Remove/install front module

AR62.30-P-1575FF

Remove/install front module

17.1.06

 

Remove/install

1

Remove front crossmember

AR62.30-P-1300FF

2

Loosen left frontal acceleration sensor and right frontal acceleration sensor, lay down to side with lines connected and fasten with adhesive tape.

 See: 

Remove/install frontal acceleration sensor

AR91.60-P-0750FF

3

Remove expansion clip (2).

4.1

Unclip refrigerant line (3) from bracket (19) on front module (1) in area of right front lamp unit (E2)

For vehicles with code (I01) Air conditioning Plus (with outside temperature indicator) (FFO)

5.1

Unclip refrigerant line (3) from bracket (20) on alarm signal horn with additional battery (H3/1) in area of right front lamp unit (E2)

On vehicles with code (I01) Air conditioning plus (with outside temperature indicator) (FFO) and code (V40) Alarm system

6

Disconnect electrical connectors (16) from horn (H2)

7

Unclip retaining clamp (17)

8

Unthread horn wiring harness (14) from front module (1) and lay down to side

9

Remove expansion clip (4) from air intake connection (5)

10

Remove air intake connection (5)

 Installation: Ensure that the air intake connection (5) is seated correctly on the air cleaner.

11.1

Unscrew bolt (22) on charge air duct mount in back of charge air cooler.

With engine 122.9 or 639.9

11.2

Unscrew bolt (22) from fuse and relay holder

On vehicles with code (I60) Stationary heater, gasoline

12.1

Loosen STH wiring harness (28) or ATA wiring harness (29) from front module (1)

On vehicles with code (V40) Alarm system or code (I60) Stationary heater, gasoline or code (I58) Stationary heater, diesel

13.1

Disconnect electrical connector (21) from ATA engine hood switch and lay wiring harness down to side.

On vehicles with code (V40) Alarm system

14.1

Disconnect connector from alarm signal horn with additional battery (H3/1x1)

On vehicles with code (V40) Alarm system

15

Unhook engine hood cable (7) from bracket (12)

16

Unhook engine hood cable (7) from bracket (6) and engine hood lock (8)

17

Disconnect electrical connector (11) from left front lamp unit (E1) and right front lamp unit (E2)

18

Unthread wiring harnesses from left front lamp unit (E1) and right front lamp unit (E2) from front module (1)

19

Remove expansion clips (13) in left and right front fender liner.

 The expansion rivet (13) is located in the outer area of the service flap for changing the low beam bulbs.

20.1

Unclip outside temperature display temperature sensor (B14) from front module (1).

For vehicles with code (I01) Air conditioning Plus (with outside temperature indicator) (FFO)

21.1

Loosen wiring harness (25) on outside temperature display temperature sensor (B14) from front module (1).

For vehicles with code (I01) Air conditioning Plus (with outside temperature indicator) (FFO)

22.1

Unscrew bolt (23) from charge air cooler (24)

With engine 122.9 or 639.9

23.1

Unscrew bolts (26) from bracket on exhaust muffler (27)

On vehicles with code (I60) Stationary heater, gasoline or code (I58) Stationary heater, diesel

24

Unscrew bolt (15) from left and right upper bracket of radiator (10)

25

Unscrew bolts (9) and bolts (arrows) from front module (1).

The front module (1) is held by a total of six bolts (9) and two bolts (arrows).

26

Lift left and right front module (1) out of guide (18) and move toward front until radiator (10) can be removed upward.

27

Lift radiator (10) upward out of lower brackets and secure.

 Aid of helper required

Prop up coolant hoses and refrigerant lines to relieve load.Secure radiator (10) against falling down.

28

Remove front module (1)

 Aid of helper required

29

Install in the reverse order

30

Check left front lamp unit (E1), right front lamp unit (E2), horn (H2), engine hood lock (8) and, if necessary, alarm system.

 Function check of alarm system only on vehicles with code (V40) Alarm system.