Remove/install upper front crossmember for hood catch

AR88.00-D-2303TE

Remove/install upper front crossmember for hood catch

28.11.2019

Model

910 with engine 780.703

1

Top front crossmember

4

Coolant expansion reservoir

6

Electrical connector

2

Seal

5

Electrical connector

7

Electrical connector

3

Electrical connector

1

Top front crossmember

11

High-voltage connection

14

Electrical connector

8

High-voltage lines

12

Electrical connector

15

Signaling horn

9

Electrical wiring harness

13

Electrical line

16

Air duct segment

10

High-voltage connection

1

Top front crossmember

17

High-voltage shutoff device

1

Top front crossmember

20

Coolant hose line

24

Bracket

4

Coolant expansion reservoir

21

Coolant hose line

25

Coolant line

18

Coolant hose line

22

Coolant line

26

Retaining clips

19

Coolant hose line

23

Coolant line

27

Connection fitting

Shown with code BA3 (Active Brake Assist)

1

Top front crossmember

30

Bracket

33

Bolts

28

Bolts

31

Bolts

34

Screw

29

Expansion rivet

32

Screw

35

Stop buffer

 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

 Warning

Risk of injury due to fan starting unexpectedly

Do not reach into the rotation or hazard area of the fan. Wear closed and close-fitting work clothes.

AS20.40-Z-0001-01A

 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 avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

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

Drain coolant of main circuit.

AR08.50-D-0023TE

2

Drain coolant of the auxiliary circuit.

AR08.50-D-0022TE

3

Remove radiator grille.

AR88.40-D-4001TS

4

Remove the seal (2).

 Remove the seal (2) only on the upper longitudinal member (arrow A).

5

Disconnect the electrical connector (3) on the coolant expansion reservoir (4) of the auxiliary circuit.

6

Disconnect electrical connector (5).

7

Disconnect electrical connectors (6, 7).

8

Remove hood catch lower section.

AR88.40-D-3201TS

9

Unhook hood cable at upper front crossmember (1) and position outside of working area.

10

Remove both front lamp units.

AR82.10-D-4733TS

11

Remove the high-voltage lines (8).

 To do so, remove the retaining clips.

 Installation: Check retaining clips for damage.

 Clip remover

*452589016300

If damage is present:



Replace damaged retaining clips.

12

Remove the electrical wiring harness (9).

 To do this, detach the retaining clip.

 Installation: Check retaining clips for damage.

 Clip remover

*452589016300

If damage is present:



Replacing retaining clip.

13

Release and disconnect the high-voltage plug (10).

14

Release and disconnect high-voltage plug (11).

15

Separate electrical connector (12).

16

Remove the electric line (13) at the DC current charge-connection unit and place to one side.

Check ground lines for high-voltage on-board electrical system potential equalization

AR47.70-D-1020-01TE

 To do this, undo bolt.

 Installation: Check the electric line (13).

 Screw, potential equalization ground line/protective ground conductor to DC current charge-connection unit

*BA47.70-N-1009-02TE

17

Disconnect electrical connector (14).

18

Place the high-voltage lines (8), electrical wiring harness (9) and electric line (13) out of the working area.

19

Remove the horn (15) and place it outside the working area.

AR54.35-D-1556TS

20

Remove the air duct segments (16).

21

Remove the high-voltage shutoff device (17).

 To do this, detach the retaining clip.

 Installation: Check retaining clips for damage.

 Clip remover

*452589016300

If damage is present:



Replacing retaining clip.

22

Remove the electrical wiring harnesses on the left and right on the front upper crossmember (1) (arrow B) and place it outside the working area.

 Installation: Check retaining clips for damage.

 Clip remover

*452589016300

If damage is present:



Replace damaged retaining clips.

23

Remove the coolant hose lines (18, 19) on the coolant expansion reservoir (4).

AR08.50-P-0018-01EQ

 Collect coolant which flows out. Plug openings.

 Commercially available devices/tools
Collecting pan

 Record plug

*129589009100

 Set of protective covers

*001589019100

24

Remove the coolant hose line (20) on the cooler.

AR08.50-P-0018-01EQ

 Collect coolant which flows out. Plug openings.

 Commercially available devices/tools
Collecting pan

 Record plug

*129589009100

25

Remove the coolant hose line (21) on the cooler.

AR08.50-P-0018-01EQ

 Collect coolant which flows out. Plug openings.

 Commercially available devices/tools
Collecting pan

 Set of protective covers

*001589019100

26

Disconnect the coolant line (22) at the separating point.

AR08.50-P-0018-01EQ

 Collect coolant which flows out. Plug openings.

 Commercially available devices/tools
Collecting pan

 Set of protective covers

*001589019100

27

Remove the coolant line (23) at the cooler.

AR08.50-P-0018-01EQ

 Collect coolant which flows out. Plug openings.

 Commercially available devices/tools
Collecting pan

 Set of protective covers

*001589019100

28

Remove the bracket (24).

 To do so, unlock the holder (24) (arrow C) and pull it up and out of the guides (arrow D).

29

Remove the coolant line (25).

 To do so, unclip the coolant line (25) from the retaining clamps (26).

30

Remove the connection fitting (27) for the coolant line (25) on the cooler.

AR08.50-P-0018-01EQ

 Collect coolant which flows out. Plug openings.

 Commercially available devices/tools
Collecting pan

 Set of protective covers

*001589019100

31

Unscrew the screws (28).

32

Remove the expansion rivet (29).

 Installation: Check the expansion rivet (29) for damage.

 Clip remover

*452589016300

If damage is present:



Replace the expansion rivet (29) if damaged.

33

Remove the holder (30) and place outside the working area.

Model 910 with engine 780.703
with code BA3 (Active Brake Assist System)

 To do so, unscrew the screws (31).

34

remove the upper front crossmember (1) with the radiator.

 To do so, unscrew the screws (32, 33, 34).
Helper required.

 Bolt, crossmember for hood catch to front upper longitudinal member

*BA88.00-N-1001-05TS

 Bolt, crossmember for hood catch to front upper inner longitudinal member

*BA88.00-N-1002-05TS

 Bolt, crossmember for hood catch to front longitudinal member

*BA88.00-N-1003-05TS

35

Remove seal (2).

If upper front crossmember (1) is replaced.

 Installation:
Align the seal (2) correctly. The end pieces must overhang to the same length on both sides.
Otherwise the seal (2) cannot be correctly installed on the upper longitudinal member (arrow A).

36

Remove the coolant expansion reservoir (4) from the upper front crossmember (1).

If upper front crossmember (1) is replaced.

 Long wedge

*115589035900

37

Remove radiator unit.

If upper front crossmember (1) is replaced.

AR08.50-D-0120TE

38

Remove the stop buffers (35).

If upper front crossmember (1) is replaced.

39

Remove the socket for the external power supply.

If upper front crossmember (1) is replaced.

AR47.70-D-0025TE

40

Install in the reverse order.

 High-voltage on-board electrical system potential equalization ground lines

Number

Designation

Engine 780.703 in model 910

BA47.70-N-1009-02TE

Screw, potential equalization ground line/protective ground conductor to DC current charge-connection unit

Nm

7

 Cross member for hood catch

Number

Designation

Model 907, 910

BA88.00-N-1001-05TS

Bolt, crossmember for hood catch to front upper longitudinal member

Nm

10

 Cross member for hood catch

Number

Designation

Model 907, 910

BA88.00-N-1002-05TS

Bolt, crossmember for hood catch to front upper inner longitudinal member

Nm

10

 Cross member for hood catch

Number

Designation

Model 907, 910

BA88.00-N-1003-05TS

Bolt, crossmember for hood catch to front longitudinal member

Nm

20