Retrofit transmission oil cooler

AN27.55-S-1000B

Retrofit transmission oil cooler

13.12.07



Removing

1

Disconnect ground cable at battery



AR54.10-S-0005A

2

Drain power-steering hydraulic system.



AR46.30-S-9999A

3

Drain transmission oil



AP27.00-D-2701A

4

Remove front grille



AR88.00-S-2115A

5

Take off front wheels



AR40.10-S-1100A

6

Remove front bumper



AR88.20-S-2000A

7

Remove charge air pipe



 For engine 601.970

AR09.41-S-8620A



 For engine 611.980

AR09.41-S-8620B

8

Remove connector hose between steering fluid reservoir and cooling pipe

9

Remove return line (6) from automatic transmission and oil cooler

10.1

Detach mounting clamp from housing of automatic transmission

 For engine 601.970

11.1

Remove steering low-pressure line

 For engine 601.970

12

Remove steering cooling pipe

13.1

Remove mounting clamp from feed line

 For engine 601.970

 The mounting clamp is on the side of the automatic transmission oil pan.



Install

14.1

Install steering low-pressure line (1)

 For engine 601.970

 Installation: Use a spacer (2) between the new low-pressure line (1) and axle/engine subframe (26).



*BA46.20-N-1002-01A

15.1

Attach bracket (4) to housing of automatic transmission

 For engine 601.970

 The bracket (4) is installed in place of the previously installed mounting clamp.



*BA27.40-N-1010-01A

16

Secure feed line (5) to bracket (4) using a mounting clamp

17

Route oil line (3) to oil cooler and position so that it points downward

18

Secure oil line (3) to holder (4) using a mounting clamp

19

Tighten union nut securing oil line (3) to oil cooler



*BA27.55-N-1004-01E

20

Install new return line (6)

Replace gasket (7).



*BA27.55-N-1003-01E

21

Attach bracket (8) to housing of automatic transmission



*BA27.40-N-1010-01A

22

Secure new return line (6) to existing bracket (arrow) using a mounting clamp

23

Secure new return line (6) to bracket (8) using a mounting clamp

24.1

Unscrew two bolts securing oil pan and install bracket (9)

 With engine 601.970 without code H06 (Air conditioning system).

 The bracket (9) is fitted to the side of the oil dipstick guide tube.



*BA01.45-N-1001-01H

25

Secure return line (6) to bracket (9) using an additional mounting clamp (30)

Replace bolt (10) with a longer bolt.

26

Secure return line (6) to oil line (3) using mounting clamps (11)

27

Bolt lower bracket (12) to axle/engine subframe

 Make sure that the rubber guides are seated correctly.



*BA27.55-N-1008-01E

28

Screw screw-in fitting (14) onto oil cooler (13)

 Use the seal ring (15).



*BA27.55-N-1007-01E

29

Insert oil cooler (13) in lower bracket (12)

 Do not damage the condenser.

30

Insert upper bracket (16) at oil cooler (13)

 Make sure that the rubber guides are seated correctly.

31

Bolt upper bracket (16) onto crossmember (17)

 Avoid damaging paint on the body.

 Use a new clip nut.



*BA27.55-N-1009-01E

32

Attach fuses to oil cooler (13) below lower bracket (12)

33

Bolt oil line (3) and return line (6) to oil cooler (13)

 Counterhold the oil lines (3, 6) when tightening.

 Ensure unstressed installation.



*BA27.55-N-1005-01E



*BA27.55-N-1006-01E

34

Bolt bracket (18) on left and right of axle/engine subframe



*BA27.40-N-1010-01A

35

Secure hose (22) to connecting pipe (21) and low-pressure line (1)

 Do not tighten the screw clamps yet.

36

Secure connecting pipe (21) to axle/engine subframe using a mounting clamp

 Use spacer (24).

37

Secure hose (23) to cooling pipe (19) and connecting pipe (21)

 Do not tighten the screw clamps yet.

38

Secure cooling pipe (19) to bracket (18) using mounting clamps (20)

 Do not tighten the screw clamps yet.

39

Secure return hose (24) to cooling pipe (19) and fluid reservoir (25)

 Do not tighten the screw clamps yet.

Attach supplied rubber bumpers.

 Installation: Fit the supplied rubber bumpers to the return hose (24) and position the rubber bumpers such that there can be no contact with the cooler housing (27), axle/engine subframe (26) and oil pan (transmission).

40

Secure return hose (24) to existing screw bolts of axle/engine subframe (26)

 Position the return hose (24) such that there can be no contact between the cooler housing (27) and axle/engine subframe (26).

 Use spacer (25).

41

Tighten mounting clamps on hose (22), hose (23), cooling pipe (19) and return hose (24)

 Ensure unstressed installation.

42

Install charge air pipe



 For engine 601.970

AR09.41-S-8620A



 For engine 611.980

AR09.41-S-8620B

43

Install front bumper



AR88.20-S-2000A

44

Attach front wheels



AR40.10-S-1100A

45

Install grille



AR88.00-S-2115A

46

Fill steering hydraulic system



AR46.30-S-9999A

47

Pour in gear oil



AP27.00-D-2701A

48

Connect ground cable to battery



AR54.10-S-0005A

Checking

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running

Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

49

Check steering and automatic transmission for leaks

 Run engine, switch off and inspect for leaks.

50

Perform function test on steering and automatic transmission

Number

Designation

Engine
601.970

BA01.45-N-1001-01H

Bolt, oil pan to cylinder crankcase

M6

Nm

10

M8

Nm

23

M10

Nm

-

Number

Designation

Model
638.014/034/094/114/134/194/214/234/294
with code
G40

BA27.40-N-1010-01A

Bolt, oil pump housing with multi-disk brake B1 to torque converter housing

Nm

-

Number

Designation

Model
638.074/094/174/194/274/294
with code G40
and code GK3

BA27.55-N-1002-01E

Banjo bolt, oil feed line to transmission

Nm

25

BA27.55-N-1003-01E

Banjo bolt, oil return line to transmission

Nm

25

BA27.55-N-1004-01E

Union nut, oil lines to oil cooler

Nm

25

BA27.55-N-1005-01E

Union nut, oil line to additional oil cooler

Nm

18

BA27.55-N-1006-01E

Union nut, return line to additional oil cooler

Nm

18

BA27.55-N-1007-01E

Screw-in fitting to additional oil cooler

Nm

18

BA27.55-N-1008-01E

Bolt, lower bracket to axle/engine subframe

Nm

8

BA27.55-N-1009-01E

Bolt, upper bracket to crossmember

Nm

8

Number

Designation

Model
638.074/094/174/194/274/294
with code G40
and code GK3

BA31.35-N-1006-01A

Nut, bracket to axle/engine subframe

Nm

8

Number

Designation

Steering 763.000 in model 638

BA46.20-N-1002-01A

Return flow line to steering gear

Nm

37

Part no.

Designation

Quantity

A000 500 02 00 05

Additional oil cooler kit (OM601.970)

1

A000 500 03 00 05

Additional oil cooler kit (OM611.980)

1