Inspect cooling system for leaks - AR20.00-P-1010P

ENGINE 111, 112, 113, 271, 611, 612, 646 in MODEL 203 

ENGINE 112 in MODEL 170 

ENGINE 112, 113, 271, 612, 646 in MODEL 209 

ENGINE 271 in MODEL 211 

ENGINE 113.989 in MODEL 171.473 

ENGINE 646.8 in MODEL 211 

Illustrated on model 203.035 

Fig 1: Inspecting Cooling System For Leaks - Illustrated On Model 203.035

	Checking
	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
	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	Figure
6	Connect pressure pump (3).	Pressure pump	Figure
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	Figure
11	Detach pressure pump (3)	Pressure pump	Figure
12	Move heater switch to starting position
13	Close cap on expansion reservoir (2)

Fig 2: Identifying Test Cap (210 589 00 91 00)

Fig 3: Identifying Pressure Pump (124 589 24 21 00)