Remove/Install Front Module - Ar88.30-D-1064SE
WARNING: This page does not describe the selected car, but rather 12 other vehicles, including the 2018 Mercedes-Benz Sprinter 3500XD, 2018 Mercedes-Benz Sprinter 3500, 2018 Mercedes-Benz Sprinter 2500, 2017 Mercedes-Benz Sprinter 3500XD, and 2017 Mercedes-Benz Sprinter 3500. However, it is still accessible from the selected car via links, so may be relevant.
Model 906 with engine 642
| 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 | |
| Risk of burns and scalding when handling hot fluids and components they come into contact with. Risk of injury to skin and eyes when handling hot fluids. | Wear protective gloves, protective clothing and safety glasses, if necessary. Pour hot fluids in suitable containers only. | AS00.00-Z-0033-01A | |
| Notes on automatic transmission | Model 906 with engine 642 with transmission 722.9 Model 906 with engine 642 with transmission 722.9 Model 906 with engine 642 with transmission 722.9 Model 906 with engine 642 with transmission 722.6 Model 906 with engine 642 with transmission 722.6 Model 906 with engine 642 with transmission 722.6 Model 906 with engine 642 with transmission 722.6 |
AH27.19-P-0001-01NKB | |
| Remove/install | |||
| 1 | Drain air conditioning system | Model 906 with engine 642 with code HK4 (Rear air conditioning, reinforced) with code ZL3 (National version for Latin America) |
AR83.30-D-1760WE |
| Model 906 with engine 642 with code H08 (Roof-mounted air conditioning system, reinforced) with code HH9 (Air conditioner, automatic heater control) except code HH7 (Roof-mounted air conditioning system, basic) except code HK4 (Rear air conditioning, reinforced) |
AR83.30-D-1760D | ||
| Model 906 with engine 642 with code HH7 (Roof-mounted air conditioning system, basic) with code HH9 (Air conditioner, automatic heater control) except code H08 (Roof-mounted air conditioning system, reinforced) except code HK4 (Rear air conditioning, reinforced) Model 906 with engine 642 with code HH9 (Air conditioner, automatic heater control) except code H08 (Roof-mounted air conditioning system, reinforced) except code HH7 (Roof-mounted air conditioning system, basic) except code HK4 (Rear air conditioning, reinforced) except code HX1 (Refrigerant R-1234yf) |
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| 2 | Remove transmitter key | ||
| 3 | Remove front bumper | Model 906 with engine 642 with code XM0 (Facelift) Model 906 with engine 642 with code XM5 (Facelift Latin America) | AR88.20-D-2000M |
| Model 906 with engine 642 except code XM0 (Facelift) except code XM5 (Facelift Latin America) except code ZX8 (Dodge execution) except code ZX9 (Freightliner execution) | AR88.20-D-2000SD | ||
| Model 906 with engine 642 with code ZX8 (Dodge execution) except code XM0 (Facelift) Model 906 with engine 642 with code ZX9 (Freightliner execution) except code XM0 (Facelift) |
AR88.20-D-2000SE | ||
| 4 | Remove air duct inserts (4) | ||
| 5 | Remove air intake pipe (3) | ||
| 6 | Pull air filter housing (2) out of mounts on front module (1) (arrows) | ||
| 7 | Drain off coolant | AR20.00-D-1140SD | |
| 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 | |
| Risk of explosion/risk of fire caused by highly flammable materials in the vicinity of damaged xenon bulbs. Risk of injury caused by UV light, hot components on xenon headlamps and glass splinters produced by bursting xenon bulbs. Risk of poisoning caused by inhalation of mercury vapors and by swallowing of/skin contact with toxic salts and mercury compounds. | Do not touch parts conducting high voltage. Persons with active electronic implants (e.g. cardiac pacemakers) must never work on xenon headlamps. Switch off the entire lighting system. Wear insulated safety shoes, safety glasses and protective gloves. Remove highly inflammable materials from the danger zone. Ensure sufficient ventilation in the working area. | AS82.10-Z-0001-01A | |
| 8 | Disconnect electrical lines to remove front module (1) | AR88.30-D-1064-02SD | |
| 9 | Unhook engine hood release cable (5) from engine hood catch (6) and lay down to side | ||
| 10 | Disconnect coolant hoses from cooler | AR20.20-D-3865-09SD | |
| *BA00.10-N-1002-04A | |||
| 11 | Disconnect charge air hose (11) from charge air cooler (12) | AR09.41-D-8619M | |
| 12 | Unscrew nut (21) from refrigerant line separating point (20) | Model 906 with engine 642 with code H08 (Roof-mounted air conditioning system, reinforced) with code HH9 (Air conditioner, automatic heater control) except code HH7 (Roof-mounted air conditioning system, basic) except code HK4 (Rear air conditioning, reinforced) Model 906 with engine 642 with code HH7 (Roof-mounted air conditioning system, basic) with code HH9 (Air conditioner, automatic heater control) except code H08 (Roof-mounted air conditioning system, reinforced) except code HK4 (Rear air conditioning, reinforced) Model 906 with engine 642 with code HH9 (Air conditioner, automatic heater control) except code H08 (Roof-mounted air conditioning system, reinforced) except code HH7 (Roof-mounted air conditioning system, basic) except code HK4 (Rear air conditioning, reinforced) Model 906 with engine 642 with code HK4 (Rear air conditioning, reinforced) |
*BA83.30-N-1001-01F |
| 13 | Disconnect refrigerant lines from condenser | Model 906 with engine 642 with code H08 (Roof-mounted air conditioning system, reinforced) with code HH9 (Air conditioner, automatic heater control) except code HH7 (Roof-mounted air conditioning system, basic) except code HK4 (Rear air conditioning, reinforced) Model 906 with engine 642 with code HH7 (Roof-mounted air conditioning system, basic) with code HH9 (Air conditioner, automatic heater control) except code H08 (Roof-mounted air conditioning system, reinforced) except code HK4 (Rear air conditioning, reinforced) Model 906 with engine 642 with code HH9 (Air conditioner, automatic heater control) except code H08 (Roof-mounted air conditioning system, reinforced) except code HH7 (Roof-mounted air conditioning system, basic) except code HK4 (Rear air conditioning, reinforced) Model 906 with engine 642 with code HK4 (Rear air conditioning, reinforced) |
|
| Compressor oils (specification 362.0) | BB00.40-P-0362-00A | ||
| *BA83.30-N-1005-01F | |||
| 14 | Immediately plug connections with clean stop plug | Model 906 with engine 642 with code H08 (Roof-mounted air conditioning system, reinforced) with code HH9 (Air conditioner, automatic heater control) except code HH7 (Roof-mounted air conditioning system, basic) except code HK4 (Rear air conditioning, reinforced) Model 906 with engine 642 with code HH7 (Roof-mounted air conditioning system, basic) with code HH9 (Air conditioner, automatic heater control) except code H08 (Roof-mounted air conditioning system, reinforced) except code HK4 (Rear air conditioning, reinforced) Model 906 with engine 642 with code HH9 (Air conditioner, automatic heater control) except code H08 (Roof-mounted air conditioning system, reinforced) except code HH7 (Roof-mounted air conditioning system, basic) except code HK4 (Rear air conditioning, reinforced) Model 906 with engine 642 with code HK4 (Rear air conditioning, reinforced) |
|
| > |
*129589009100 | ||
| Risk of injury to skin or eyes from hydraulic fluid spraying out under pressure. Risk of poisoning from swallowing hydraulic fluid. | Depressurize hydraulic system completely before starting any work on it. Wear protective clothing and safety glasses. |
AS00.00-Z-0013-01A | |
| 15 | Disconnect hydraulic lines from radiator of power steering | Model 906 as of 12/2/11 with engine 642 |
AR46.25-D-3020-01SE |
| Model 906 up to 12/2/11 with engine 642 | AR46.25-D-3020-01SD | ||
| *129589009100 | |||
| *210589007100 | |||
| 16 | Disconnect upper return line (24) from cooler | Model 906 with engine 642 with transmission 722.902 with automatic transmission cooler integrated into cooler Model 906 with engine 642 with transmission 722.683 Model 906 with engine 642 with transmission 722.902 with automatic transmission cooler integrated into cooler Model 906 with engine 642 with transmission 722.908 with automatic transmission cooler integrated into cooler Model 906 with engine 642 with transmission 722.908with automatic transmission cooler integrated into cooler |
|
| AR27.55-D-0100-01US *129589009100 |
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| 17.1 | Disconnect rear return line (25) from cooler | Model 906 with engine 642 with transmission 722.902 with automatic transmission cooler integrated into cooler Model 906 with engine 642 with transmission 722.683 Model 906 with engine 642 with transmission 722.902 with automatic transmission cooler integrated into cooler Model 906 with engine 642 with transmission 722.908 with automatic transmission cooler integrated into cooler Model 906 with engine 642 with transmission 722.908 with automatic transmission cooler integrated into cooler |
|
| AR27.55-D-0100-01US *129589009100 |
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| 17.2 | Disconnect front return line (29) from rear return line (25) | Model 906 with engine 642 with transmission 722.902 without automatic transmission cooler integrated into cooler Model 906 with engine 642 with transmission 722.902 without automatic transmission cooler integrated into cooler Model 906 with engine 642 with transmission 722.908 without automatic transmission cooler integrated into cooler Model 906 with engine 642 with transmission 722.908without automatic transmission cooler integrated into cooler | |
| AR27.10-D-0501-03WE *129589009100 |
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| 18 | Disconnect front return line (29) from upper return line (24) | Model 906 with engine 642 with transmission 722.902 with automatic transmission cooler integrated into cooler Model 906 with engine 642 with transmission 722.902 with automatic transmission cooler integrated into cooler Model 906 with engine 642 with transmission 722.908 with automatic transmission cooler integrated into cooler Model 906 with engine 642 with transmission 722.908with automatic transmission cooler integrated into cooler |
|
| AR27.10-D-0501-03WE *129589009100 |
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| 19 | Disconnect front feed line (27) from rear feed line (28) |
Model 906 with engine 642 with transmission 722.902 Model 906 with engine 642 with transmission 722.902 Model 906 with engine 642 with transmission 722.908 Model 906 with engine 642 with transmission 722.908 |
AR27.10-D-0501-03WE |
| *129589009100 | |||
| 20 | Clamp off spray nozzle hose (10) with clamp (9) | Model 906 with engine 642 with code F46 (Headlamp washing system) |
*000589403700 |
| 21.1 | Disconnect spray nozzle hose (7) from spray nozzles (8) | Model 906 with engine 642 with code F46 (Headlamp washing system) except code XM0 (Facelift) |
|
| 21.2 | Unclip spray nozzles (8) from headlamps | Model 906 with engine 642 with code F46 (Headlamp washing system) with code XM0 (Facelift) Model 906 with engine 642 with code F46 (Headlamp washing system) | |
| 22 | Immediately plug connections with clean stop plug | Model 906 with engine 642 with code F46 (Headlamp washing system) except code XM0 (Facelift) | |
| *129589009100 | |||
| 23 | Unscrew bolts (19) on left and right side of vehicle | *BA88.00-N-1002-01B | |
| 24 | Unscrew bolts (17) on left and right side of vehicle and unclip bracket (18) on fender (13) | ||
| 25 | Insert subbases (22) on left and right side of vehicle between front module (1) and longitudinal member | *906589003100 | |
| 26 | Mark (14) fenders (13) on both sides to indicate installation position of front module (1) | Model 906 with engine 642 except code XM0 (Facelift) except code XM5 (Facelift Latin America) |
|
| 27 | Unscrew bolts (15) on left and right side of vehicle | *BA00.10-N-1002-04A | |
| 28 | Unscrew bolts (23) on left and right side of vehicle | *BA88.00-N-1003-01B | |
| 29 | Fold air duct insert (16) toward inside | ||
| 30 | Lift out front module (1) with aid of helper | ||
| 31 | Install assembly device on front module (1) | AR88.30-D-1064-01SD | |
| *639589026200 | |||
| *906589026200 | |||
| 32 | Install in the reverse order | ||
| 33 | Fill power steering pump and bleed | AR46.30-S-0010S | |
| 34 | Check oil level in A/T and correct if necessary | Model 906 with engine 642 with transmission 722.9 Transmission without guide tube for oil dipstickModel 906 with engine 642 with transmission 722.9 Transmission without guide tube for oil dipstick Model 906 with engine 642 with transmission 722.9 Transmission without guide tube for oil dipstick |
AR27.00-D-0270WE |
| Model 906 with engine 642 with transmission 722.9 Transmission with guide tube for oil dipstick Model 906 with engine 642 with transmission 722.9 Transmission with guide tube for oil dipstick Model 906 with engine 642 with transmission 722.9Transmission with guide tube for oil dipstick |
AR27.00-D-0101WE | ||
| Model 906.1/2/6/7 with engine 642 with transmission 722.6 Model 906 with engine 642 with transmission 722.6 Model 906 with engine 642 with transmission 722.6 Model 906 with engine 642 with transmission 722.6 |
AR27.00-D-0270-01A | ||
| *BF27.00-N-1001-01A | |||
| *126589126300 | |||
| Model 906 with engine 642 with transmission 722.6 Dipstick | *140589152100 | ||
| *210589007100 | |||
| 35 | Check feed lines (27, 28) or return lines (24, 25, 29) for leakage when engine is running. |
Model 906 with engine 642 with transmission 722.9 Model 906 with engine 642 with transmission 722.6 Model 906 with engine 642 with transmission 722.9 Model 906 with engine 642 with transmission 722.9 |
|
| 36 | Check headlamp adjustment and correct if necessary | After aligning lamp units in relation to fenders (13). | |
| Model 906 with engine 642 except code LG0 (Bi-xenon headlamps) except code LG1 (Bi-xenon headlamps with cornering function) |
AP82.10-D-8260A | ||
| Model 906 with engine 642 with code LG0 (Bi-xenon headlamps) with code LG1 (Bi-xenon headlamps with cornering function) |
AP82.10-D-8260B |
METRIC BOLTS AND NUTS AS PER MBN 10 105, 10 143
| Number | Designation | 8.8 | 10.9 | |
|---|---|---|---|---|
| BA00.10-N-1002-04A | M6X1 | Nm | 9 | 13 |
AIR CONDITIONING
| Number | Designation | Model 906 with code H08 | Model 906 with code HH9 | |
|---|---|---|---|---|
| BA83.30-N-1001-01F | Nut, refrigerant lines to expansion valve | Nm | 6 | 6 |
AIR CONDITIONING
| Number | Designation | Model 906 with code HH7 | Model 906 as of 14.04.14 up to 31.12.15 with code HK4, IR4, ZL3 (without condenser module on roof (KONVEKTA)) | |
|---|---|---|---|---|
| BA83.30-N-1001-01F | Nut, refrigerant lines to expansion valve | Nm | 6 | - |
AIR CONDITIONING
| Number | Designation | Model 906 up to 13.04.14 with code HK4, IR4, ZL3 (with condenser module on roof (KONVEKTA)) Model 906 up to 31.12.15 with code HK4, ZL3, except code IR4 (with condenser module on roof (KONVEKTA)) | Model 906 as of 01.01.16 with code HK4, ZL3, except code IR4 (with condenser module on roof (MAHLE)) | |
|---|---|---|---|---|
| BA83.30-N-1001-01F | Nut, refrigerant lines to expansion valve | Nm | - | 8 |
AIR CONDITIONING
| Number | Designation | Model 906 as of 01.01.16 with code HK4, IR4, ZL3 (without condenser module on roof (MAHLE)) | |
|---|---|---|---|
| BA83.30-N-1001-01F | Nut, refrigerant lines to expansion valve | Nm | 8 |
AIR CONDITIONING
| Number | Designation | Model 906 with code H08 | Model 906 with code HH9 | |
|---|---|---|---|---|
| BA83.30-N-1005-01F | Nut, refrigerant lines to condenser | Nm | 6 | 6 |
AIR CONDITIONING
| Number | Designation | Model 906 with code HH7 | Model 906 as of 14.04.14 up to 31.12.15 with code HK4, IR4, ZL3 (without condenser module on roof (KONVEKTA)) | |
|---|---|---|---|---|
| BA83.30-N-1005-01F | Nut, refrigerant lines to condenser | Nm | 6 | 6 |
AIR CONDITIONING
| Number | Designation | Model 906 up to 13.04.14 with code HK4, IR4, ZL3 (with condenser module on roof (KONVEKTA)) Model 906 up to 31.12.15 with code HK4, ZL3, except code IR4 (with condenser module on roof (KONVEKTA)) | Model 906 as of 01.01.16 with code HK4, ZL3, except code IR4 (with condenser module on roof (MAHLE)) | |
|---|---|---|---|---|
| BA83.30-N-1005-01F | Nut, refrigerant lines to condenser | Nm | - | 8 |
AIR CONDITIONING
| Number | Designation | Model 906 as of 01.01.16 with code HK4, IR4, ZL3 (without condenser module on roof (MAHLE)) | |
|---|---|---|---|
| BA83.30-N-1005-01F | Nut, refrigerant lines to condenser | Nm | 6 |
LOCK CROSSMEMBER
| Number | Designation | Model 906 | |
|---|---|---|---|
| BA88.00-N-1002-01B | Bolt, module carrier to upper and lower M8 A-pillar inner section | Nm | 10 |
LOCK CROSSMEMBER
| Number | Designation | Model 906 | ||
|---|---|---|---|---|
| BA88.00-N-1003-01B | Bolt, module carrier to longitudinal member bracket | M8 | Nm | 20 |
AUTOMATIC TRANSMISSION
| Number | Designation | Transmission 722.683/684/685/68 6 | |||
|---|---|---|---|---|---|
| BF27.00-N-1001-01A | Automatic transmission fluid ATF | Filling capacity -complete refill | Liter | 7, 1 | |
| Filling capacity - oil change | Liter | 7, 1 | |||
| Filling capacity, transmission oil change | with torque converter | Liter | 7, 1 | ||
| Filling capacity, transmission oil change | without torque Liter converter | Liter | 5, 5 | ||
| Sheet | BB00.40-P-0236-14A - | ||||