Drain/Pour In Coolant - AR20.00-P-1142GQ

ENGINE 157, 276, 278, 642 in MODEL 292

ENGINE 157, 276, 278, 642, 651 in MODEL 166

MODIFICATION NOTES

06.07.2015	Refrigeration Equipment	Engine 278 in Model 166	BF20.00-P-1001-02EA
15.04.2016	Work procedure completely revised.

Shown on model 166 with engine 278

Engine 276

Shown on model 222 with engine 651

	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
	Notes on coolant level		AH20.00-P-1142-01CW
	Drain off
1	Unscrew cap (2) on coolant expansion reservoir (4)
2	Remove front and center underfloor paneling		AR61.30-P-1001GQ
3	Push drain hose (3) onto left fitting (3a) on radiator (6)
4	Open drain valve (7) at radiator (6) and drain coolant	Observe regulations to dispose of coolant.
5	Unfasten drain screw from coolant line to ATL and drain off coolant	Engine 157, 278 in model 166, 292
6	Unfasten coolant pump drain screw (5) at coolant pump (1)	Engine 276 in model 166, 292
7	Push drain hose (3) onto coolant pump drain screw (5)	Engine 276 in model 166, 292
8	Open coolant pump drain screw (5) at coolant pump (1) and drain off coolant	Engine 276 in model 166, 292
9	Remove catalytic converter DPF unit	Engine 651 in model 166	AR49.10-P-5501GQ
10	Remove screw/bolts (11) and take off heat shield (12)	Engine 651 in model 166
11	Remove screw/bolts (13) and take off heat shield (14)	Engine 651 in model 166
12	Unfasten crankcase drain screw (10)	Engine 651 in model 166
13	Push drain hose (3) onto crankcase drain screw (10)	Engine 651 in model 166
14	Open crankcase drain screw (10) and drain off coolant	Engine 651 in model 166
	Pour in
15	Close jiggle valve (7) on cooler (6) and detach drain hose (3) from fitting (3a)
16	Fasten drain screw from coolant line to ATL	Engine 157, 278 in model 166, 292
16	Fasten drain screw from coolant line to ATL	Drain screw to coolant line	*BA09.40-P-1010-01R
17	Push drain hose (3) onto coolant pump drain screw (5)	Engine 276 in model 166, 292
18	Tighten coolant pump drain screw (5) at coolant pump (1)	Engine 276 in model 166, 292 Drain screw on coolant pump	*BA20.10-P-1008-01AA
19	Push drain hose (3) onto crankcase drain screw (10)	Engine 651 in model 166
20	Tighten down crankcase drain screw (10)	Engine 651 in model 166 Coolant drain plug on crankcase	*BA20.00-P-1001-02A
21	Install heat shield (14)	Engine 651 in model 166 Heat shield on starter	*BA15.30-P-1004-01P
22	Install heat shield (12)	Engine 651 in model 166 Bolt, heat shield to engine support	*BA22.10-P-1003-02A
23	Install catalytic converter DPF unit	Engine 651 in model 166	AR49.10-P-5501GQ
24	Pour in coolant and bleed cooling system		AR20.00-P-1142-04A
		Re-use clean coolant.
		Engine 157 in model 166 Engine 157 in model 292 Cooling system	*BF20.00-P-1001-02FA
		Engine 651 in model 166 Cooling system	*BF20.00-P-1001-02AA
		Engine 276 in model 166 except code ME05 (HYBRID DRIVE 80KW VARIANT (INCLUDING PLUGIN))	*BF20.00-P-1001-02BA
		Engine 276 in model 166 with code ME05 (HYBRID DRIVE 80KW VARIANT (INCLUDING PLUGIN))
		Engine 276 in model 292 Cooling system
		Engine 278 in model 166 Engine 278 in model 292 Cooling system	*BF20.00-P-1001-02EA
		Engine 642 in model 166 Engine 642 in model 292 Cooling system	*BF20.00-P-1001-02W
		Electric vacuum pump	Fig 2
		NTKL Adaption	Fig 3
		Test cap	Figure
		Cooler vacuum filling device	Fig 4
	Check
25	Check cooling system for leaktightness		AR20.00-P-1010GQ
26	Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running. Carry out engine test run and check the cooling system for proper operation and leaktightness	Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A

TURBOCHARGER

Number	Designation			Engine 157	Engine 278
BA09.40-P-1010-01R	Drain screw to coolant line	Stage 1	Nm	6	6
BA09.40-P-1010-01R	Drain screw to coolant line	Stage 2	∠°	90	90

STARTER

Number	Designation		Engine 651
BA15.30-P-1004-01P	Heat shield on starter	Nm	9

ENGINE COOLING, GENERAL

Number	Designation		Engine 651
BA20.00-P-1001-02A	Coolant drain plug on crankcase	Nm	12

COOLANT PUMP, COOLANT THERMOSTAT

Number	Designation			Engine 276
BA20.10-P-1008-01AA	Drain screw on coolant pump	Stage 1	Nm	6
BA20.10-P-1008-01AA	Drain screw on coolant pump	Stage 2	∠°	90

ENGINE SUPPORT (ENGINE SIDE)

Number	Designation		Engine 651
BA22.10-P-1003-02A	Bolt, heat shield to engine support	Nm	9

COOLING SYSTEM

Number	Designation				Engine 651 in model 166
BF20.00-P-1001-02AA	Cooling system	Workshop replacement amount	Main circuit	Liter	≈ 10, 0
		Workshop replacement amount	Low temperature circuit	Liter	-
		Antifreeze/water	Down to -37°C	%	50/50
			-38°C and below	%	55/45
			Specifications for Operating Fluids, sheet		BB00.40-P-0310-01A
			Specifications for Operating Fluids, sheet		BB00.40-P-0325-00A
			Specifications for Operating Fluids, sheet		BB00.40-P-0326-00A

COOLING SYSTEM

Number	Designation				Engine 276 in model 166 except code ME05 (HYBRID DRIVE 80KW VARIANT (INCLUDING PLUGIN))	Engine 276 in model 166 with code ME05 (HYBRID DRIVE 80KW VARIANT (INCLUDING PLUGIN))
BF20.00-P-1001-02BA	Cooling system	Workshop replacement amount	Main circuit	l	≈ 10, 5	≈ 9, 7
		Workshop replacement amount	Low-temperature circuit	l	≈ 1, 9	≈ 6, 0
		Antifreeze/water	Up to -37°C	%	50/50	50/50
			As of -38 °C	%	55/45	55/45
			Specifications for Operating Fluids, sheet		BB00.40-P-0310-01A	BB00.40-P-0310-01A
			Specifications for Operating Fluids, sheet		BB00.40-P-0325-00A	BB00.40-P-0325-00A
			Specifications for Operating Fluids, sheet		BB00.40-P-0326-00A	BB00.40-P-0326-00A

COOLING SYSTEM

Number	Designation				Engine 276 in model 292
BF20.00-P-1001-02BA	Cooling system	Workshop replacement amount	Main circuit	l	≈ 10, 5
		Workshop replacement amount	Low-temperature circuit	l	≈ 1, 9
		Antifreeze/water	Up to -37°C	%	50/50
			As of -38 °C	%	55/45
			Specifications for Operating Fluids, sheet		BB00.40-P-0310-01A
			Specifications for Operating Fluids, sheet		BB00.40-P-0325-00A
			Specifications for Operating Fluids, sheet		BB00.40-P-0326-00A

COOLING SYSTEM

Number	Designation				Engine 278 in model 166	Engine 278 in model 292
BF20.00-P-1001-02EA	Cooling system	Workshop replacement quantity	Main circuit	Liter	≈ 11, 4	≈ 11, 4
		Workshop replacement quantity	Low temperature circuit	Liter	≈ 2, 5	≈ 2, 5
		Antifreeze/water	Up to -37°C	%	50/50	50/50
			As of -38 °C	%	55/45	55/45
			Sheet		BB00.40-P-0310-01A	BB00.40-P-0310-01A
			Sheet		BB00.40-P-0325-00A	BB00.40-P-0325-00A
			Sheet		BB00.40-P-0326-00A	BB00.40-P-0326-00A

COOLING SYSTEM

Number	Designation				Engine 157 in model 166	Engine 157 in model 292
BF20.00-P-1001-02FA	Cooling system	Workshop change quantity	Main circuit	Liter	≈ 8	≈ 8
		Workshop change quantity	Low-temperature circuit	Liter	≈ 2	≈ 2
		Antifreeze/water	Up to -37 °C	%	50/50	50/50
			As of -38 °C	%	55/45	55/45
			Sheet		BB00.40-P-0310-01A	BB00.40-P-0310-01A
			Sheet		BB00.40-P-0325-00A	BB00.40-P-0325-00A
			Sheet		BB00.40-P-0326-00A	BB00.40-P-0326-00A

COOLING SYSTEM

Number	Designation				Engine 642 in model 166	Engine 642 in model 292
BF20.00-P-1001-02W	Cooling system	Workshop replacement amount	Main circuit	l	≈ 11, 5	≈ 11, 5
		Workshop replacement amount	Low-temperature circuit	l	-	-
		Antifreeze/water	Down to -37°C	%	50/50	50/50
			-38°C and below	%	55/45	55/45
			Sheet		BB00.40-P-0310-01A	BB00.40-P-0310-01A
			Sheet		BB00.40-P-0325-00A	BB00.40-P-0325-06A
			Sheet		BB00.40-P-0326-00A	BB00.40-P-0326-06A

Fig 1: Identifying Test Cap (210 589 00 91 00)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Electric Vacuum Pump (285 589 02 21 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying NTKL Adaption (285 589 01 21 00)

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Cooler Vacuum Filling Device (285 589 00 21 00)

Courtesy of MERCEDES-BENZ USA