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Home >> Mercedes Benz >> 2003 >> G500 >> Repair and Diagnosis >> Engine Mechanical >> Cooling System (Mechanical) >> Engine Cooling -- Maintenance -- G-Class (463) >> Maintenance >> Replace coolant - AP20.00-P-2080G

Replace coolant - AP20.00-P-2080G

MODEL 460 with ENGINE 102.964 

MODEL 463.200 /220 /221 with ENGINE 102.965 

MODEL 461.227 /229 /238 /239 /249 /266 /267 with ENGINE 102.979 

MODEL 460, 461.219 with ENGINE 102.981 

MODEL 460 with ENGINE 102.987 

MODEL 463.204 /224 /225 with ENGINE 102.989 

MODEL 461.227 /229 /238 /239 /249 /266 /267 with ENGINE 102.996 

MODEL 461.217 with ENGINE 102.997 

MODEL 463.207 /227 /228 with ENGINE 103.987 

MODEL 463.208 /230 /231 with ENGINE 104.996 

MODEL 460 with ENGINE 110 

MODEL 460 with ENGINE 115 

MODEL 463.228 with ENGINE 117.965 

MODEL 460 with ENGINE 602.930 

MODEL 463.304 /324 /325 with ENGINE 602.931 

MODEL 461.456 with ENGINE 602.938 

MODEL 461.401 /402 /405 with ENGINE 602.939 

MODEL 461.323 /328 /329 /337 /338 /341 /367 /368 /403 /404 /450 /451 /452 /454 /455 /458 /459 with ENGINE 602.94 

MODEL 461.321 /322 /326 /327 /335 /336 /365 /366 with ENGINE 602.983 

MODEL 463.307 /327 /328 with ENGINE 603.931 

MODEL 463.300 /320 /321 with ENGINE 603.972 

MODEL 463.308 /330 /331 with ENGINE 606.964 

MODEL 463.322 /323 with ENGINE 612.965 

MODEL 461.302 /331 /332 /342 /345 with ENGINE 612.966 

MODEL 460 with ENGINE 616 

MODEL 460 with ENGINE 617 

MODEL 463.309 /332 /333 with ENGINE 628.962 

MODEL 463.303 /340 /341 with ENGINE 642.970 

MODEL 463.306 /336 /346 with ENGINE 642.886 

Fig 1: Identifying Cap
G07871335Courtesy of MERCEDES-BENZ USA
Fig 2: Identifying Drain Plug At Radiator
G07871336Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Drain Plug
G07871337Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Drain Screw On Crankcase (Example)
G07871338Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Cap
G07871339Courtesy of MERCEDES-BENZ USA
Fig 6: Identifying Drain Plug At Radiator
G07871340Courtesy of MERCEDES-BENZ USA
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 Inspect cooling and heating system for leaks and proper condition IMPORTANT Before replacing coolant. AP20.00-P-2050G 
2 Take off cap (1)    
3 Open water regulating valve of heating system    
4 Remove underride guard    
5 Clear any drain openings which are clogged by deposits    
6 Drain coolant IMPORTANT Attach a drain hose to the drain valve in order to collect the coolant more easily.
IMPORTANT Disposing of coolants:
Pay attention to legal requirements and local wastewater regulations.		  
NOTES Notes on coolant   AH20.00-N-2080-01A
7 Inspect seals of drain plug IMPORTANT Replace according to condition.  
8 Clean cooling and heating system NOTES Clean cooling and heating system if soiled, otherwise this may result in a reduced cooling and heating capacity: ↓  
Remove oil from cooling and heating system. AR20.00-P-1250GG
9 Pour in coolant FLUID SPECIFICATION Engine 102 *BF20.00-P-1001-02G 
FLUID SPECIFICATION Engine 103 *BF20.00-P-1001-02H 
FLUID SPECIFICATION Engine 104 *BF20.00-P-1001-02A 
FLUID SPECIFICATION Engines 110, 115, 117 *BF20.00-P-1001-02I 
FLUID SPECIFICATION Engines 602, 603 *BF20.00-P-1001-02D 
FLUID SPECIFICATION Engine 616, 617 *BF20.00-P-1001-02J 
FLUID SPECIFICATION Engine 612 *BF20.00-P-1001-02O 
FLUID SPECIFICATION Engines 606, 628 *BF20.00-P-1001-02E 
FLUID SPECIFICATION Engine 642 *BF20.00-P-1001-02W 
DANGER Risk of accident  caused by vehicle starting off by itself when engine is running. Risk of injury  caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.		 AS00.00-Z-0005-01A
10 Start the engine and allow to run at varying speeds until the control temperature of the thermostat is reached
11 Bleed cooling system Engine 612.965 AR20.00-P-1142-06GI
Engine 612.966 AR20.00-P-1142-06GL
Engine 628.962 AR20.00-P-1142-06M
Engine 642 AR20.00-P-1142-06GY
Engine 606.964 AR20.00-P-1142-06GA
12 Switch off engine and top up coolant to the specified coolant level    
13 Close water regulating valve of heating system    
14 Inspecting cooling system for leaks    
COOLING SYSTEM

Number Designation Engine 104.996 in model 463.208/230/231
BF20.00-P-1001-02A Cooling system Total filling capacity without AC Liters 11, 8
with AC Liters 11, 8
Filling capacity of anticorrosion/ without AC Liters 5, 9
antifreeze down to -37°C with AC Liters 5, 9
Filling capacity of anticorrosion/ without AC Liters 6.5
antifreeze down to -45°C with AC Liters 6.5
Specifications for Operating Fluids Sheet BB00.40-P-0310-01A
Sheet BB00.40-P-0325-00A
COOLING SYSTEM

Number Designation Engine 602.930 Engine 602.931
BF20.00-P-1001-02D Cooling system Total filling capacity without AC Liters 10.5 9.0
with AC Liters - -
Filling capacity of anticorrosion/ without AC Liters 5, 25 4.5
antifreeze down to -37°C with AC Liters - -
Filling capacity of anticorrosion/ without AC Liters 5, 75 4, 95
antifreeze down to -45°C with AC Liters - -
Specifications for Operating Fluids Sheet BB00.40-P-0310-01A BB00.40-P-0310-01A
Sheet BB00.40-P-0325-00A BB00.40-P-0325-00A
COOLING SYSTEM

Number Designation Engine 602.938/939/942/946/947 Engine 603.931/972
BF20.00-P-1001-02D Cooling system Total filling capacity without AC Liters 10.5 9.5
with AC Liters - -
Filling capacity of anticorrosion/ without AC Liters 5, 25 4, 75
antifreeze down to -37°C with AC Liters - -
Filling capacity of anticorrosion/ without AC Liters 5, 75 5, 25
antifreeze down to -45°C with AC Liters - -
Specifications for Operating Fluids Sheet BB00.40-P-0310-01A BB00.40-P-0310-01A
Sheet BB00.40-P-0325-00A BB00.40-P-0325-00A
COOLING SYSTEM

Number Designation Engine 628.962 without code H12 Engine 628.962 with code H12
BF20.00-P-1001-02E Cooling system Total filling capacity Liters ≈14, 71 ≈15, 25
Filling capacity of anticorrosion/antifreeze down to -37°C Liters ≈7, 36 ≈7, 62
Filling capacity of anticorrosion/antifreeze down to -45°C Liters ≈8, 10 ≈8, 39
Specifications for Operating Fluids Sheet BB00.40-P-0310-01A BB00.40-P-0310-01A
Sheet BB00.40-P-0325-00A BB00.40-P-0325-00A
COOLING SYSTEM

Number Designation Engine 606.964
BF20.00-P-1001-02E Cooling system Total filling capacity Liters 10.0
Filling capacity of anticorrosion/antifreeze down to -37°C Liters 5, 0
Filling capacity of anticorrosion/antifreeze down to -45°C Liters 5, 5
Specifications for Operating Fluids Sheet BB00.40-P-0310-01A
Sheet BB00.40-P-0325-00A
COOLING SYSTEM

Number Designation Engine 102.964/981/987 in model 460 Engine 102.979/996/997 in model 461 Engine 102.965 in model 463.200/220/221 Engine 102.989 in model 463.204/224/225
BF20.00-P-1001-02G Cooling system Total filling capacity Liters 9.5 10.5 8.5
Filling capacity of anticorrosion/antifreeze down to -37°C Liters 4, 75 5, 25 4, 25
Filling capacity of anticorrosion/antifreeze down to -45°C Liters 5, 25 5, 75 4, 65
Specifications for Operating Fluids Sheet BB00.40-P-0310-01A BB00.40-P-0310-01A BB00.40-P-0310-01A
Sheet BB00.40-P-0325-00A BB00.40-P-0325-00A BB00.40-P-0325-00A
COOLING SYSTEM

Number Designation Engine 103.987 in model 463.207/227/228
BF20.00-P-1001-02H Cooling system Total filling capacity Liters 9.0
Filling capacity of anticorrosion/antifreeze down to -37°C Liters 4, 50
Filling capacity of anticorrosion/antifreeze down to -45°C Liters 4, 95
Specifications for Operating Fluids Sheet BB00.40-P-0310-01A
Sheet BB00.40-P-0325-00A
COOLING SYSTEM

Number Designation Engine 110.994 in model 460 Engine 115.973 in model 460 Engine 117.965 in model 463
BF20.00-P-1001-02I Cooling system Total filling capacity Liters 10.5 10.5 11, 5
Filling capacity of anticorrosion/antifreeze down to -37°C Liters 5, 25 5, 25 5, 75
Filling capacity of anticorrosion/antifreeze down to -45°C Liters 5, 75 5, 75 6, 35
Specifications for Operating Fluids Sheet BB00.40-P-0310-01A BB00.40-P-0310-01A BB00.40-P-0310-01A
Sheet BB00.40-P-0325-00A BB00.40-P-0325-00A BB00.40-P-0325-00A
COOLING SYSTEM

Number Designation Engine 616.936 in model 460 Engine 617.931 in model 460
BF20.00-P-1001-02J Cooling system Total filling capacity Liters 10.5 10.5
Filling capacity of anticorrosion/antifreeze down to -37°C Liters 5, 25 5, 25
Filling capacity of anticorrosion/antifreeze down to -45°C Liters 5, 75 5, 75
Specifications for Operating Fluids Sheet BB00.40-P-0310-01A BB00.40-P-0310-01A
Sheet BB00.40-P-0325-00A BB00.40-P-0325-00A
COOLING SYSTEM

Number Designation Engine 612.965 in model 463.322/323
BF20.00-P-1001-02O Cooling system Total filling capacity Without auxiliary heater Liters ≈12.75
With auxiliary heater Liters ≈13, 3
Filling capacity of anticorrosion/ Without auxiliary heater Liters ≈6, 4
antifreeze down to -37°C With auxiliary heater Liters ≈6, 7
Filling capacity of anticorrosion/ Without auxiliary heater Liters ≈7, 0
antifreeze down to -45°C With auxiliary heater Liters ≈7, 3
Specifications for Operating Fluids Sheet BB00.40-P-0310-01A
Sheet BB00.40-P-0325-00A
COOLING SYSTEM

Number Designation Engine 612.966 in model 461.302/331/332/342/345
BF20.00-P-1001-02O Cooling system Total filling capacity Without auxiliary heater Liters ≈12, 8
With auxiliary heater Liters ≈13, 4
Filling capacity of anticorrosion/ Without auxiliary heater Liters ≈6, 4
antifreeze down to -37°C With auxiliary heater Liters ≈6, 7
Filling capacity of anticorrosion/ Without auxiliary heater Liters ≈7, 0
antifreeze down to -45°C With auxiliary heater Liters ≈7, 4
Specifications for Operating Fluids Sheet BB00.40-P-0310-01A
Sheet BB00.40-P-0325-00A
COOLING SYSTEM

Number Designation Engine 642 in model 463
BF20.00-P-1001-02W Cooling system Workshop change quantity ≈Liters 7.5
Antifreeze/water Up to -37°C 50/50
up to -45°C 55/45
Service specifications Sheet BB00.40-P-0310-01A
Sheet BB00.40-P-0325-00A
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