AR20.10-S-2710A Remove/install coolant thermostat housing 5.2.

09
ENGINES 111.948 /950 /978 /980 in MODEL 638

1 Coolant thermostat housing

2 Expansion reservoir coolant hose
3 Radiator coolant hose
4 Coolant pump coolant hose
5 Sealing ring
6 Lifting eye
7 Screw
8 Screw
9 Screw
10 Shock absorber
11 Bolt+washer

B1.1 Temperature sensor connector for

coolant temperature gauge
B60.1 Temperature sensor connector for
pressurized engine control coolant

S20.10-3002-06

ed Remove/install
1 Switch off ignition
a Danger! Risk of injury to skin and eyes caused by
scalding from contact with hot coolant spray.
Risk of poisoning caused by swallowing
coolant.
2 Drain coolant
3 Remove air filter housing
4 Detach coolant hoses (2, 3) on coolant
thermostat housing (1)
5 Unplug electrical connectors on temperature
sensor (B60.1, B1.1)
6 Unscrew bolt (11) of damper (10) and guide
damper (10) out to the side
7 Unscrew bolt (9).
8 Remove housing of coolant thermostat (1)
with lifting eyes (6)
9 Install in the reverse order
a 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
10 Inspecting cooling system for leaks
Do not open cooling system unless coolant AS20.00-Z-0001-01A
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.
AP20.00-D-2080A
AR09.10-S-1150A
i Check coolant hoses (2, 3) and clamps
for condition, replace if necessary
7 mm socket hexagon on flexible shaft for
hose clamps with worm drive
p The damper (10) is pressurized.
i Installation: Observe installation position
of poly-V belt.
n *BA13.25-N-1004-01A
p Pay attention to the bolt assignment.
Clean sealing surfaces. Replace sealing ring
(5).
n *BA20.10-N-1003-01A
Secure vehicle to prevent it from moving by AS00.00-Z-0005-01A
itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.
AR20.00-S-1010A

n Belt tensioning device

Number Designation Engine

111.948/
950/978/
980

© Daimler AG, 12/11/12, G/07/11, ar20.10-s-2710a, Remove/install coolant thermostat housing Page 1 of 2
ENGINES 111.948 /950 /978 /980 in MODEL 638
 BA13.25-N-1004-01A Shock absorber belt tensioning device to coolant Nm 21
thermostat housing

n Coolant pump, coolant thermostat

Number Designation Engine 111.948/

950/978/980

BA20.10-N-1003-01A Housing of coolant thermostat to cylinder head M6 Nm 10

cover

M8 Nm 21

© Daimler AG, 12/11/12, G/07/11, ar20.10-s-2710a, Remove/install coolant thermostat housing Page 2 of 2
ENGINES 111.948 /950 /978 /980 in MODEL 638
AR20.10-S-2460B Removing and installing engine coolant thermostat 4.12.95
ENGINE 601 in MODEL 638

1 Coolant pipe
2 Bolt
3 Coolant thermostat
4 Seal

S20.10-2003-11

ed Removing, installing
1 Disconnect ground cable at the battery i Installation: encode radio AR54.10-S-0005A
set time
2 Remove coolant pipe (1) AR20.20-S-7450A
3.1 Remove oil return flow line at crankcase Engine 601.970
i Oil may flow out.
i Installation: replace gasket and seal
n *BA09.40-N-1005-01A

a Danger! Risk of injury to skin and eyes from Do not open the cooling system unless the AS20.00-Z-0001-01A
scalding from hot coolant which splashes coolant temperature is below 90 °C. Open
out. Risk of poisoning from swallowing cap slowly and allow the pressure to
coolant. release. Do not pour coolant into containers
for drinks.
Wear protective gloves, protective clothes,
and eye protection.
4 Unscrew bolt (2) from the cover of the n *BA20.10-N-1004-01B
coolant thermostat (3) at the coolant pump
housing
l *000589011000
5 Remove cover of coolant thermostat i Installation: replace seal (4).
6 Install in the reverse order
g Inspecting
7 Inspect cooling system for leaks AR20.00-S-1010B

n Turbocharger

Number Designation Engine

601.970

BA09.40-N-1001-01A Nut of turbocharger to exhaust manifold Nm 21

BA09.40-N-1002-01A Lubricating oil line to union of turbocharger Nm 22

BA09.40-N-1003-01A Lubrication oil line to crankcase Nm 30

BA09.40-N-1004-01A Oil return flow line to turbocharger Nm 9

BA09.40-N-1005-01A Oil return flow line to crankcase Nm 9

BA09.40-N-1006-01A Stud bolts in turbocharger Nm 11

© Daimler AG, 12/11/12, G/07/11, ar20.10-s-2460b, Removing and installing engine coolant thermostat Page 1 of 2
ENGINE 601 in MODEL 638
n Coolant pump, coolant thermostat

Code Name Engine

601.942
601.970

BA20.10-N-1004-01B Coolant thermostat cover in the coolant pump box Nm 10

000 589 01 10 00
Torx bit set

© Daimler AG, 12/11/12, G/07/11, ar20.10-s-2460b, Removing and installing engine coolant thermostat Page 2 of 2
ENGINE 601 in MODEL 638
AR20.10-S-2710C Removing and installing coolant thermostat housing 19.10.99
ENGINE 611.980 in MODEL 638

1 Screw
2 Bracket
3 Fuel pressure line
4 Coolant thermostat housing
5 Coolant hose
6 Screw

B60 Coolant temperature sensor

B60.1 Plug connection of coolant
temperature sensor

S20.10-4001-06

ed Removing, installing
a Danger! Risk of injury to skin and eyes from Do not open the cooling system unless the AS20.00-Z-0001-01A
scalding from hot coolant which splashes coolant temperature is below 90 °C. Open
out. Risk of poisoning from swallowing cap slowly and allow the pressure to
coolant. release. Do not pour coolant into containers
for drinks.
Wear protective gloves, protective clothes,
and eye protection.
1 Drain coolant AR20.00-S-1142A
2 Remove front grille AR88.00-S-2115A
3 Remove air guide
4 Take out screw (1) n *BA07.03-N-1001-01D
l External torx set *001589760900
5 Detach coolant hose (5) from coolant p Inspect condition of hose clamps and
thermostat housing (4) coolant hose (5).
6 Detach coolant return flow hose at coolant p Inspect condition of hose clamps and
thermostat housing (4) coolant return flow hose.
7 Separate plug connection of coolant
temperature sensor (B60.1)
8 Remove screws (6) n *BA20.10-P-1005-01A
l External torx set
9 Remove coolant thermostat housing (4) at p Installation: clean sealing surfaces,
cylinder head replace gasket.
10 Install in the reverse order
g Inspecting
11 Inspect cooling system for leaks AR20.00-S-1010A

n Injection nozzles, injectors, lines

Number Designation Engine

611.980 in
model
638

BA07.03-N-1001-01D Screw of bracket of fuel pressure line to coolant Nm 12

thermostat housing

© Daimler AG, 12/11/12, G/07/11, ar20.10-s-2710c, Removing and installing coolant thermostat housing Page 1 of 2
ENGINE 611.980 in MODEL 638
n Coolant pump, coolant thermostat

Number Designation Engine

611.980

BA20.10-P-1005-01A Screw of coolant thermostat housing to cylinder Nm 8

head

001 589 76 09 00
External torx set

© Daimler AG, 12/11/12, G/07/11, ar20.10-s-2710c, Removing and installing coolant thermostat housing Page 2 of 2
ENGINE 611.980 in MODEL 638
AR20.10-S-2710B Remove/install coolant thermostat housing 9.11.09
ENGINE 104.900 in MODEL 638.2

1 Ignition coil
2 Coolant connections
3 Coolant thermostat housing
4 Coolant temperature sensor
5 Bolts
6 Cylinder head
7 Sealing ring

S20.10-2500-06

ed Remove/install
a Danger! Risk of injury to skin and eyes caused by Do not open cooling system unless coolant AS20.00-Z-0001-01A
scalding from contact with hot coolant spray. temperature is below 90°C. Open cap slowly
Risk of poisoning caused by swallowing and release the pressure. Do not pour
coolant. coolant into beverage containers.
Wear protective gloves, protective clothing
and safety glasses.
1 Drain coolant AR20.00-S-1142A
2 Remove the ignition coil (1) AR15.12-S-2003B
3 Remove coolant hoses from coolant Wrench hexagon
thermostat housing (3)
Wrench hexagon
4 Disconnect connectors for coolant
temperature sensor (4) on coolant
thermostat housing (3)
5 Unscrew bolts (5) from coolant thermostat n *BA20.10-N-1003-01F
housing (3) on cylinder head (6)
6 Remove coolant thermostat housing (3) p Installation: Install new sealing rings (7).
7 Install in the reverse order
g Checking
8 Check for leaks

n Coolant pump, coolant thermostat

Number Designation Engine

104.900

BA20.10-N-1003-01F Bolt, thermostat housing to cylinder head Nm 8

© Daimler AG, 12/11/12, G/07/11, ar20.10-s-2710b, Remove/install coolant thermostat housing Page 1 of 1
ENGINE 104.900 in MODEL 638.2
AR20.10-S-2460C Remove/install coolant thermostat 9.11.09
ENGINE 104.900 in MODEL 638.2

1 Coolant thermostat housing

2 Cover
3 Temperature control switch
4 Gasket
5 Bolt

S20.10-2504-12

ed Remove/install
a Danger! Risk of injury to skin and eyes caused by Do not open cooling system unless coolant AS20.00-Z-0001-01A
scalding from contact with hot coolant spray. temperature is below 90°C. Open cap slowly
Risk of poisoning caused by swallowing and release the pressure. Do not pour
coolant. coolant into beverage containers.
Wear protective gloves, protective clothing
and safety glasses.
1 Drain coolant AR20.00-S-1142A
2 Remove coolant thermostat housing (1) AR20.10-S-2710B
3 Unscrew bolts (5) from cover (2) for coolant n *BA20.10-N-1005-01F
thermostat housing (1)
4 Remove temperature control (3) p Installation: Replace seal (4).
5 Install in the reverse order
g Checking
6 Check for leaks

n Coolant pump, coolant thermostat

Number Designation Engine

104.900

BA20.10-N-1005-01F Bolt, thermostat cover to cylinder head Nm 8

© Daimler AG, 12/11/12, G/07/11, ar20.10-s-2460c, Remove/install coolant thermostat Page 1 of 1

ENGINE 104.900 in MODEL 638.2