Remove/Install Radiator - AR20.20-P-3865GQ

Engine 642 in model 292 

Engine 642, 651 in model 166 

Fig 1: Radiator Components Location - Engine 642 In Model 166

Courtesy of MERCEDES-BENZ USA

Shown on model 166 

Courtesy of MERCEDES-BENZ USA

	Risk of fire  due to ignition of R1234yf refrigerant on hot components. Risk of  poisoning caused by inhaling overheated refrigerant vapors. Risk of injury  to skin and eyes caused by contact with escaped R1234yf refrigerant and when working on pressurized parts. Risk of explosion  due to formation of ignitable refrigerant/air mixtures	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-0007-01A
	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
	Risk of injury  . Skin or eye injuries may result when handling hot or glowing objects.	Wear protective gloves, protective clothing and safety glasses, if necessary.	AS00.00-Z-0002-01A
	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
	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
	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
	Protect air conditioning circuit and components from moisture when carrying out repair work		AH83.30-N-0005-01A
	Notes on coolant		AH20.00-N-2080-01A
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
	Notes on avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
	Notes on handling refrigerant R134a		AH83.30-N-0003-01A
	Notes on handling refrigerant R1234yf		AH83.30-P-0003-02A
	Remove/install
1	Remove front lower engine compartment paneling	Install lower front engine compartment lining only after leak test.	AR61.30-P-1001GQ
2	Drain air conditioning system	Evacuate air conditioning system, refill it and check it for proper operation and leaktightness.	AR83.30-P-1760CW
3	Remove fan unit (1)		AR20.40-P-5050GQ
4	Drain off coolant		AR20.00-P-1142GQ
5	Remove coolant hoses (3) from the cooler (2)		AR20.20-P-7441-01RQ
6	Remove oil lines from the oil cooler (5) and place to one side		AR27.55-P-0600GQ
7	Remove refrigerant lines from the condenser (6), place to one side, and seal openings with suitable stop plugs	Install new sealing rings.
		Nut/bolt, high-pressure line to fluid reservoir	*BA83.30-P-1001-01J
		Record plug	Fig 2
8	Unclip the brackets (4)
9	Remove complete radiator package upwards	Observe routing of hood release cable. Otherwise, the hood release cable will be damaged. Aid of helper required. Radiator package consisting of a cooler (6), condenser and oil cooler for the transmission.
10	Unclip oil cooler (5) condenser (6) unit with retaining frame from the cooler (2) (arrows)	The oil cooler (5) and condenser (6) form a single unit.
11	Check oil cooler (5) condenser (6) unit for damage.	Only when reusing the oil cooler (5) condenser (6) unit.
		The oil cooler (5) and condenser (6) form a single unit. In the event of damage to the oil cooler (5) condenser (6) unit ↓ Replace oil cooler (5) condenser (6) unit.
12	Check cooler (2) for damage	Only when reusing the cooler (2). In the event of damage to the cooler (2) ↓ Replace the cooler (2).
13	Check that the bottom elastomer bearings of the cooler (2) are seated correctly and correct if necessary
14	Install in the reverse order
15	Check transmission oil level and correct if necessary	Engine 642 in model 292 with transmission 722.9	AR27.00-P-0270W
	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
16	Perform engine test run and, while doing so, check engine, transmission, connections, and radiator package for leak tightness and function		AR20.00-P-1010GQ
17	Install front lower engine compartment paneling		AR61.30-P-1001GQ

Fig 2: Identifying Record Plug (129 589 00 91 00)

Courtesy of MERCEDES-BENZ USA