Remove/install radiator unit

AR20.20-W-3871Z

Remove/install radiator unit

10.06.2020

Engine

460.9 in model 959

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

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

22

Screws

23

Screws

 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.

AS83.00-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

 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

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-N-5000-01H

Topical note

Notes on coolant

AH20.00-N-2080-01A

Topical note

Protect air conditioning circuit and components from moisture when carrying out repair work

AH83.30-N-0005-01A

Notes on handling refrigerant R134a

AH83.30-N-0003-01A

 

Remove/install

1

Drain coolant at radiator.

AR20.00-W-1142Z

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)

AR83.30-W-1760ZE

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

*BA09.41-N-1002-01Z

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)

BB00.40-P-0362-00A

 Installation: Moisten new O-ring on refrigerant line (8) with compressor oil.

 Bolt, refrigerant line to condenser

*BA83.30-N-1002-01Z

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)

BB00.40-P-0362-00A

 Installation: Moisten new O-ring on refrigerant line (21) with compressor oil.

 Bolt, refrigerant line to condenser

*BA83.30-N-1002-01Z

18

Attach lifting device for the cooler unit.

AR20.20-W-3865-12Z

 Lifting device

*963589006200

19

Unscrew left and right screws (22) of the upper main radiator mounts.

 Bolt, bracket for engine radiator to engine radiator main bearing, top

*BA20.20-N-1002-02Z

20

Unscrew left and right screws (23) on the lower radiator mounts.

 Bolt, retainer wedge to engine radiator bearing, bottom

*BA20.20-N-1003-02Z

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)
Only when replacing the condenser (13) or charge air cooler (16).

 Screw/bolt, condenser to charge air cooler

*BA83.30-N-1001-01Z

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.

 Charge air pipe, charge air cooling

Number

Designation

Engine 460.9 in model 959

BA09.41-N-1002-01Z

Clamp, charge air hose to charge air pipe and charge air cooler

Nm

6

 Engine radiator, coolant hoses and lines

Number

Designation

Engine 460.9 in model 959

BA20.20-N-1002-02Z

Bolt, bracket for engine radiator to engine radiator main bearing, top

Nm

51

 Engine radiator, coolant hoses and lines

Number

Designation

Engine 460.9 in model 959

BA20.20-N-1003-02Z

Bolt, retainer wedge to engine radiator bearing, bottom

Nm

20

 Air conditioning

Number

Designation

Model 959 with body 959.820
with code D6F (Air-conditioning system)

BA83.30-N-1001-01Z

Screw/bolt, condenser to charge air cooler

Nm

18

 Air conditioning

Number

Designation

Model 959 with body 959.820
with code D6F (Air-conditioning system)

BA83.30-N-1002-01Z

Bolt, refrigerant line to condenser

Nm

18