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

ENGINE 780 in MODEL 242 

MODIFICATION NOTES

26.9.14

Mixing ratio coolant

BF20.00-P-1001-04A

Fig 1: Inspecting Cooling System For Leaks

Courtesy of MERCEDES-BENZ USA

	Risk of injury  due to fan starting unexpectedly	Do not reach into the rotation or hazard area of the fan. Wear closed and close-fitting work clothes.	AS20.40-Z-0001-01A
	Risk of death  when touching components on vehicles with high-voltage on-board electrical system	Do not touch components and open lines of the high-voltage on-board electrical system. Persons who wear electronic implants (e.g. cardiac pacemakers), must not carry out any work on high-voltage on-board electrical systems.	AS54.00-Z-0001-01A
	Risk of injury  to skin and eyes suffering 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
	Notes on coolant		AH20.00-N-2080-01A
	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
	Remove
1	Unscrew low-temperature circuit cap (1) on coolant expansion reservoir (2)	For working on low-temperature circuit. Open low-temperature circuit cap (1) slowly and relieve overpressure, then unscrew low-temperature circuit cap (1).
2	Unscrew cooling circuit cap (3) on coolant expansion reservoir (2)	For working on cooling circuit. Open cooling circuit cap (3) slowly and relieve overpressure, then unscrew cooling circuit cap (3).
3	Check coolant level and antifreeze content of coolant and correct if necessary
	Notes on coolant level		AH20.00-P-1142-01CW
		If antifreeze content of coolant is too low, either antifreeze protection must be added or the coolant must be replaced.
		Coolant mixing ratio	*BF20.00-P-1001-04A
4	Screw on tester cap (4) at coolant expansion reservoir (2)	For working on low-temperature circuit.
		Test cap	Figure
5	Screw on tester cap (4) at coolant expansion reservoir (2)	For working on cooling circuit.
		Test cap	Figure
6	Connect pressure pump (5) at tester cap (4)	Pressure pump	Fig 2
7	Apply a test pressure of a maximum of 1.4 bar to the cooling system	The test pressure must not be greater than 1.4 bar. Damage can occur to the cooling system otherwise.
	Check
8	Perform a visual inspection on the components carrying coolant	Check condition and coolant loss for all coolant carrying components and connections. The coolant carrying components should be checked for inner leaktightness if there is no external coolant loss. There is the possibility, for example, that coolant can find its way over a defective cylinder head gasket into the combustion chamber or over a defective water heat exchanger into the oil circuits. Check condition and seating of the Henn coupling. Replace safety spring if necessary to avoid coolant loss.
	Install
9	Remove test pressure in the cooling system	To do this actuate pressure relief button on the pressure pump (4).
10	Detach pressure pump (5) from tester cap (4)
11	Unscrew tester cap (4) at coolant expansion reservoir (2)
12	Check coolant level
	Notes on coolant level		AH20.00-P-1142-01CW
13	Unscrew low-temperature circuit cap (2) on coolant expansion reservoir (1)	For working on low-temperature circuit.
14	Screw cooling circuit cap (3) onto coolant expansion reservoir (2)	For working on cooling circuit.

COOLANT MIXING RATIO

Number	Designation			ENGINE ALL
BF20.00-P-1001-04A	Coolant mixing ratio	Antifreeze/water	to -37°C	50/50
		Antifreeze/water	to -45°C	55/45
		Specification		Coolant (Specification 310.1). See https://bevo.mercedes-benz.com/index.php?language_id=1

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

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Test Cap (169 589 00 91 00)

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Test Cap (210 589 00 91 00)

Courtesy of MERCEDES-BENZ USA