|
| Drain off
|
|
|
Danger
| Risk of death caused by vehicle slipping or toppling off of the lifting platform.
| Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.
| AS00.00-Z-0010-01A
|
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
|
Topical note
| Notes on coolant
|
| AH20.00-N-2080-01A
|
1
| Open hood
|
Engine 628.963 in model 163.128
| AR88.40-P-1000GI
|
|
|
| Engine 611.960 in model 202.133/134/193/194
| AR88.40-P-1000E
|
|
|
| Engine 611.962 in model 203.004/006/204/206/706
Engine 612.962 in model 203.016/216
Engine 612.990 in model 203.018/218/718
Engine 646.962 in model 203
Engine 646.963 in model 203
| AR88.40-P-1000P
|
|
|
| Engine 612.967 in model 209.316
Engine 646.966 in model 209
| AR88.40-P-1000Q
|
|
|
| Engine 611.961 in model 210.006/007/206/606
Engine 612.961 in model 210.016/216/616
Engine 613.961 in model 210.026/226
| AR88.40-P-1000F
|
|
|
| Engine 628.961 in model 211.028
Engine 646.8 in model 211
Engine 646.951 in model 211.004
Engine 646.961 in model 211.006/206/606
Engine 647.9 in model 211
Engine 648.9 in model 211
| AR88.40-P-1000T
|
|
|
| Engine 613.960 in model 220.026/126
Engine 628.960 in model 220.028/128
Engine 648.960 in model 220.025/125
| AR88.40-P-1000M
|
2
| Disconnect battery ground line
| Engine 628.960 in model 220.028/128
Engine 628.961 in model 211.028
Engine 628.963 in model 163.128
Only when draining coolant at right crankcase
|
|
|
|
| Engine 628.963 in model 163.128
| AR54.10-P-0003A
|
|
|
| Engine 628.961 in model 211.028
| AR54.10-P-0003T
|
|
|
| Engine 628.960 in model 220.028/128
| AR54.10-P-0003I
|
|
|
| Do not connect no-load current retention unit.
|
|
3
| Open the cooling system cap (2) on coolant expansion reservoir (1)
| Turn cooling system cap (2) half a revolution counterclockwise, release overpressure and unscrew cooling system cap (2).
|
|
4
| Remove fuel main filter
| 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 613.960 in model 220.026/126
Engine 613.961 in model 210.026/226
Only for draining of the coolant at crankcase
|
|
|
|
|
| AR47.20-P-1070HB
|
|
|
| To improve accessibility of the crankcase drain screw (4).
|
|
5.1
| Remove bottom sections of soundproofing
| 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 613.960 in model 220.026/126
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
Engine 646.963 in model 203
Engine 646.966 in model 209
Engine 647.9 in model 211
Engine 648.9 in model 211
Engine 648.960 in model 220.025/125
|
|
|
|
| Engine 611.961 in model 210.006/007/206/606
Engine 612.961 in model 210.016/216/616
Engine 613.961 in model 210.026/226
| AR94.30-P-5300AB
|
|
|
| Engine 611.960 in model 202.133/134/193/194
| AR94.30-P-5300A
|
|
|
| Engine 628.963 in model 163.128
| AR94.30-P-5400GH
|
|
|
| Engine 611.962 in model 203.004/006/204/206/706
Engine 612.962 in model 203.016/216
Engine 612.967 in model 209.316
Engine 646.962 in model 203
Engine 646.963 in model 203
Engine 646.966 in model 209
| AR94.30-P-5300P
|
|
|
| Engine 628.961 in model 211.028
Engine 646.8 in model 211
Engine 646.951 in model 211.004
Engine 646.961 in model 211.006/206/606
Engine 647.9 in model 211
Engine 648.9 in model 211
| AR94.30-P-5300T
|
|
|
| Engine 613.960 in model 220.026/126
Engine 628.960 in model 220.028/128
Engine 648.960 in model 220.025/125
| AR94.30-P-5300M
|
5.2
| Remove lower engine compartment paneling
| Engine 612.990 in model 203.018/218/718
|
|
|
|
| Engine 612.990 in model 203.018/218/718
| AR61.20-P-1105P
|
|
| Drain coolant at radiator
|
|
|
6
| Push drain hose (3a) onto radiator drain screw (3)
| 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 220.026/126
Engine 613.961 in model 210.026/226
Engine 628.960 in model 220.028/128
Engine 628.961 in model 211.028
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
Engine 646.963 in model 203
Engine 646.966 in model 209
Engine 647.9 in model 211
Engine 648.9 in model 211
Engine 648.960 in model 220.025/125
|
|
7.1
| Open radiator drain screw (3) and 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 220.026/126
Engine 613.961 in model 210.026/226
Engine 628.960 in model 220.028/128
Engine 628.961 in model 211.028
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
Engine 646.963 in model 203
Engine 646.966 in model 209
Engine 647.9 in model 211
Engine 648.9 in model 211
Engine 648.960 in model 220.025/125
|
|
|
|
| Collect coolant in a suitable container.
|
|
7.2
| Remove coolant return hose on radiator at bottom right and drain off coolant
| Engine 628.963 in model 163.128
|
|
|
|
| Collect coolant in a suitable container.
|
|
8.1
| Tighten radiator drain screw (3)
| 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 220.026/126
Engine 613.961 in model 210.026/226
Engine 628.960 in model 220.028/128
Engine 628.961 in model 211.028
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
Engine 646.963 in model 203
Engine 646.966 in model 209
Engine 647.9 in model 211
Engine 648.9 in model 211
Engine 648.960 in model 220.025/125
|
|
8.2
| Attach coolant return hose on radiator at bottom right
| Engine 628.963 in model 163.128
|
|
9
| Detach drain hose (3a) from fitting on cooler drain screw (3)
| 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 220.026/126
Engine 613.961 in model 210.026/226
Engine 628.960 in model 220.028/128
Engine 628.961 in model 211.028
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
Engine 646.963 in model 203
Engine 646.966 in model 209
Engine 647.9 in model 211
Engine 648.9 in model 211
Engine 648.960 in model 220.025/125
|
|
|
| Drain coolant on crankcase
|
|
|
10
| Push drain hose (4a) onto crankcase drain screw (4)
| 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 220.026/126
Engine 613.961 in model 210.026/226
Engine 628.960 in model 220.028/128
Engine 628.961 in model 211.028
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
Engine 646.963 in model 203
Engine 646.966 in model 209
Engine 647.9 in model 211
Engine 648.9 in model 211
Engine 648.960 in model 220.025/125
|
|
11
| Open the crankcase drain screw (4) and drain off the 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 220.026/126
Engine 613.961 in model 210.026/226
Engine 628.960 in model 220.028/128
Engine 628.961 in model 211.028
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
Engine 646.963 in model 203
Engine 646.966 in model 209
Engine 647.9 in model 211
Engine 648.9 in model 211
Engine 648.960 in model 220.025/125
|
|
|
|
| Collect coolant in a suitable container.
|
|
12
| Tighten down cylinder crankcase drain screw (4) and pull out drain hose (4a)
| 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 220.026/126
Engine 613.961 in model 210.026/226
Engine 628.960 in model 220.028/128
Engine 628.961 in model 211.028
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
Engine 646.963 in model 203
Engine 646.966 in model 209
Engine 647.9 in model 211
Engine 648.9 in model 211
Engine 648.960 in model 220.025/125
|
|
|
|
| Coolant drain plug on crankcase
| *BA20.00-P-1001-02A
|
13
| Remove oil from cooling and heating system
| 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 220.026/126
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
Engine 646.963 in model 203
Engine 646.966 in model 209
Engine 647.9 in model 211
Engine 648.9 in model 211
|
|
|
|
| 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-1250B
|
|
|
| For impurity in the cooling and heating system.
|
|
14
| Install fuel main filter
| 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 613.960 in model 220.026/126
Engine 613.961 in model 210.026/226
|
|
|
|
|
| AR47.20-P-1070HB
|
|
| Pour in
|
|
|
15
| Pour in coolant and bleed cooling system
|
|
|
|
| Notes on coolant level
|
| AH20.00-P-1142-01CW
|
| Anticorrosion/antifreeze agents (Sheet 325.0)
|
| BB00.40-P-0325-00A
|
| Coolant specifications
|
| BB00.40-P-0310-01A
|
|
|
| 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 220.026/126
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
Engine 646.963 in model 203
Engine 646.966 in model 209
Engine 647.9 in model 211
Engine 648.9 in model 211
Engine 648.960 in model 220.025/125
| AR20.00-P-1142-04AK
|
|
|
| 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
|
|
|
| Re-use clean 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 220.026/126
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 647.961 in model 211
Engine 648.9 in model 211
Engine 648.960 in model 220.025/125Cooling system
| *BF20.00-P-1001-02E
|
|
|
| Engine 646.962 in model 203
Engine 646.963 in model 203
Engine 646.966 in model 209Cooling system
| *BF20.00-P-1001-02AA
|
|
|
| Test cap
| *169589009100
|
|
|
| Test cap
| *210589009100
|
|
|
| Cooler vacuum filling device
| *285589002100
|
|
|
| NTKL Adaption
| *285589012100
|
|
|
| Electric vacuum pump
| *285589022100
|
16
| Check cooling system for leaktightness
| 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 220.026/126
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
Engine 646.963 in model 203
Engine 646.966 in model 209
Engine 647.9 in model 211
Engine 648.9 in model 211
Engine 648.960 in model 220.025/125
|
|
|
|
| Engine 612.967 in model 209.316
Engine 646.8 in model 211
Engine 646.962 in model 203
Engine 646.963 in model 203
Engine 646.966 in model 209
| AR20.00-P-1010P
|
|
|
| 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 220.026/126
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 646.951 in model 211.004
Engine 646.961 in model 211.006/206/606
Engine 647.9 in model 211
Engine 648.9 in model 211
Engine 648.960 in model 220.025/125
| AR20.00-P-1010HA
|
17.1
| Install bottom sections of soundproofing
| 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 613.960 in model 220.026/126
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
Engine 646.963 in model 203
Engine 646.966 in model 209
Engine 647.9 in model 211
Engine 648.9 in model 211
Engine 648.960 in model 220.025/125
|
|
|
|
| Remove/install bottom parts of soundproofingEngine 611.960 in model 202.133/134/193/194
| AR94.30-P-5300A
|
|
|
| Remove/install bottom parts of soundproofingEngine 611.961 in model 210.006/007/206/606
Engine 612.961 in model 210.016/216/616
Engine 613.961 in model 210.026/226
| AR94.30-P-5300AB
|
|
|
| Engine 628.963 in model 163.128
| AR94.30-P-5400GH
|
|
|
| Engine 611.962 in model 203.004/006/204/206/706
Engine 612.962 in model 203.016/216
Engine 612.967 in model 209.316
Engine 646.962 in model 203
Engine 646.963 in model 203
Engine 646.966 in model 209
| AR94.30-P-5300P
|
|
|
| Engine 628.961 in model 211.028
Engine 646.8 in model 211
Engine 646.951 in model 211.004
Engine 646.961 in model 211.006/206/606
Engine 647.9 in model 211
Engine 648.9 in model 211
| AR94.30-P-5300T
|
|
|
| Engine 613.960 in model 220.026/126
Engine 628.960 in model 220.028/128
Engine 648.960 in model 220.025/125
| AR94.30-P-5300M
|
17.2
| Install lower engine compartment paneling
| Engine 612.990 in model 203.018/218/718
|
|
|
|
| Engine 612.990 in model 203.018/218/718
| AR61.20-P-1105P
|
18
| Connect ground cable to battery
| Engine 628.960 in model 220.028/128
Engine 628.961 in model 211.028
Engine 628.963 in model 163.128
Only when coolant has been drained at crankcase on the right.
|
|
|
|
| Engine 628.963 in model 163.128
| AR54.10-P-0003A
|
|
|
| Engine 628.961 in model 211.028
| AR54.10-P-0003T
|
|
|
| Engine 628.960 in model 220.028/128
| AR54.10-P-0003I
|
19
| Perform basic programming
| Engine 628.960 in model 220.028/128
Engine 628.961 in model 211.028
Engine 628.963 in model 163.128
Only if the ground line for the battery has been disconnected.
|
|
|
|
| Engine 628.963 in model 163.128
| AR00.19-P-0200GH
|
|
|
| Engine 628.961 in model 211.028
| AR00.19-P-0200T
|
|
|
| Engine 628.960 in model 220.028/128
| AR00.19-P-0200M
|
20
| Connect STAR DIAGNOSIS, read out and clear fault memory
| Engine 628.960 in model 220.028/128
Engine 628.961 in model 211.028
Engine 628.963 in model 163.128
Only if the ground line for the battery has been disconnected.
|
|
|
|
| AD00.00-P-2000-04A
|
|
|
| Stored faults which may be caused by assembly work, test work, removed lines or a simulation, must be processed and cleared in fault memories after completing the work.
|
|
21
| Close engine hood
|
Engine 628.963 in model 163.128
| AR88.40-P-1000GI
|
|
|
| Engine 611.960 in model 202.133/134/193/194
| AR88.40-P-1000E
|
|
|
| Engine 611.962 in model 203.004/006/204/206/706
Engine 612.962 in model 203.016/216
Engine 612.990 in model 203.018/218/718
Engine 646.962 in model 203
Engine 646.963 in model 203
| AR88.40-P-1000P
|
|
|
| Engine 612.967 in model 209.316
Engine 646.966 in model 209
| AR88.40-P-1000Q
|
|
|
| Engine 611.961 in model 210.006/007/206/606
Engine 612.961 in model 210.016/216/616
Engine 613.961 in model 210.026/226
| AR88.40-P-1000F
|
|
|
| Engine 628.961 in model 211.028
Engine 646.8 in model 211
Engine 646.951 in model 211.004
Engine 646.961 in model 211.006/206/606
Engine 647.9 in model 211
Engine 648.9 in model 211
| AR88.40-P-1000T
|
|
|
| Engine 613.960 in model 220.026/126
Engine 628.960 in model 220.028/128
Engine 648.960 in model 220.025/125
| AR88.40-P-1000M
|
