Inspect cooling system for leaks

AR20.00-G-1010B

Inspect cooling system for leaks

9.1.12



Checking

 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

1

Open engine hood

Model 437.42/43

AR88.40-G-1000C

Model 437.46

 See information from vehicle manufacturer.

2

Slowly open cap (1) on coolant expansion reservoir (2)

 To enable excess pressure in cooling system to be reduced.

3

Set heater control to warm and fan to stage 3

4

Check coolant level, pour in coolant if necessary

Engine 900.915/916, 902.923/924/935, 904.927/928, 906.935/955

AP20.00-G-2010B

Engine 900.920/921, 904.952/953, 924.916/923/ 931, 926.969

AP20.00-G-2010C

5

Rub dry inside of coolant filler neck at the coolant expansion reservoir (2)

6

Adapt sealing rubber on adapter by turning at inside diameter on coolant filler neck

 Adapter

*655589006300

7

Attach adapter to the coolant expansion reservoir (2)

 Adapter

*655589006300

8

Attach testing unit to adapter

 Testing unit

*001589832100

 Adapter

*655589006300

9

Apply compressed air to cooling system through testing unit and check cooling system for leaks

 Observe test pressure 1.0 bar and test period 5 to
10 min. The cooling system can be damaged otherwise.

 A pressure drop at the pressure gauge of the testing unit is visible for leaks in the cooling system.


 Testing unit

*001589832100

10

Perform visual inspection on all coolant carrying components

 For 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 gasket, core hole cap or core hole screw in screw plug; remove leaks in cooling system if necessary.

 If there is a pressure drop, but no visible coolant loss, check the cylinder head for cracks.

11

Relieve test pressure on cooling system and adapter and testing unit on the coolant expansion reservoir (2)

 Testing unit

*001589832100

 Adapter

*655589006300

12

Check, correct fluid levels in engine cooling system

Engine 900.915/916, 902.923/924/935, 904.927/928, 906.935/955

AP20.00-G-2010B

Engine 900.920/921, 904.952/953, 924.916/923/ 931, 926.969

AP20.00-G-2010C

13

Tighten down cap (1) on coolant expansion reservoir (2)

14

Close engine hood

Model 437.42/43

AR88.40-G-1000C

Model 437.46

 See information from vehicle manufacturer.