Inspect cooling system for leaks

AR20.00-P-1010GZB

Inspect cooling system for leaks

24.7.07



Checking

 Danger!

Risk of injury caused by fingers being pinched or crushed when removing, installing or aligning hoods, doors, trunk lids, tailgates or sliding roof

Keep body parts and limbs well clear of moving parts.

AS00.00-Z-0011-01A

 Danger!

Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by 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



Notes on coolant

AH20.00-N-2080-01A



Notes on coolant level

AH20.00-P-1142-01GZB

1

Set heater switches to maximum heat output

2

Unscrew 2-stage cap from coolant expansion reservoir (1)

 Turn 2-stage cap half a turn in an anti-clockwise direction, release pressure, and then unscrew 2-stage cap.

3

Check coolant level

 If the antifreeze content of the coolant is too low, either add more antifreeze or replace the coolant: 

Drain/fill in coolant

Engine 642

AR20.00-P-1142GZB

Engine 629

AR20.00-P-1142GZD



Coolant specifications

Sheet 310.1

BB00.40-P-0310-01A



Anticorrosion/antifreeze agents (Sheet 325.0)

Sheet 325.0

BB00.40-P-0325-00A

4

Screw test cap (2) onto coolant expansion reservoir (1).



*210589009100

5

Attach pressure pump (3) to the test connection (2)



*124589242100

6

Pressurize cooling system

 Test pressure not higher than 1.4 bar.

 If new cylinder head gasket fitted, first of all warm up engine to operating temperature before testing cooling system for leaks.

Test pressure for pressure-testing cooling system

*BE20.30-P-1005-01A

7

Check hose clamps for condition and seating

 If hose clamps are loose, tighten them or replace them.

8

Check coolant hoses and heater hoses and their connecting points for condition and coolant loss.

 Replace damaged parts in order to prevent leaks.

9

Unscrew test cap (2) at coolant expansion reservoir (1).

 Slowly unscrew test cap (2) and reduce excess pressure.



*210589009100

10

Remove pressure pump (3) from test cap (2)



*124589242100

11

Close off expansion reservoir for coolant (1) using a 2-stage test cap

12

Move heater switch to starting position

Number

Designation

2-stage
cap

BE20.30-P-1005-01A

Test pressure for pressure-testing cooling system

bar gage

1.4