Remove/install radiator unit

AR20.20-Y-3871D

Remove/install radiator unit

23.10.2019

Engine

400.925/926/927/928 in model 831.001/002/005

(LHD)

Radiator and charge air cooler removal and installation procedure

1

Expansion reservoir coolant feed hose (worm-drive clamps)

2

Expansion reservoir inlet hose

3

Expansion reservoir coolant return hose (radiator end)

4

Water pump outlet hose (radiator inlet hose)

5

Radiator coolant outlet hose (bottom hose)

6

Water pump inlet hose

9

Cotter pin

11

Radiator mounting bracket bolts

7

Inter-cooler inlet hose

10

Stay rod

12

Radiator unit

8

Inter-cooler outlet hose

 

Remove/install

 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 on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Notes on coolant

AH20.00-N-2080-01A

1

Drain coolant from radiator.

AR20.00-Y-1142D

2

Drain coolant from expansion reservoir.

AR20.30-Y-4949D

3

Remove expansion reservoir coolant feed hose by loosening the worm-drive clamps (1).

 Coolant feed hose lies between expansion reservoir and radiator coolant outlet pipe.

 Expansion reservoir coolant feed hose (worm-drive clamps)

*BA20.20-Y-1010-02A

4

Remove expansion reservoir inlet hose (2) by loosening the tag and remove the hose clamp bolt on expansion reservoir.

 Expansion reservoir inlet hose (2) lies between expansion reservoir and expansion reservoir metal pipe.

 Expansion line inlet hose clamp bolt

*BA20.20-Y-1009-02A

5

Remove expansion reservoir coolant return hose (radiator end) (3) from radiator by loosening the worm-drive clamps.

 Expansion reservoir coolant return hose (worm-drive clamps)

*BA20.20-Y-1007-02A

6

Remove water pump outlet hose (radiator inlet hose) (4) by loosening the worm-drive clamps.

 Radiator inlet hose (4) lies between water pump and radiator.

 Water pump outlet hose (worm-drive clamps)

*BA20.20-Y-1008-02A

7

Remove radiator coolant outlet hose (Bottom hose) (5) by loosening the worm-drive clamps.

 Radiator coolant outlet hose (bottom hose) (5) lies between radiator and coolant outlet pipe.

 Radiator coolant outlet hose (bottom hose) - worm-drive clamps

*BA20.20-Y-1006-02A

8

Remove water pump inlet hose (6) by loosening the worm-drive clamps.

 Water pump inlet hose (6) lies between coolant outlet pipe and water pump.

 Water pump inlet hose (worm-drive clamps)

*BA20.20-Y-1005-02A

9

Remove the inter-cooler inlet hose (7) from inter-cooler intake port by loosening the worm gear drive clamps.

 Inter cooler inlet hose to the intercooler inlet port (worm-drive clamp)

*BA20.20-Y-1004-02A

10

Remove inter-cooler outlet hose (8) between inter-cooler outlet port and outlet pipe by removing the worm- drive clamps.

 Inter-cooler outlet hose (8) lies between inter-cooler outlet port and outlet pipe.

 Intercooler outlet hose to the intercooler outlet port (worm-drive clamp)

*BA20.20-Y-1003-02A

11

Remove the cotter pin (9) on the stay rod groove on both sides.

 Take out the washers, and remove the stay rod (10) from the radiator.

12

Remove radiator mounting bracket bolts (11) on both sides with rubber buffer, support washer and thrust plate.

 Radiator mounting bracket bolts

*BA20.20-Y-1002-02A

13

Lift the radiator unit (12) from the vehicle.


Be cautious while lifting the radiator.
To avoid damaging the radiator fins and the chassis frame.

 Installation: Ensure radiator fins are not damaged during installation into vehicle.

14

Remove the charge air cooler from the radiator.

 Charge air cooler to the radiator

*BA20.20-Y-1001-02A

15

Install in the reverse order.

 Radiator and charge air cooler

Number

Designation

Engine 400.925/926/927/928 in model 831.001/002/005

BA20.20-Y-1001-02A

Charge air cooler to the radiator

Nm

202

 Radiator and charge air cooler

Number

Designation

Engine 400.925/926/927/928 in model 831.001/002/005

BA20.20-Y-1002-02A

Radiator mounting bracket bolts

Nm

9018

 Radiator and charge air cooler

Number

Designation

Engine 400.925/926/927/928 in model 831.001/002/005

BA20.20-Y-1003-02A

Intercooler outlet hose to the intercooler outlet port (worm-drive clamp)

Nm

5.50.5

 Radiator and charge air cooler

Number

Designation

Engine 400.925/926/927/928 in model 831.001/002/005

BA20.20-Y-1004-02A

Inter cooler inlet hose to the intercooler inlet port (worm-drive clamp)

Nm

5.50.5

 Radiator and charge air cooler

Number

Designation

Engine 400.925/926/927/928 in model 831.001/002/005

BA20.20-Y-1005-02A

Water pump inlet hose (worm-drive clamps)

Nm

5.50.5

 Radiator and charge air cooler

Number

Designation

Engine 400.925/926/927/928 in model 831.001/002/005

BA20.20-Y-1006-02A

Radiator coolant outlet hose (bottom hose) - worm-drive clamps

Nm

3.90.5

 Radiator and charge air cooler

Number

Designation

Engine 400.925/926/927/928 in model 831.001/002/005

BA20.20-Y-1007-02A

Expansion reservoir coolant return hose (worm-drive clamps)

Nm

5.50.5

 Radiator and charge air cooler

Number

Designation

Engine 400.925/926/927/928 in model 831.001/002/005

BA20.20-Y-1008-02A

Water pump outlet hose (worm-drive clamps)

Nm

4.5

 Radiator and charge air cooler

Number

Designation

Engine 400.925/926/927/928 in model 831.001/002/005

BA20.20-Y-1009-02A

Expansion line inlet hose clamp bolt

Nm

3.90.5

 Radiator and charge air cooler

Number

Designation

Engine 400.925/926/927/928 in model 831.001/002/005

BA20.20-Y-1010-02A

Expansion reservoir coolant feed hose (worm-drive clamps)

Nm

3.90.5