Remove/install radiator unit

AR20.20-S-3871PS

Remove/install radiator unit

06.03.2020

Engine

642 in model 470, 471

1

Lower coolant hose

5

Crossmember

8.2

Oil cooler

2

Upper coolant hose

6

Nuts

9

Transmission oil lines

3

Radiator

7

Refrigerant lines

10

Strut

4

Electrical wiring harness

8.1

Condenser

3

Radiator

8.1

Condenser

8.2

Oil cooler

11

Upper elastomer bearing (2 pcs.)

12

Fluid reservoir

13

Screw

14

Vent line

 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 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

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

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

AH83.30-N-0005-01A

Topical note

General information on repair work on transmission

AH27.00-S-1000-01PS

Notes on handling refrigerant R134a

AH83.30-N-0003-01A

 

Remove/install

1

Discharge air conditioning system.

AR83.30-S-1760P

2

Drain coolant.

AR20.00-S-1142PS

3

Remove fan unit.

AR20.40-S-5050PS

4

Remove charge air cooler.

AR09.41-S-6817PS

5

Remove charge air hoses.

AR09.41-S-8619PS

6

Remove lower coolant hose (1) at radiator (3).

AR20.20-S-3865-09S

7

Seal openings at lower coolant hose (1) and at radiator (3) using suitable protective covers.

 Set of protective caps

*001589029100

8

Remove upper coolant hose (2) at radiator (3).

AR20.20-S-3865-09S

9

Seal openings at upper coolant hose (2) and at radiator (3) with suitable protective covers.

 Set of protective caps

*001589029100

10

Disconnect bleed line (14) at radiator (3).

 Hose clamp pliers

*454589003700

11

Unclip electrical wiring harness (4) from crossmember (5) and place to one side.

12

Unscrew screws (13) at upper elastomer bearings (11).

 Bolt, cooler to top front cross member for hood catch

*BA20.20-N-1002-01PD

13

Slacken nuts (6).

 Nut, vertical strut to front center cross member

*BA62.30-N-1004-01D

14

Unscrew nuts of struts (10) at top at crossmember (5).

 Nut, charge air cooler holder to upper front crossmember

*BA09.41-N-1002-03PS

15

Release screws at struts (10) at bottom.

 Screw, charge air cooler holder to center front crossmember

*BA09.41-N-1003-03PS

16

Remove crossmember (5).

AR88.00-S-2303P

17

Disconnect refrigerant lines (7) at condenser (8.1).

 Nut, refrigerant line to condenser

*BA83.30-N-1010-01P

18

Seal openings at condenser (8.1) and refrigerant lines (7) with suitable stop plugs.



Compressor oils (specification 362.1)

BB00.40-P-0362-01A

 Installation: Replace O-rings at refrigerant lines (7) and coat with compressor oil.

 Assembly tool

*000589936300

 Record plug

*129589009100

19

Disconnect transmission oil lines (9) at oil cooler (8.2) and seal openings with suitable stop plugs.

AR27.10-S-0501-03PS

Assembly cleaner

*BR00.45-Z-1028-04A

 Record plug

*129589009100

20

Pull radiator unit out of elastomer bearings at body upwards and remove.

 Aid of helper required.
Radiator unit consists of radiator (3), condenser (8.1), oil cooler (8.2) and refrigerant reservoir (12).



Check

21

Check elastomer bearings on body.

If there is a problem,



replace elastomer bearing.

22

Check upper elastomer bearings (11).

If there is a problem,



Replace upper elastomer bearings (11).

23

Install in the reverse order.



Check

24

Correct oil level at automatic transmission.

AR27.00-S-0270PS

 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

25

Perform engine test run and check in area of radiator unit for leaks.

 Charge air cooler

Number

Designation

Engine 642 in model 470, 471

BA09.41-N-1002-03PS

Nut, charge air cooler holder to upper front crossmember

Nm

20

 Charge air cooler

Number

Designation

Engine 642 in model 470, 471

BA09.41-N-1003-03PS

Screw, charge air cooler holder to center front crossmember

Nm

20

 Cooler, coolant hoses, coolant lines

Number

Designation

Engine 642 in model 470, 471

BA20.20-N-1002-01PD

Bolt, cooler to top front cross member for hood catch

Nm

21

 Front cross member

Number

Designation

Model 470, 471

BA62.30-N-1004-01D

Nut, vertical strut to front center cross member

Nm

10

 Air conditioning

Number

Designation

Model 470, 471 with engine 642

BA83.30-N-1010-01P

Nut, refrigerant line to condenser

Nm

12

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01