Remove oil from cooling and heating system

AR20.00-P-1250PI

Remove oil from cooling and heating system

12.11.2018

Engine

642 in model 203, 209

Modification notes

27.09.2013

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

Step 4

27.09.2013

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

Step 5

01.10.2013

Repeat operation steps 5 and 12 if necessary, added.

Operation step 13

20.11.2013

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

Operation steps 14 to 26

AR20.00-P-1142-04A

2

Coolant thermostat

 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

 Warning

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

Topical note

Notes on coolant

AH20.00-N-2080-01A

Notes on coolant level

AH20.00-P-1142-01CW



Remove

1

Drain off coolant

AR20.00-P-1142PI

2

Remove the coolant thermostat (2)

AR20.10-P-2460PI

3

Install housing to remove oil from the cooling and heating system



WF58.50-P-2000-01A

 Installation: The housing may be used only for the purpose of removing the oil and must be removed again after it has been rinsed.

 Bolt, coolant thermostat housing to charge air manifold

*BA20.10-P-1002-01S



Clean

4

Set heater control to full output

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

5

Fill cooling and heating system with rinsing solution

AR20.00-P-1142-04A

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

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

*BR00.45-Z-1009-04A

 Cooling system

*BF20.00-P-1001-02W

 Electric vacuum pump

*285589022100

 NTKL Adaption

*285589012100

 Test cap

*210589009100

 Cooler vacuum filling device

*285589002100

6

Warm up engine to normal operating temperature

 Maintain operating temperature (approx. 80 0C) for running engine for approx. 5 min.

7

Turn off engine

 Let the cooling system cool down to about 50°C.

8

Drain the rinsing solution

AR20.00-P-1142PI

 The rinsing solution must be completely drained at the drain screw of the radiator. Observe environmental protection regulations of cleaner manufacturer.

9

Fill cooling system with fresh water

AR20.00-P-1142-04A

 Electric vacuum pump

*285589022100

 NTKL Adaption

*285589012100

 Cooler vacuum filling device

*285589002100

 Test cap

*210589009100

10

Warm up engine to normal operating temperature

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

11

Turn off engine

 Let the cooling system cool down to about 50°C.

12

Drain fresh water

AR20.00-P-1142PI

 Repeat rinsing procedure with fresh water, if required, so that all of the rinsing solution is removed.

13

If necessary, repeat operation steps 5 and 12



Install

14

Remove housing to remove oil from the cooling and heating system



WF58.50-P-2000-01A

 Bolt, coolant thermostat housing to charge air manifold

*BA20.10-P-1002-01S

15

Install coolant thermostat (2)

AR20.10-P-2460PI

16

Pour in coolant and bleed cooling system

AR20.00-P-1142-04A



Coolant specifications

BB00.40-P-0310-01A



Anticorrosion/antifreeze agents (Sheet 325.0)

BB00.40-P-0325-00A

 Cooling system

*BF20.00-P-1001-02W

 Electric vacuum pump

*285589022100

 NTKL Adaption

*285589012100

 Cooler vacuum filling device

*285589002100

 Test cap

*210589009100



Check

17

Check cooling system for leak tightness

AR20.00-P-1010PI

 Coolant pump, coolant thermostat

Number

Designation

Engine 642

BA20.10-P-1002-01S

Bolt, coolant thermostat housing to charge air manifold

Nm

9

 Cooling system

Number

Designation

Engine 642 in model 203, 209, 211, 219, 221

BF20.00-P-1001-02W

Cooling system

Workshop replacement amount

Main circuit

l

7,5

Low-temperature circuit

l

-

Antifreeze/water

Down to -37°C

%

50/50

-38°C and below

%

55/45

Sheet

BB00.40-P-0310-01A

Sheet

BB00.40-P-0325-00A

Sheet

BB00.40-P-0326-00A

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