Remove/install upper cross member front module

AR88.30-S-1940EV

Remove/install upper cross member front module

27.11.2019

Model

639.603/703 with engine 780.994

with code MA0 (E-CELL 60 kW)

Shown on MODEL 639.603 with vehicle identification number up to 745075

1

Upper cross member front module

4

Engine hood cable

6

Electrical connector

2

Bracket

5

Engine hood catch

7

Electrical connector

3

Electrical wiring harness

Shown on MODEL 639.603 with vehicle identification number up to 745075

1

Upper cross member front module

9

Bolts

10

Electrical wiring harness

8

Screw

1

Upper cross member front module

2

Bracket

11

Electrical wiring harness

12

Electrical wiring harness

 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

Topical note

General information on handling vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system

AH00.00-Z-0300-01A

 

Remove/install

1

Open engine hood and secure against falling down

2

Perform power disconnect on high voltage system

AR54.10-S-1160EV

3

Remove front bumper

AR88.20-S-2000S

4

Remove left front lamp unit and right front lamp unit

AR82.10-S-4720S

5

Unclip electrical wiring harness (3) from brackets (2) on upper front module crossmember (1)

6

Disconnect electrical connection (6, 7)

7

Detach coolant hoses

AR88.30-S-1065EV

8

Unclip engine hood cable (4) from bracket on upper front module crossmember (1) and unhook from engine hood catch (5)

9

Remove electrical wiring harness (10) from upper front module carrier (1)

 Installation: Replace cable ties.

10

Unscrew bolts (8, 9) from upper front module crossmember (1)

 Bolt, upper crossmember to lower crossmember

*BA62.30-N-1005-01A

 Bolt, frame to front module reinforcement

*BA62.30-N-1006-01A

11

Remove upper front module crossmember (1) with aid of helper and lay down on workbench

12

Remove signal horn

When replacing upper front module crossmember (1).

AR54.35-S-1556S

13

Remove radiator unit

Model 639.603 ## up to 745075, 639.703 ## up to 717332 with engine 780.994 with code MA0 (E-CELL 60 kW)
When replacing upper front module crossmember (1).

AR20.20-S-3871EV

14

Remove radiator

Model 639.603 ## as of 745076, 639.703 ## as of 717332 with engine 780.994 with code MA0 (E-CELL 60 kW)
When replacing upper front module crossmember (1).

AR20.20-S-3865EVV

15

Remove electrical wiring harness (12) from upper front module crossmember (1)

When replacing upper front module crossmember (1).

16

Remove fan unit

When replacing upper front module crossmember (1).

AR20.40-S-5050EV

17

Remove electrical wiring harness (11) from upper front module crossmember (1)

When replacing upper front module crossmember (1).

18

Remove engine hood catch (5)

When replacing upper front module crossmember (1).

 Screw/bolt, engine hood catch to lock carrier

*BA88.40-N-1002-01B

19

Remove bracket (2) from upper front module crossmember (1)

When replacing upper front module crossmember (1).

20

Install in the reverse order

21

Adjust engine hood catch, if necessary adjust engine hood catch (5)

AR88.40-S-3020S

 Cross member and front reinforcement

Number

Designation

Model 636, 639

BA62.30-N-1005-01A

Bolt, upper crossmember to lower crossmember

M8

Nm

18

 Cross member and front reinforcement

Number

Designation

Model 636, 639

BA62.30-N-1006-01A

Bolt, frame to front module reinforcement

M8

Nm

25

 Engine hood

Number

Designation

Model 636, 639

BA88.40-N-1002-01B

Screw/bolt, engine hood catch to lock carrier

Nm

10