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

ENGINE 111

ENGINE 112 (except 112.961/946/953/947/960/916/955/912)

ENGINE 112.945

ENGINE 113.962

ENGINE 113 (except 113.992/987/988/968/991/990/963/995)

ENGINE 120

ENGINE 137

ENGINE 601

ENGINE 602

ENGINE 602.931

ENGINE 603

ENGINE 603.931

ENGINE 603.972

ENGINE 604

ENGINE 605

ENGINE 606

ENGINE 606.964

ENGINE 611

ENGINE 612

ENGINE 612.965

ENGINE 613

ENGINE 628

ENGINE 628.962

ENGINE 628.963

ENGINE 646.951

ENGINE 646.961

ENGINE 647.961

ENGINE 648.960/961

ENGINE 285.950

ENGINE 612.966

ENGINE 113.982

ENGINE 271.941/943

ENGINE 275/(except 275.953/982)

ENGINE 285.980

Fig 1: Identifying Expansion Reservoir, Cap With Detent, And Pressure Pump

Courtesy of MERCEDES-BENZ USA

	Remove/install
	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 cap with detent (2) or 2-stage cap (2a) at expansion reservoir (1) or radiator.	When closing cover with detent (2): rotate closing cover with detent carefully up to first detent, release pressure relief, then unscrew closing cover with detent (2).
		For model 163 with 2-stage cap (2a) or 1-stage cap: Rotate cap half a revolution in anti-clockwise direction, release pressure, then unscrew 2-stage cap (2a) or 1-stage cap.
2	Set heating switches to maximum heating capacity	All model except model 163. Model 163 does not have any pulsed valve; the heater heat exchanger has coolant permanently flowing through it.
	Checking
3	Check coolant level, if required adjust correctly.	Replace coolant against a separate order if the antifreeze protection is insufficient:
4	Fit test cap (3) on expansion reservoir or radiator	Model 124, 126, 129, 140, 170, 201, 202, 210, Model 463.209/232/233 with engine 112.945, Model 463.304/324/325 with engine 602.931 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	Fig 3
		Model 170, 202, 203, 208, 209, 210, 211 Model 215, Model 220 with engine 137, 275, 628, Model 230 with engine 112, 113, 275, Model 240 with engine 285 Model 461.302/331/332/342/345 with engine 612.966, Model 463.243/246 with engine 113.982, Model 463.244/245/250 with engine 112.945, Model 463.247/248/249/254 with engine 113.962, Model 463.322/323 with engine 612.965, Model 463.309/332/333 with engine 628.962	Fig 5
		Model 163 with engine 111, 112, 113, 612, 628	Fig 4
5	Connect pressure pump (4).		Fig 2
6	Apply pressure to cooling system and check leaktightness of cooling system		*BE20.30-P-1005-01A
7	Inspect cooling and heating hoses as well as their connection points for proper condition and loss of coolant; replace coolant hoses, if necessary
8	Check hose clamps for condition and seating	If necessary, retighten hose clamps and replace if required.
			*WH58.30-Z-1001-06A
			*WH58.30-Z-1002-06A
			*WH58.30-Z-1019-02A
9	Install in the reverse order

RADIATOR OR EXPANSION RESERVOIR CAP

Number	Designation		Cap	2-stage cap
BE20.30-P-1005-01A	Test pressure for pressure-testing cooling system	bar gage	1.4	1.4

Fig 2: Identifying Pressure Pump (124 589 24 21 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Test Cap (124 589 00 91 00)

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Test Cap (163 589 00 91 00)

Courtesy of MERCEDES-BENZ USA

Fig 5: Identifying Test Cap (210 589 00 91 00)

Courtesy of MERCEDES-BENZ USA

COMMERCIALLY AVAILABLE TOOLS

Number	Designation
WH58.30-Z-1019-02A	Hose clamp pliers (length 210 mm, clamping range 80 mm)
WH58.30-Z-1001-06A	6 mm socket hexagon on flexible shaft for hose clamps with worm drive
WH58.30-Z-1002-06A	7 mm socket hexagon on flexible shaft for hose clamps with worm drive