 with transmission 722.9Transmission without guide tube for oil dipstick

AR27.00-D-0270WE

Model 906 with engine 642.896 with transmission 722.9
Transmission with guide tube for oil dipstickModel 906 with engine 642.898 with transmission 722.9
Transmission with guide tube for oil dipstickModel 906 with engine 642.993 with transmission 722.9Transmission with guide tube for oil dipstick

AR27.00-D-0101WE

Model 906.1/2/6/7 with engine 642.896 with transmission 722.6
Model 906.1/2/6/7 with engine 642.898 with transmission 722.6
Model 906.1/2/6/7 with engine 642.992 with transmission 722.6
Model 906.1/2/6/7 with engine 642.993 with transmission 722.6

AR27.00-D-0270-01A

 Model 906 with engine 642.896/898/992/993 with transmission 722.683Automatic transmission fluid ATF

*BF27.00-N-1001-01A

 Funnel

*126589126300

 Model 906 with engine 642.896/898/992/993 with transmission 722.6
Dipstick

*140589152100

 Hand pump

*210589007100

35

Check feed lines (27, 28) or return lines (24, 25, 29) for leakage when engine is running.

Model 906 with engine 642.896 with transmission 722.9
Model 906 with engine 642.896/898/992/993 with transmission 722.6
Model 906 with engine 642.898 with transmission 722.9
Model 906 with engine 642.993 with transmission 722.9

36

Check headlamp adjustment and correct if necessary

After aligning lamp units in relation to fenders (13).



Model 906 with engine 642.896/898/992/993
except code LG0 (Bi-xenon headlamps)
except code LG1 (Bi-xenon headlamps with cornering function)

AP82.10-D-8260A



Model 906 with engine 642.896/898/992/993
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

 Air conditioning

Number

Designation

Model 906.6/7 with code H08

Model 906, 909 with code HH9

BA83.30-N-1001-01F

Nut, refrigerant lines to expansion valve

Nm

6

6

 Air conditioning

Number

Designation

Model 906.6/7 with code HH7

Model 906 as of 14.04.14 up to 31.12.15 with code HK4, IR4, ZL3 (without condenser module on roof (KONVEKTA))

BA83.30-N-1001-01F

Nut, refrigerant lines to expansion valve

Nm

6

-

 Air conditioning

Number

Designation

Model 906 up to 13.04.14 with code HK4, IR4, ZL3 (with condenser module on roof (KONVEKTA))
Model 906 up to 31.12.15 with code HK4, ZL3, except code IR4 (with condenser module on roof (KONVEKTA))

Model 906 as of 01.01.16 with code HK4, ZL3, except code IR4 (with condenser module on roof (MAHLE))

BA83.30-N-1001-01F

Nut, refrigerant lines to expansion valve

Nm

-

8

 Air conditioning

Number

Designation

Model 906 as of 01.01.16 with code HK4, IR4, ZL3 (without condenser module on roof (MAHLE))

BA83.30-N-1001-01F

Nut, refrigerant lines to expansion valve

Nm

8

 Air conditioning

Number

Designation

Model 906.6/7 with code H08

Model 906, 909 with code HH9

BA83.30-N-1005-01F

Nut, refrigerant lines to condenser

Nm

6

6

 Air conditioning

Number

Designation

Model 906.6/7 with code HH7

Model 906 as of 14.04.14 up to 31.12.15 with code HK4, IR4, ZL3 (without condenser module on roof (KONVEKTA))

BA83.30-N-1005-01F

Nut, refrigerant lines to condenser

Nm

6

6

 Air conditioning

Number

Designation

Model 906 up to 13.04.14 with code HK4, IR4, ZL3 (with condenser module on roof (KONVEKTA))
Model 906 up to 31.12.15 with code HK4, ZL3, except code IR4 (with condenser module on roof (KONVEKTA))

Model 906 as of 01.01.16 with code HK4, ZL3, except code IR4 (with condenser module on roof (MAHLE))

BA83.30-N-1005-01F

Nut, refrigerant lines to condenser

Nm

-

8

 Air conditioning

Number

Designation

Model 906 as of 01.01.16 with code HK4, IR4, ZL3 (without condenser module on roof (MAHLE))

BA83.30-N-1005-01F

Nut, refrigerant lines to condenser

Nm

6

 Lock crossmember

Number

Designation

Model 906

BA88.00-N-1002-01B

Bolt, module carrier to upper and lower A-pillar inner section

M8

Nm

10

 Lock crossmember

Number

Designation

Model 906

BA88.00-N-1003-01B

Bolt, module carrier to longitudinal member bracket

M8

Nm

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

-