Remove oil from cooling and heating system

AR20.00-P-1250B

Remove oil from cooling and heating system

09.06.2016

Engine

611.960 in model 202.133/134/193/194

Engine

611.961 in model 210.006/007/206/606

Engine

611.962 in model 203.004/006/204/206/706

Engine

612.961 in model 210.016/216/616

Engine

612.962 in model 203.016/216

Engine

612.963 in model 163.113

Engine

612.967 in model 209.316

Engine

612.990 in model 203.018/218/718

Engine

613.960 in model 220.026

Engine

613.961 in model 210.026/226

Engine

628.960 in model 220.028/128

Engine

628.961 in model 211.028

Engine

628.963 in model 163.128

Engine

646.8 in model 211

Engine

646.951 in model 211.004

Engine

646.961 in model 211.006/206/606

Engine

646.962 in model 203.007/207/707

Engine

646.963 in model 203.008/208/708

Engine

646.966 in model 209.308

Engine

647.961 in model 211.016/216/616

Engine

648.961 in model 211.023/026/223/226

Modification notes

27.09.2013

The vehicle heater must be set to the highest temperature stage. The heater circuit is not flushed out otherwise, added.

Operation step 5

27.09.2013

Mix the cleaner to make a 5% flushing solution (10 l water, 0.5 l cleaner), added

Operation step 6

01.10.2013

Repeat operation steps 6 to 12, if necessary,added.

Operation step 13

20.11.2013

Work procedure altered and the special tools for electrical vacuum pump and NTKL adaptation, added.

Operation steps 14 to 26

AR20.00-P-1142-04A

Shown on engine 611.962

1

Coolant expansion reservoir

18

Radiator

20

Coolant thermostat

 Danger !

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

 Danger !

Risk of injury caused by fingers being jammed or pinched when removing, installing or aligning hoods, doors, trunk lid/rear-end door or sliding roof.

No parts of the body or limbs should be within the operating area when the components are moving.

AS00.00-Z-0011-01A

 Danger !

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



Remove

1

Open engine hood

Model 163

AR88.40-P-1000GI

Model 202

AR88.40-P-1000E

Model 203

AR88.40-P-1000P

Model 209

AR88.40-P-1000Q

Model 210

AR88.40-P-1000F

Model 211

AR88.40-P-1000T

Model 220

AR88.40-P-1000M

2

Drain coolant

Engine 611.960 in model 202.133/134/193/194
Engine 611.961 in model 210.006/007/206/606
Engine 611.962 in model 203.004/006/204/206/706
Engine 612.961 in model 210.016/216/616
Engine 612.962 in model 203.016/216
Engine 612.967 in model 209.316
Engine 612.990 in model 203.018/218/718
Engine 613.960 in model 220.026
Engine 613.961 in model 210.026/226
Engine 628.960 in model 220.028/128
Engine 628.961 in model 211.028
Engine 628.963 in model 163.128
Engine 646.8 in model 211
Engine 646.951 in model 211.004
Engine 646.961 in model 211.006/206/606
Engine 646.962 in model 203.007/207/707
Engine 646.963 in model 203.008/208/708
Engine 646.966 in model 209.308
Engine 647.961 in model 211.016/216/616
Engine 648.961 in model 211.023/026/223/226

AR20.00-P-1142HB

Engine 612.963 in model 163.113

AR20.00-P-1142M

3

Remove coolant thermostat (20)

Engine 611.9, 612.9, 613.9, 646.9, 647.9, 648.9

AR20.10-P-2460PP

Engine 646.8 in model 211

AR20.10-P-2460TXX

Engine 628.960/963

AR20.10-P-2460M

Engine 628.961 in model 211.028

AR20.10-P-2460TD



Clean

4

Fit housing for de-oiling and flushing of cooling and heating system



WF58.50-P-2000-01A

 Engine 646.8 in model 211
Engine 646.951 in model 211.004
Engine 646.961 in model 211.006/206/606
Engine 646.962 in model 203.007/207/707
Engine 646.963 in model 203.008/208/708
Engine 646.966 in model 209.308
Engine 647.961 in model 211.016/216/616
Engine 648.961 in model 211.023/026/223/226Bolt, coolant thermostat housing to cylinder head

*BA20.10-P-1002-01G

 Engine 628.960 in model 220.028/128
Engine 628.961 in model 211.028
Engine 628.963 in model 163.128Bolt, coolant thermostat housing to crankcase

*BA20.10-P-1002-01F

 Engine 611.960 in model 202.133/134/193/194
Engine 611.961 in model 210.006/007/206/606
Engine 611.962 in model 203.004/006/204/206/706
Engine 612.961 in model 210.016/216/616
Engine 612.962 in model 203.016/216
Engine 612.963 in model 163.113
Engine 612.967 in model 209.316
Engine 612.990 in model 203.018/218/718
Engine 613.960 in model 220.026
Engine 613.961 in model 210.026/226Bolt, coolant thermostat housing to cylinder head

*BA20.10-P-1005-01A

5

Set heater control to full output


The vehicle heater must be set to the highest temperature stage.
The heater circuit is not flushed out otherwise.

 For vehicles with an auxiliary heater; also set auxiliary heater to full output.

6

Fill cooling and heating system with flushing solution

Engine 628.960 in model 220.028/128
Engine 628.961 in model 211.028
Engine 628.963 in model 163.128

AR20.00-P-1142-04A

Engine 611.960 in model 202.133/134/193/194
Engine 611.961 in model 210.006/007/206/606
Engine 611.962 in model 203.004/006/204/206/706
Engine 612.961 in model 210.016/216/616
Engine 612.962 in model 203.016/216
Engine 612.963 in model 163.113
Engine 612.967 in model 209.316
Engine 612.990 in model 203.018/218/718
Engine 613.960 in model 220.026
Engine 613.961 in model 210.026/226
Engine 646.8 in model 211
Engine 646.951 in model 211.004
Engine 646.961 in model 211.006/206/606
Engine 646.962 in model 203.007/207/707
Engine 646.963 in model 203.008/208/708
Engine 646.966 in model 209.308
Engine 647.961 in model 211.016/216/616
Engine 648.961 in model 211.023/026/223/226

AR20.00-P-1142-04AK

 Mix the cleaner to make a 5% flushing solution (10 l water, 0.5 l cleaner).

Cleaner for engine and cooling system for oil drag-in, 10 l

*BR00.45-Z-1009-04A

 Electric vacuum pump

*285589022100

 NTKL Adaption

*285589012100

 Test cap

*210589009100

 Test cap

*169589009100

 Cooler vacuum filling device

*285589002100

7

Warm up engine to operating temperature at medium rotational speed

 While engine is running, maintain operating temperature at about 80°C for about 5 min.

8

Switch off engine and allow cooling system to cool down to 50°C

9

Drain flushing solution completely at drain screw of radiator (18)

 Observe environmental protection regulations of cleaner manufacturer.

10

Fill cooling system with fresh water

Engine 628.960 in model 220.028/128
Engine 628.961 in model 211.028
Engine 628.963 in model 163.128

AR20.00-P-1142-04A

Engine 611.960 in model 202.133/134/193/194
Engine 611.961 in model 210.006/007/206/606
Engine 611.962 in model 203.004/006/204/206/706
Engine 612.961 in model 210.016/216/616
Engine 612.962 in model 203.016/216
Engine 612.963 in model 163.113
Engine 612.967 in model 209.316
Engine 612.990 in model 203.018/218/718
Engine 613.960 in model 220.026
Engine 613.961 in model 210.026/226
Engine 646.8 in model 211
Engine 646.951 in model 211.004
Engine 646.961 in model 211.006/206/606
Engine 646.962 in model 203.007/207/707
Engine 646.963 in model 203.008/208/708
Engine 646.966 in model 209.308
Engine 647.961 in model 211.016/216/616
Engine 648.961 in model 211.023/026/223/226

AR20.00-P-1142-04AK

 Electric vacuum pump

*285589022100

 NTKL Adaption

*285589012100

 Test cap

*210589009100

 Test cap

*169589009100

 Cooler vacuum filling device

*285589002100

11

Warm up engine to operating temperature at medium rotational speed

 While engine is running, maintain operating temperature at about 80°C for about 5 min.

12

Drain fresh water completely at drain screw of radiator (18)

13

Repeat operation steps 6 to 12 if required

14

Fit housing for de-oiling and flushing of cooling and heating system



Install

15

Install coolant thermostat (20)

Engine 611.9, 612.9, 613.9, 646.9, 647.9, 648.9

AR20.10-P-2460PP

Engine 646.8

AR20.10-P-2460TXX

Engine 628.960/963

AR20.10-P-2460M

ENGINE 628.961

AR20.10-P-2460TD

16

Pour in coolant and bleed cooling system

ENGINE 611.960/961/962, 612.961/962/967/990, 613.960/961, 628.960/961/963, 646, 647, 648

AR20.00-P-1142HB

ENGINE 612.963

AR20.00-P-1142M

17

Close engine hood

Model 163

AR88.40-P-1000GI

Model 202

AR88.40-P-1000E

Model 203

AR88.40-P-1000P

Model 209

AR88.40-P-1000Q

Model 210

AR88.40-P-1000F

Model 211

AR88.40-P-1000T

Model 220

AR88.40-P-1000M

 Coolant pump, coolant thermostat

Number

Designation

Engine 628.960/961/962/963

BA20.10-P-1002-01F

Bolt, coolant thermostat housing to crankcase

Nm

9

 Coolant pump, coolant thermostat

Number

Designation

Engine 647, 648

Engine 646.951/961

BA20.10-P-1002-01G

Bolt, coolant thermostat housing to cylinder head

Nm

9

9

 Coolant pump, coolant thermostat

Number

Designation

Engine 646.8

Engine 646.962/963/966

BA20.10-P-1002-01G

Bolt, coolant thermostat housing to cylinder head

Nm

9

9

 Coolant pump, coolant thermostat

Number

Designation

Engine 611.960/961

Engine 611.962

BA20.10-P-1005-01A

Bolt, coolant thermostat housing to cylinder head

Nm

9

9

 Coolant pump, coolant thermostat

Number

Designation

Engine 612.961/963

Engine 612.962/967

BA20.10-P-1005-01A

Bolt, coolant thermostat housing to cylinder head

Nm

9

9

 Coolant pump, coolant thermostat

Number

Designation

Engine 612.990

Engine 613.960/961

BA20.10-P-1005-01A

Bolt, coolant thermostat housing to cylinder head

Nm

9

9

Repair materials

Number

Designation

Order number

BR00.45-Z-1009-04A

Cleaner for engine and cooling system for oil drag-in, 10 l

A 002 986 42 71