Engine | 541.9 in model 930, 932, 933, 934 |
with code ML3 (High-speed fan drive with belt drive) | |
with code MZ3 (Electromagnetic viscous coupling for fan) | |
with code ZX1 (Common Powertrain Controller (CPC)) | |
Engine | 542.9 in model 930, 932, 934 |
with code ML3 (High-speed fan drive with belt drive) | |
with code MZ3 (Electromagnetic viscous coupling for fan) | |
with code ZX1 (Common Powertrain Controller (CPC)) |
W20.20-1061-09
1 | Coolant pipe (heater) | 9 | Coolant hose | 16.1 | Gear oil hoses (only for code N55(Transmission cooling)) | ||
2 | Coolant hoses (heater) | 10 | Charge air distributor | 16.2 | Oil line (only for code N55(Transmission cooling)) | ||
3 | Coolant expansion reservoir | 11 | Coolant pipe | 17 | Radiator mounting | ||
4 | Coolant hose (from engine) | 12 | Fan | 18 | Charge air cooler | ||
5 | Coolant hose (to coolant pump) | 13 | Guide tube (oil dipstick) | 19 | Protective grille | ||
6 | Radiator | 14 | Filler pipe (engine oil) | 20 | Condenser | ||
7 | Coolant hose | 15 | Coolant hose | 21 | Cover | ||
8 | Electrical connection | 16 | Connection (only for code N55 (Transmission cooling)) | B6 | Coolant level switch |
Only vehicles with code H03 (Air conditioning in front end) or code H07 (AAC) |
26 | Low-pressure refrigerant line |
27 | High-pressure refrigerant line |
28 | Connection |
29 | Connection |
30 | Connection |
31 | Connection |
W20.20-1031-01
W83.55-1023-01
32 | Viscous fan clutch, BorgWarner |
33 | Viscous fan clutch, Behr |
34 | Electrical connection |
35 | Torque arm |
36 | Adapter with freewheel bearing |
A | with code MZ3 (Electromagnetic viscous coupling for fan) |
B | with code MO1 (Electromagnetic viscous fan clutch, Behr) |
W20.40-1188-06
Danger ! | 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. | |
Danger ! | Risk of injury caused by body parts being pinched or crushed as cab is tilted | Ensure that no one is within the tilting range of the cab as it is being tilted. Always tilt the cab all the way to the end position and secure with the safety strut. | |
Danger ! | 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. | |
| Notes on tilting the cab | ||
| Notes on self-locking nuts and bolts | ||
| Note on calculation of tightening torque when using insertion or socket tools with various effective lengths | ||
| Remove | ||
1 | Switch off ignition | ||
2 | Remove cover on the rear panel of the cab | Only for vehicles with code F15 (MEGASPACE cab). | |
3 | Remove soundproofing below on the radiator (6) | ||
4 | Drain coolant at radiator (6) | ||
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5 | Open maintenance flap | ||
6 | Remove middle trim panel (21) over the bumper | ||
7 | Drain air conditioning system | ||
| Only for vehicles with code H03 (Air conditioning in front end) or code H07 (AAC). | ||
8 | Remove coolant hoses (2) to heater heat exchanger | ||
9.1 | Remove sensor unit with hydraulic lines on cab | Vehicles with code GS3 ("Hydraulic" gearshift) | |
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9.2 | Tilt cab | Vehicles without code GS3 ("Hydraulic" gearshift). | |
10 | Remove soundproofing on the left and right side of the engine | ||
11 | Disconnect electrical connection (8) from coolant level switch (B6) | ||
12 | Remove all coolant hoses (4, 5, 7, 9, 15) on the cooler side | ||
13 | Remove coolant expansion reservoir (3) on radiator (6) | ||
14 | Remove oil filler pipe (14) and oil dipstick guide tube (13) on radiator (6) and tie up on engine | ||
15 | Disconnect low-pressure refrigerant line (26) and high-pressure refrigerant line (27) at connections (28, 29) | Only for vehicles with code H03 (Air conditioning in front end) or with code H07 (AAC). | |
When undoing the union nut, counterhold on fitting hexagon. | |||
16 | Remove screw/bolts at radiator mounting (17) on the right and left | ||
17 | Disconnect transmission oil hoses (16.1) from oil lines (16.2) at connections (16) and connect below on radiator (6) | Only on vehicles with code N55 (Transmission cooling). | |
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Collect feathering-out transmission oil with a suitable container and seal lines with stop plug. | |||
18 | Attach removal and installation tools onto radiator (6) | ||
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19 | Remove radiator (6) with charge air cooler (18) upwards | ||
20 | Disconnect electrical connection (34) | ||
21 | Remove torque arm (35) on engine | ||
22 | Slacken fan poly-V belt (12) and remove from the belt pulley of the coolant pump | ||
23 | Remove viscous fan clutch, BorgWarner (32) on adapter with freewheel bearing (36) | ||
24 | Lift out fan (12) with viscous fan clutch, BorgWarner (32) | ||
25 | Remove adapter with freewheel bearing (36) | ||
| Install | ||
26 | Install new adapter with freewheel bearing (36) | Intermediate piece with freewheel bearing on vibration damper | |
27 | Fit on fan poly-V belt (12) | ||
| Damage profiles for a poly-V belt | ||
| Routing diagram for poly-V belt | ||
28 | Remove viscous fan clutch, Behr (33) on adapter with freewheel bearing (36) | Electromagnetic fan clutch on adapter | |
29 | Attach torque arm (35) to engine | Bolt, support for electromagnetic fan clutch to coolant pump | |
30 | Attach electrical connection (34) for fan clutch | ||
31 | Attach fan (12) | Bolt, fan to viscous fan clutch | |
32 | Insert cooler (6) with the charge air cooler (18) | ||
33 | Remove removal and installation tools on radiator (6) | ||
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34 | Attach transmission hoses (16.1) | Only on vehicles with code N55 (Transmission cooling). | |
Hose on transmission oil cooling line, vehicles with code GE3 (Mercedes PowerShift) or code GE7 (Mercedes PowerShift 2).Hose to transmission oil cooling line | |||
Hose on transmission oil cooling line, vehicles with code GS3("Hydraulic" gearshift) or code GS7 (Gear control II).Hose to transmission oil cooling line | |||
35 | Tighten down screw/bolts at radiator mounting (17) on the right and left | ||
36 | Attach low-pressure refrigerant line (26) and high-pressure refrigerant line (27) with new sealing rings at connections (28, 29) | Only for vehicles with code H03 (Air conditioning in front end) or with code H07 (AAC). | |
Union nut, refrigerant lines | |||
37 | Attach filler pipe (14) and guide tube (13) on radiator (6) | ||
38 | Attach coolant expansion reservoir (3) to radiator (6) | ||
39 | Attach all coolant hoses (4, 5, 7, 9, 15) to the cooler side | ||
40 | Connect electrical connection (8) to coolant level switch (B6) | ||
41 | Attach soundproofing to the left and right side of the engine | ||
42.1 | Tilt back cab | Vehicles without code GS3 ("Hydraulic" gearshift). | |
42.2 | Detach/attach shift control unit along with hydraulic lines at cab | Vehicles with code GS3 ("Hydraulic" gearshift) | |
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Clamp bolt for gearshift lever | |||
Bracket for lines to engine tunnel | |||
Sensor unit to engine tunnel | |||
43 | Attach coolant hoses (2) to heater heat exchanger | ||
44 | Charge air conditioning system | Only for vehicles with code H03 (Air conditioning in front end) or code H07 (AAC). | |
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45 | Install middle trim panel (21) over the bumper | ||
46 | Pour in coolant | ||
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47 | Close maintenance flap | ||
48 | Attach soundproofing below on the radiator (6) | ||
49 | Attach cover to rear panel of the cab | Only for vehicles with code F15 (MEGASPACE cab). | |
50 | Connect diagnostic system and start XENTRY | ||
51 | Check software release in engine control (MR) control unit | ||
52 | Perform download "MR1_35" in engine control (MR) control unit | Only for vehicles without code MU5 (Engine, V6, LA, 350 kW (476 hp), 1800 rpm. | |
The process is completely menu-assisted under: | |||
53 | Perform download "MR1_40" in engine control (MR) control unit | Only for vehicles with code MU5 (Engine, V6, LA, 350 kW (476 hp), 1800 rpm. | |
The process is completely menu-assisted under: | |||
54 | Change fan control parameter in drive control (FR) control unit | The process is completely menu-assisted under: | |
55 | Check viscous fan clutch, Behr (33) | Perform the check on a warm engine; perform a second check if necessary. | |
The process is completely menu-assisted under: | |||
56 | Perform a final quick test | There must be no fault codes in the control units being updated. If necessary, process any fault codes in other control units, subject to separate repair order. | |
57 | End Xentry and remove diagnostic system | ||
Update Vehicle Documentation (VeDoc) | |||
58 | Replace the previous code MZ3 (Electromagnetic viscous fan coupling) by the new code MO1 (Electromagnetic viscous fan coupling, Behr). | ||
59 | Replace number of SAA (SAA) Z 505.154/14 by Z 505.154/19 | For the viscose fan clutch, Behr (33). | |
60 | Replace number of SAA (SAA) Z 505.169/03 by Z 505.169/04 | | |
61 | Replace number of SAA (SAA) Z 505.154/15 by Z 505.154/19 | For the fan (12). |
Parts ordering note |
Part no. | Designation | Quantity |
A 542 200 10 22 | Viscous fan clutch, Behr | 1 |
A 542 030 02 94 | Adapter with freewheel bearing | 1 |
A 003 205 49 06 | Fan | 1 |
N 910112 010001 | Nuts (fan clutch on adapter with freewheel bearing) | 3 |
N 910105 008005 | Screw/bolts M8x25 (adapter with freewheel bearing on vibration damper) | 6 |
N 910105 008012 | Screw/bolt M8x30 (fan on fan clutch) | 6 |