Inspect cooling system for leaks · ar2000w1010a · Mercedes-Benz WIS

AR20.00-W-1010A

Inspect cooling system for leaks

13.12.11

ENGINES 541.9 in MODEL 950, 952, 953, 954

ENGINES 542.9 in MODEL 950, 952, 954

W20.00-1016-12

1 Coolant expansion reservoir

2  Clamp

3  Adapter

4  Knurled nut

5  Testing unit

6  Angled piece

Modification notes

14.12.04	Work procedure completely revised.
1.7.05	Coolant	Engine 541.9 with code BA1	*BF20.00-N-1001-01B
	Coolant	Engine 541.9 with code BA9
	Coolant	Engine 542.9 without code BA1 or BA9
	Coolant	Engine 542.9 with code BA1

	Checking
1	Open regulating valve of heating system	 On vehicles with the standard heater temperature selector wheel in the "max. heat" position, on vehicles with the AAC air-conditioning system or heater control steering wheel lock in the "Ignition On" position.
 Danger!	Risk of injury caused by body parts being pinched or crushed as cab is tilted	Ensure that no one is within tilting range of cab as it is being tilted. Always tilt cab all the way to end position and secure with safety strut.	AS60.80-Z-0001-01A
2	Tilt cab
	Notes on tilting the cab		AH60.80-N-0003-01A
 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
3	Remove cap on coolant expansion reservoir (1)
	Notes on coolant		AH20.00-N-2080-01A
4	Check coolant level, pour in coolant if necessary	 If the antifreeze in the coolant is too little, either add more anti-corrosion/antifreeze agent or change the coolant.
			*BF20.00-N-1001-01B
		Antifreeze tester
5	Rub dry coolant filler neck on the inside of the coolant expansion reservoir (1)
6	Adapt sealing rubber on adapter (3) by twisting on the inside diameter of the coolant filler neck		*655589006300
7	Push up knurled nut (4) on adapter (3)		*655589006300
			*950589126300
8	Tighten angular piece (6) and testing unit (5) on the adapter (3)		*001589832100
			*655589006300
9	Attach adapter (3) with testing unit (5) on coolant expansion reservoir (1) and hook clamp (2) over the knurled nut (4) on adapter (3)	 Hook the clamp (2) under the raised bead (arrow) on the coolant filler neck and pre-tension clamp (2) with knurled nut (4).
			*001589832100
			*655589006300
			*950589126300
10	Apply compressed air to the cooling system at the testing unit (5) and check cooling system for leaks	 Observe test pressure and test period since otherwise damage may occur to the cooling system.	*BE20.30-N-1001-01E
		 A pressure drop at the pressure gauge of the testing unit (5) is visible in case of leaks in the cooling system.
			*001589832100
11	Perform visual inspection on all coolant carrying components	 Only in the case of a pressure drop and visible coolant loss: 
		Check radiator, heater, coolant pump, cooling and heating hoses, coolant lines and their connecting points, hose clamps, cylinder head gaskets, core hole cap or core hole plug screws; remove leaks in the cooling system.
		In case of pressure drop and no visible coolant loss: 
		Check cylinder head and cylinder liner for cracks.
12	Release test pressure on the testing unit (5), remove clamp (2) and remove adapter (3) with testing unit (5) on coolant expansion reservoir (1)		*001589832100
			*655589006300
			*950589126300
13	Check coolant level, pour in coolant if necessary	 Only if there was a pressure drop in the cooling system.
		If the antifreeze in the coolant is too little, either add more anti-corrosion/antifreeze agent or change the coolant.
			*BF20.00-N-1001-01B
		Antifreeze tester
14	Tighten cap on coolant expansion reservoir (1)
 Danger!	Risk of injury caused by body parts being pinched or crushed as cab is tilted	Ensure that no one is within tilting range of cab as it is being tilted. Always tilt cab all the way to end position and secure with safety strut.	AS60.80-Z-0001-01A
15	Lower cab
	Notes on tilting the cab		AH60.80-N-0003-01A

Check values for cooling system

Number	Designation			Engine 541.9, 542.9


BE20.30-N-1001-01E	Pressure drop in the cooling system	Test pressure 1.0 bar / test period 5 - 10 minutes	bar	0

 Engine cooling system

Number	Designation			Engine 541.9 without code BA1 or BA9	Engine 541.9 with code BA1	Engine 541.9 with code BA9


BF20.00-N-1001-01B	Coolant	Total filling capacity	Liters	41.0	53.0	56.0
		Anticorrosion/antifreeze agent down to -37°C	Liters	20.5	26.5	28.0
		Anticorrosion/antifreeze agent down to -45°C	Liters	22.5	29.0	31.0
		Specifications for Operating Fluids	Sheet	BB00.40-P-0310-01A	BB00.40-P-0310-01A	BB00.40-P-0310-01A
			Sheet	BB00.40-P-0325-02A	BB00.40-P-0325-02A	BB00.40-P-0325-02A
			Sheet	BB00.40-P-0325-05A	BB00.40-P-0325-05A	BB00.40-P-0325-05A

 Engine cooling system

Number	Designation			Engine 542.9 without code BA1, BA9, KMKL	Engine 542.9 with code BA1	Engine 542.9 with code BA9


BF20.00-N-1001-01B	Coolant	Total filling capacity	Liters	45.0	57.0	60.0
		Anticorrosion/antifreeze agent down to -37°C	Liters	22.5	28.5	30.0
		Anticorrosion/antifreeze agent down to -45°C	Liters	25.0	31.5	33.0
		Specifications for Operating Fluids	Sheet	BB00.40-P-0310-01A	BB00.40-P-0310-01A	BB00.40-P-0310-01A
			Sheet	BB00.40-P-0325-02A	BB00.40-P-0325-02A	BB00.40-P-0325-02A
			Sheet	BB00.40-P-0325-05A	BB00.40-P-0325-05A	BB00.40-P-0325-05A

655 589 00 63 00

Clamp

Adapter

Tester

001 589 83 21 00

950 589 12 63 00

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