1 | Coolant hose |
2 | Air recirculation partition |
3 | Coolant hose |
4 | Coolant hose |
5 | Radiator |
6 | Screw |
7 | Refrigerant line |
8 | Refrigerant line |
9 | Left charge air hose |
10 | Right charge air hose |
11 | Lines |
12 | Steering gear oil reservoir |
24 | Fan shroud |
W20.20-A003-76
5 | Radiator |
8 | Refrigerant line |
11 | Lines |
13 | Condenser |
14 | Screw |
15 | Screw |
16 | Charge air cooler |
17 | Screw |
18 | Screw |
19 | Screw |
20 | Screw |
21 | Refrigerant line |
W20.20-A002-76
22 | Screws |
23 | Screws |
W20.20-A001-76
Danger | Risk of explosion caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant. | Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been drained. | |
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. | |
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. | |
Topical note | Notes on self-locking nuts and bolts | ||
Topical note | Notes on avoiding damage through contamination and foreign objects | ||
Topical note | Notes on coolant | ||
Topical note | Protect air conditioning circuit and components from moisture when carrying out repair work | ||
Notes on handling refrigerant R134a | |||
| Remove/install | ||
1 | Drain coolant at radiator. | ||
2 | Remove protective plate under engine. | Only in vehicles with code M7H (protective plate, cooler to engine) | |
3 | Remove lower coolant hose (1) from radiator (5). | ||
4 | Discharge air conditioning system. | Only for vehicles with code D6F (Air conditioning) | |
5 | Remove air recirculation partition (2) from the cooler unit. | ||
6 | Remove upper coolant hose (3) from radiator (5). | ||
7 | Remove coolant hose (4) on radiator (5) and fasten to one side. | ||
8 | Unscrew screws (6) and remove refrigerant line (7) from radiator (5), fasten to one side. | Only for vehicles with code D6F (Air conditioning) | |
9 | Remove left charge air hose (9) and right charge air hose (10). | Clamp, charge air hose to charge air pipe and charge air cooler | |
10 | Remove screw (18). | Only for vehicles with code D6F (Air conditioning) | |
11 | Unscrew screw (17) and remove refrigerant line (8) from condenser (13). | Only for vehicles with code D6F (Air conditioning) | |
| Compressor oils (specification 362.0) | ||
Installation: Moisten new O-ring on refrigerant line (8) with compressor oil. | |||
Bolt, refrigerant line to condenser | |||
12 | Remove screws (14, 15). | ||
13 | Remove steering lines (11) from charge air cooler (16). | ||
14 | Remove steering gear oil reservoir (12) from the cooler unit and fasten to one side with connected lines (11). | ||
15 | Fasten refrigerant line (8) to one side. | Only for vehicles with code D6F (Air conditioning) | |
16 | Remove screw (19). | Only for vehicles with code D6F (Air conditioning) | |
17 | Unscrew screw (20) and remove refrigerant line (21) from condenser (13). | Only for vehicles with code D6F (Air conditioning) | |
| Compressor oils (specification 362.0) | ||
Installation: Moisten new O-ring on refrigerant line (21) with compressor oil. | |||
Bolt, refrigerant line to condenser | |||
18 | Attach lifting device for the cooler unit. | ||
Lifting device | |||
19 | Unscrew left and right screws (22) of the upper main radiator mounts. | Bolt, bracket for engine radiator to engine radiator main bearing, top | |
20 | Unscrew left and right screws (23) on the lower radiator mounts. | Bolt, retainer wedge to engine radiator bearing, bottom | |
21 | Lift the cooler unit out upwards. | Aid of helper required. | |
The radiator (5), the charge air cooler (16), and the condenser (13) are removed together as a cooler unit. | |||
Installation: Check both upper main radiator mounts and both lower radiator mounts for damage. | |||
If the upper main radiator mounts/lower radiator mounts are damaged: | |||
| |||
Replace the upper main radiator mounts/the lower radiator mounts. | |||
22 | Remove condenser (13) on charge air cooler (16). | Only for vehicles with code D6F (Air conditioning) | |
Screw/bolt, condenser to charge air cooler | |||
23 | Remove fan shroud (24). | Only when replacing the radiator (5) or the fan shroud (24). | |
24 | Remove the charge air cooler (16) on radiator (5). | Only when replacing the radiator (5) or charge air cooler (16). | |
25 | Install in the reverse order. |
963 589 00 62 00
Lifting device
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