Inspect cooling system for leaks

AR20.00-P-1010HA

Inspect cooling system for leaks

04.04.2019

Engine

111, 120, 137, 285.950/980, 601, 602, 603, 604, 605, 606, 611, 612, 613, 628, 646.951/961, 647.961, 648.960/961

Engine

112 (except 112.912/916/946/947/953/955/960/961)

Engine

112.945, 113.962, 606.964, 612.965/966, 628.962

Engine

113 (except 113.963/968/987/988/990/991/992/995)

Engine

271.941

Engine

275 (except 275.953/982)

Engine

603.931

Engine

603.972

1

Expansion reservoir

2

Cap with notch

2a

2-stage cap

3

Tester cap

4

Pressure pump

 

Remove/install

 Warning

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

1

Open cap with notch (2) or 2-stage cap (2a) on the expansion reservoir (1) or cooler

 For the cap with notch (2): Carefully turn cap up to the first notch, relieve overpressure, and then unscrew cap with notch (2).

 For model 163 with 2-stage cap (2a) or 1-stage cap: Turn cap by half a revolution counterclockwise, relieve overpressure, and then unscrew the 2-stage cap (2a) or 1-stage cap.

2

Set heater switches to maximum heat output

 All models except model 163: The model 163 has no small pulsed valves; coolant constantly flows through the heater core.



Check

3

Check coolant level; correct if necessary

 If there is not enough antifreeze, replace coolant after obtaining a special work order.

4

Mount tester cap (3) on the expansion reservoir or cooler

 Typ 124, 126, 129, 140, 170, 201, 202, 210, Typ 463.209 /232 /233 mit Motor 112.945, Typ 463.304 /324 /325 mit Motor 602.931, Typ 463.307 /327 /328 mit Motor 603.931, Typ 463.300 /320 /321 mit Motor 603.972, Typ 463.308 /330 /331 mit Motor 606.964
Test cap

*124589009100

 Typ 170, 202, 203, 208, 209, 210, 211 Typ 215, Typ 220 mit Motor 137, 275, 628, Typ 230 mit Motor 112, 113, 275, Typ 240 mit Motor 285, Typ 461.302 /331 /332 /342 /345 mit Motor 612.966, Typ 463.243 /246 mit Motor 113.982, Typ 463.244 /245 /250 mit Motor 112.945, Typ 463.247 /248 /249 /254 mit Motor 113.962, Typ 463.322 /323 mit Motor 612.965, Typ 463.309 /332 /333 mit Motor 628.962
Test cap

*210589009100

 Engine 111, 112, 113, 612, 628 in model 163
Test cap

*163589019100

5

Connect pressure pump (4)

 Pressure pump

*124589242100

6

Apply pressure to cooling system and check leak tightness of the cooling system

1-stage cap, 2-stage capTest pressure for pressure-testing the engine cooling system

*BE20.30-P-1005-01A

7

Check cooling and heating hoses and their connections for proper condition and coolant loss; replace coolant hoses if necessary

8

Check condition and correct seating of hose clamps

 Retighten hose clamps if necessary; replace if applicable.

9

Install in the reverse order

Radiator or expansion reservoir cap

Number

Designation

1-stage cover latch

Engine 100, 102, 103, 104, 110, 111, 112, 113, 114, 115, 116, 117, 119, 120, 121, 123, 127, 129, 130, 133, 137, 139, 152, 155, 156, 157, 159, 166, 180, 256, 260, 264, 266, 270, 271, 272, 273, 274, 275, 276, 277, 278, 279, 282, 285
2-stage latch cover
Engine 601, 602, 603, 604, 605, 606, 607, 608, 611, 612, 613, 615, 616, 617, 621, 626, 628, 629, 640, 642, 646, 648, 651, 654, 656, 668
2-stage latch cover

BE20.30-P-1005-01A

Test pressure for pressure-testing the engine cooling system

Overpressure

bar

1,4

1,4