Remove/Install Front Module - AR88.30-P-1064MFG
Model 118, 177, 247 with engine 139
MODIFICATION NOTES
| 11.10.2023 | Bolt, assembly carrier at top to body | Model 118 | BA62.30-P-1007-02O |
| 11.10.2023 | Bolt, impact absorber/mounting support to longitudinal member | Model 118 | BA62.30-P-1002-02O |
| Risk of fire and explosion caused by ignition of window washing fluid or antifreeze and their vapors. Risk of poisoning caused by swallowing window washing fluid or antifreeze or inhaling their vapors. Risk of injury or physical irritations caused by contact of window washing fluid or antifreeze with eyes, mucous membranes or skin. | Wear protective clothing and tight-fitting safety glasses. No open flames, fire or ignition sources. Avoid contact with eyes, mucous membranes and skin. When working with window washing fluids or antifreeze, do not eat, drink, or smoke. Do not inhale vapors and ensure sufficient ventilation in the working area. Store window washing fluid and antifreeze leakfree in safely closed original containers and out of the reach of children. | AS82.35-Z-0001-01A | |
| 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 death caused by vehicle slipping or toppling off of the lifting platform. | Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. | AS00.00-Z-0010-01A | |
| 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 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 caused by damaged assemblies filled with refrigerant | Wear protective clothing, safety gloves and safety glasses. | AS86.61-Z-0001-01A | |
| 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 overpressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses. |
AS20.00-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 | |
| Notice | Notes on self-locking nuts and bolts | AH00.00-P-0001-01KOA | |
| Notice | Notes on avoiding damage through contamination and foreign objects | AH00.00-P-5000-01A | |
| Notice | Note on damage to lamp unit | AH82.10-P-0002-00LW | |
| Notice | General information on the impact absorber | AH88.20-P-1000-01A | |
| Notice | Notes on preventing damage to electronic components due to a magnetic tool | AH54.00-P-0002-01A | |
| Notice | Information on preventing damage to electronic components due to electrostatic discharge | AH54.00-P-0001-01A | |
| Notice | Notes on coolant | AH20.00-P-2080-01KOA | |
| Notes on handling refrigerant R134a | AH83.30-P-0003-01KOA | ||
| Notes on handling refrigerant R1234yf | AH83.30-P-0003-02A | ||
| Notes on safety-relevant components | AH00.00-Z-0019-01A | ||
| Remove/install | |||
| 1 | Remove upper engine cover. | ||
| AP01.10-P-2405-01K | |||
| 2 | Remove front bumper. | AR88.20-P-2000MFA | |
| 3 | Remove refrigerant lines from evaporator in wheel arch. | Model 118.354/654, 177.054, 247.754 with engine 139 up to YoM 20/2 |
AR83.30-P-5541MFG |
| 4 | Remove evaporator in wheel arch with bracket from body and secure against falling down. | Model 118.354/654, 177.054, 247.754 with engine 139 up to YoM 20/2 |
AR83.30-P-5541MFG |
| 5 | Release and disconnect electrical connector (1) of left horn (H2). | ||
| 6 | Release, disconnect washer fluid lines (2) and seal openings with suitable stop plugs. | Fig 2 | |
| 7 | Remove washer fluid lines (2) from front module and place outside of working area. | ||
| 8 | Remove condenser in wheel arch. | AR83.30-P-6542MFG | |
| 9 | Drain off coolant. | AR20.00-P-1142MFG | |
| 10 | Release, disconnect bleed lines (3) at expansion reservoir and seal opening with suitable stop plugs. | Fig 2 | |
| 11 | Remove nut (4), disconnect refrigerant line and seal openings with suitable stop plugs. | *BA83.30-P-1002-01T | |
| Fig 2 | |||
| 12 | Disconnect coolant lines (5) and seal openings with suitable stop plugs. | AR09.41-P-1311-01AL | |
| Fig 2 | |||
| 13 | Remove air filter housing. | AR09.10-P-1150MFG | |
| 14 | Disconnect coolant lines (6) and seal openings with suitable stop plugs. | AR09.41-P-1311-01AL | |
| Fig 2 | |||
| 15 | Remove bleed line (7) at low-temperature expansion reservoir and seal openings with suitable stop plugs. | Fig 2 | |
| Fig 1 | |||
| 16 | Release and disconnect electrical connectors (8) from right and left front lamp units (E1, E2). | ||
| 17 | Release and disconnect electrical connectors (9) from right and left frontal acceleration sensor (B48/1, B48/2). | ||
| 18 | Release and disconnect electrical connector (10) from coolant fan motor (M4/2). | ||
| 19.1 | Remove left bracket (14) and expose hood release cable located behind this. | Model 118.### 1#, 177.### 1#, 247.### 1# with engine 139 | |
| 19.2 | Remove right bracket (14) and expose hood release cable located behind this. | Model 118.### 2#, 177.### 2#, 247.### 2# with engine 139 | |
| 20 | Remove hood catch and set down outside of working area. | AR88.40-P-3201MFA | |
| 21 | Remove refrigerant line (13) from cooling module. | ||
| 22 | Remove radiator support. | AR62.30-P-1500MFA | |
| 23 | Remove screws (11). | *BA62.30-P-1002-02O | |
| 24 | Remove screws (12). | *BA62.30-P-1007-02O | |
| 25 | Remove front module towards front and set down on suitable base. | ||
| 26 | Install in the reverse order. | ||
| Check | |||
| 27 | Check engine cooling system for leak tightness. | AR20.00-P-1010MFG | |
| 28 | Connect vehicle diagnosis system, read out fault memory, and delete. | ||
| AD00.00-P-2000-06MFA | |||
| 29 | Check headlamp adjustment and correct if necessary. | ||
| Model 177 with engine 139 | AP82.10-P-8260N | ||
| Model 118 with engine 139 | AP82.10-P-8260Y | ||
| Model 247 with engine 139 | AP82.10-P-8260AO | ||
| 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 | |
| 30 | Perform engine test run. While doing so, check engine for proper operation and leak tightness. | ||
| 31 | Install upper engine cover. | ||
| AP01.10-P-2405-01K |
FROND END WITH FRONT REINFORCEMENT
| Number | Designation | Model 118 | Model 177 | ||
|---|---|---|---|---|---|
| BA62.30-P-1002-02O | Bolt, impact absorber/mounting support to longitudinal member | M12 | Nm | 120 | 120 |
FRONT END WITH FRONT REINFORCEMENT
| Number | Designation | Model 247 | ||
|---|---|---|---|---|
| BA62.30-P-1002-02O | Bolt, impact absorber/mounting support to longitudinal member | M12 | Nm | 125 |
FRONT END WITH FRONT REINFORCEMENT
| Number | Designation | Model 118 | Model 177 | ||
|---|---|---|---|---|---|
| BA62.30-P-1007-02O | Bolt, assembly carrier at top to body | M8 | Nm | 23 | 20 |
FRONT END WITH FRONT REINFORCEMENT
| Number | Designation | Model 247 | ||
|---|---|---|---|---|
| BA62.30-P-1007-02O | Bolt, assembly carrier at top to body | M8 | Nm | 20 |
AIR CONDITIONING
| Number | Designation | Model 118 | Model 177 | ||
|---|---|---|---|---|---|
| BA83.30-P-1002-01T | Nut, refrigerant line connecting point | M6 | Nm | 12 | 12 |
| M8 | Nm | 20 | 20 | ||
AIR CONDITIONING
| Number | Designation | Model 247 | ||
|---|---|---|---|---|
| BA83.30-P-1002-01T | Nut, refrigerant line connecting point | M6 | Nm | 12 |
| M8 | Nm | 20 | ||