Inspect cooling system for leaks

AR20.00-B-1010TB

Inspect cooling system for leaks

12.02.16

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Testing

Danger!

Risk of injury to skin and eyes by hot coolant leaking from cooling system. Risk of poisoning by coolant ingestion

Open cooling system only at temperatures below 90 °C. Remove filler cap slowly to release excessive pressure. Do not store coolant in reusable beverage or drinking water containers.

Wear protection gloves, clothes, and goggles.

AS20.00-B-0001-01A



Indications on the coolant

AH20.00-B-2080-01A

1

Open maintenance hatch

2

Remove cooling system filler cap (1) from expansion tank (2)

3

Open heating regulator valve

 In vehicles with standard heating adjust temperature selector wheel to "max. heat", in vehicles with (HZR) heat control turn ignition lock to "ignition ON".

4

Check coolant level and replenish as necessary

 Check antifreeze concentration in coolant, replenish antifreeze as necessary.

Observe fuel regulations.

5

Wipe to dry inner side of coolant expansion tank filler neck (2)

6

Adapt rubber sealing to adapter (3) by twisting it into inner diameter of coolant filler neck

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7

Mount adapter (3) and testing equipment (4) on expansion tank (2)

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8

Charge cooling system with compressed air through test equipment (4) and verify cooling system leak tightness

 Maintain test pressure at 1.0 bar and observe test period of 5 to 10 minutes, otherwise cooling system may be damaged.

 In case of cooling system leaks, pressure gauge readings on test equipment (4) will indicate test pressure reduction.

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9

Perform a visual inspection of all coolant conducing components

 Only in case of falling test pressure:



Check radiator, heating unit, coolant pump, cooling and heating hoses, coolant tubes and joints, hose clamps, cylinder head seal, center hole sealing plug or cap and eliminate any cooling system leaks found.

In case of falling test pressure without any visible coolant leaks:



Perform additional checks on the cylinder head.

10

Release test pressure at test equipment (4) and remove adapter (3) and test equipment (4) from expansion tank (2)

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11

Check coolant level and replenish as necessary

 Check antifreeze concentration in coolant, replenish antifreeze as necessary.

Observe fuel regulations.