Remove/install upper front crossmember for hood catch

AR88.00-D-2303TSF

Remove/install upper front crossmember for hood catch

28.11.2019

Model

910 with engine 651

Modification notes

28.11.2019

Work procedure updated; images adapted

The whole document

1

Top front crossmember

5

Electrical connectors

2

Seal

6

Cover

3

Electrical connector

11

Air duct segment

4

Electrical connector

22

Coolant expansion reservoir

Shown with code BA3 (Active Brake Assist) and with code HH9 (semiautomatically controlled air-conditioning system, TEMPMATIC)

8

Bracket

12

Electrical connector

9

Bolts

14

Refrigerant lines

10

Signaling horn

1

Top front crossmember

15

Coolant hose

16

Radiator unit

17

Coolant hoses

26

Coolant hose line

1

Top front crossmember

18

Coolant line

19

Screw

20

Screw

21

Bolts

1

Top front crossmember

23

Bracket

16

Radiator unit

24

AdBlue® filler neck

22

Coolant expansion reservoir

25

Stop buffer

 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

 Warning

Risk of burn injuries and scalding when working on AdBlue(R) lines and the component parts attached to them. Risk of injury to skin and eyes when handling AdBlue(R). Risk of poisoning caused by swallowing AdBlue(R)

Pour AdBlue® only into suitable containers. Wait until the pressure is released before starting any work on the exhaust aftertreatment system.

AS49.20-Z-0002-01A

 Warning

Risk of poisoning caused by inhaling overheated refrigerant vapors from an air conditioning system containing R134a. Risk of injury to skin and eyes caused by contact with liquid R134a refrigerant and when working on pressurized parts

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 rooms. Carry out repair work on the air conditioning system circuit only after the system has been evacuated.

AS83.00-Z-0006-01A

 Caution

Risk of injury to skin and eyes due to handling of transmission oil. Health risk caused by swallowing transmission oil

Wear protective gloves, protective clothing and safety glasses.
Do not pour transmission oil into beverage bottles.

AS00.40-Z-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

Procedure for a damaged or leaky air conditioning system

AH83.30-N-0004-01A

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

Remove the seal (2).

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

2

Remove air filter housing.

AR09.10-D-1150TSF

3

Disconnect electrical connector (3) of coolant expansion reservoir (22).

4

Disconnect electrical connection (4).

5

Disconnect electrical connectors (5).

6

Remove hood catch lower section.

AR88.40-D-3201TS

7

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

8

Remove both front lamp units.

AR82.10-D-4733TS

9

Remove the cover (6).

 To do so, unclip cover (6).

 Long wedge

*115589035900

10

Remove bracket (8) and position outside of working area.

Model 910 with engine 651
with code BA3 (Active Brake Assist System)
Model 910 with engine 651
with code ET4 (Active Distance Assist DISTRONIC)

 To do this, remove bolts (9) .

11

Remove horn (10) and position outside of working area.

AR54.35-D-1556TS

12

Remove air duct segments (11).

 To to this, unclip cable from left air duct segment (11).

 Long wedge

*115589035900

13

Remove oil cooler of automatic transmission.

Model 910 with transmission 700.750

AR27.55-D-1000TSF

 Leave the oil cooler for the automatic transmission attached to the holder.

14

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.

If damage is present:



Replace damaged retaining clips.

15

Discharge air conditioning system.

Model 910 with engine 651
with code HH4 (THERMOTRONIC automatic climate control)
Model 910 with engine 651
with code HH9 (Air conditioner, automatic heater control)

AR83.30-D-1760TS

16

Separate electrical connector (12).

Model 910 with engine 651
with code HH4 (THERMOTRONIC automatic climate control)
Model 910 with engine 651
with code HH9 (Air conditioner, automatic heater control)

17

Remove refrigerant lines (14) from condenser.

Model 910 with engine 651
with code HH4 (THERMOTRONIC automatic climate control)
Model 910 with engine 651
with code HH9 (Air conditioner, automatic heater control)

AR83.30-D-6540TSF

18

Remove hoses at NOx reducing agent tank.

AR49.20-D-3900TS

19

Remove charge air hose upstream of charge air cooler.

AR09.41-D-8621TSR

 Remove charge air hose from charge air cooler only.

20

Remove charge air hose downstream of charge air cooler.

AR09.41-D-8625TSR

21

Drain off coolant.

AR20.00-D-1142TSR

22

Remove the coolant hose (15) from the radiator (16).

 Collect coolant which flows out. Plug openings.

 Commercially available devices/tools
Collecting pan

 Installation: Check the coolant hose (15) for damage.

 Set of protective covers

*001589019100

 Hose clamp pliers

*454589003700

If damage is present:



replace the coolant hose (15).

23

Remove the coolant hose line (26) from the radiator (16).

AR20.20-P-7441-01RQ

 Collect coolant which flows out. Plug openings.

 Commercially available devices/tools
Collecting pan

 Set of protective covers

*001589019100

24

Remove the coolant hoses (17) from the coolant pump.

 Collect coolant which flows out. Plug openings.

 Commercially available devices/tools
Collecting pan

 Installation: Check the coolant hoses (17) for damage.

 Set of protective covers

*001589019100

 Hose clamp pliers

*454589003700

If damage is present:



Replace the damaged coolant hoses (17).

25

Disconnect the coolant line (18).

AR20.20-P-7441-01RQ

 Collect coolant which flows out. Plug openings.

 Commercially available devices/tools
Collecting pan

 Record plug

*129589009100

26

Remove upper front crossmember (1) with radiator unit (16).

 For this purpose, remove the screws (19, 20, 21).
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

27

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).

28

Remove coolant expansion reservoir (22) from upper front crossmember (1).

If upper front crossmember (1) is replaced.

 Long wedge

*115589035900

29

Remove brackets (23).

If upper front crossmember (1) is replaced.

 To do so, remove the expansion rivet for the holder (23) and press the holder (23) together (arrow C).

30

Remove radiator unit (16).

If upper front crossmember (1) is replaced.

 Helper required.

31

Remove AdBlue® filler neck (24).

If upper front crossmember (1) is replaced.

AR49.20-D-3900TS

32

Remove stop buffers (25).

If upper front crossmember (1) is replaced.

33

Install in the reverse order.



Check

 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

34

Check for leaktightness when engine is running.

 Visual inspection only.

 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