Inspect cooling system for leaks

AR20.00-P-1010P

Inspect cooling system for leaks

23.3.06



Checking

Danger!

Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. 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

Danger!

Risk of injury caused by fingers being pinched or crushed when removing, installing or aligning hoods, doors, trunk lids, tailgates or sliding roof.

Keep body parts and limbs well clear of moving parts.

AS00.00-Z-0011-01A

1

Open engine hood

Model 170

AR88.40-P-1000G

Model 171.4

AR88.40-P-1000V

Model 203

AR88.40-P-1000P

Model 209

AR88.40-P-1000Q

Model 211

AR88.40-P-1000T

2

Open cap on expansion reservoir (2)

 2-stage cap: Rotate cap half a revolution in a counterclockwise direction, release overpressure, then unscrew cap.

3

Set heating switches to maximum heating capacity

4

Check coolant level

 If the antifreeze share of the coolant is too small, either antifreeze must be added or the coolant must be replaced:



Model 170 with Engine 112

Drain, fill system with coolant.

AR20.00-P-1142SV

Model 203 with engine 111, 271

Model 209 with engine 271

Drain, fill system with coolant.

AR20.00-P-1142PR

Model 171.473 with engine 113.989

Model 203 with engine 112, 113

Model 209 with Engine 112, 113

Drain, fill system with coolant.

AR20.00-P-1142PV

Model 203 with engine 611, 612, 646

Model 209 with engine 612, 646

Model 211 with engine 646.8

Drain, fill system with coolant.

AR20.00-P-1142HB

Model 211 with engine 271

Drain, fill system with coolant.

AR20.00-P-1142T



Notes on coolant

AH20.00-N-2080-01A



Notes on coolant level

AH20.00-P-1142-01P

5

Mount test cap (1) at expansion reservoir (2)

 Test cap

*210589009100

6

Connect pressure pump (3).

 Pressure pump

*124589242100

7

Pressurize cooling system

 The test pressure must not be greater than 1.4 bar to avoid damage.

 If new cylinder head gasket fitted, first warm up engine to operating temperature before testing cooling system for leaks.

Test pressure for pressure-testing cooling system

*BE20.30-P-1005-01A

8

Check hose clamps for condition and seating

 If hose clamps are loose, tighten them or replace them.

9

Check coolant hoses and heater hoses and their connecting points for condition and coolant loss

 Replace damaged parts in order to prevent leaks.

10

Remove test cap (1) on expansion reservoir (2)

 Test cap

*210589009100

11

Detach pressure pump (3)

 Pressure pump

*124589242100

12

Move heater switch to starting position

13

Close cap on expansion reservoir (2)

Number

Designation

2-stage
cap

BE20.30-P-1005-01A

Test pressure for pressure-testing cooling system

bar gage

1.4