17 00 039 Venting and filling cooling system with vacuum filling unit

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Special tools required:

IMPORTANT: Lifetime coolant filling:
Never reuse used coolant!
When replacing and removing components which rely on the corrosion protection effect of the coolant, it is essential to change the coolant. The cooling system must therefore be drained and refilled.
In the case of other removal work involving the draining of part quantities of coolant, replace these quantities which have been drained with new coolant.

IMPORTANT: You must protect the alternator against contamination by coolant when carrying out repair work on the cooling circuit.
Cover alternator with suitable materials.
Failure to comply with this procedure may result in an alternator malfunction.

Note on ordering:

Workshop equipment
Workshop equipment catalogue
No.- 81 39 2 152 473

IMPORTANT: Risk of slipping due to coolant on the floor.
Danger of injury!

Catch and dispose of emerging coolant in drip tray (1) and if necessary special tool 00 2 030 (universal hydraulic lifting equipment).

Recycling:

Observe country-specific waste disposal regulations.

Fig 1: Identifying Drip Tray And Special Tool (00 2 030)

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Graphic shows the N63 engine, procedure for other engines identical.

IMPORTANT: Check all the coolant hoses before filling the cooling system with the vacuum filling unit.
If necessary, replace damaged and porous coolant hoses.

Vacuum filling unit consists of:

1) Filling unit with vacuum meter and shutoff valves
2) Filler hose
3) Coolant container
4) Venturi nozzle
5) Compressed air connection (max. 6 bar)
6) Outgoing-air hose (lead outgoing-air hose into a collecting container)

Fig 2: Identifying Vacuum Filling Unit Components
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Preconditions

Cooling system expansion tank must be empty.
There must be sufficiently premixed coolant in the filling unit container, 1 - 2 liters more than the vehicle FILLING CAPACITY .
- Use only recommended coolant and observe mixture ratio. See COOLANT REQUIREMENTS, MIXTURE RATIO, AND WATER QUALITY .
- Observe FILLING CAPACITIES .
Position the filling unit container at the same height as the coolant expansion tank.
Compressed-air connection with 6 bar pressure present.
Set heating to maximum temperature.

Application

Connect filling unit (1) to coolant expansion tank using suitable adapter (2) from set of special tools 17 0 100 .

Shutoff valves (A) and (B) must be closed.

Fig 3: Identifying Coolant Filling Unit, Adapter And Shut-Off Valves

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Connect venturi nozzle (1) to filling unit (2).

Fig 4: Connecting Venturi Nozzle To Filling Unit

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Connect compressed air (1) and open shutoff valve (B).

The venturi nozzle produces a flow noise.

Fig 5: Identifying Compressed Air Connection And Shutoff Valve

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Then open shutoff valve (A) until the filling hose (1) is free of bubbles. Close shutoff valve (A) again. The filling hose (1) is vented in this way.

Fig 6: Identifying Filling Hose And Shut-Off Valve

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Shutoff valve (B) will remain open. Generate vacuum in cooling cycle for approx. 1 minute. The end vacuum is reached at a vacuum of -0.7 to - 0.95 bar. Green scale on the vacuum meter.

NOTE: The coolant hoses contract during vacuum build-up.

Then close shutoff valve (B) again.

Fig 7: Identifying Compressed Air Connection And Shutoff Valve

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Both shutoff valves (A) and (B) must be closed. Then seal Venturi nozzle (1).

Fig 8: Identifying Venturi Nozzle And Shutoff Valves

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The cooling system must hold the vacuum for 30 seconds. If the needle in the vacuum meter falls, this indicates a leak in the cooling system.

If the vacuum remains constant, proceed with filling.

In the event of leaks, check cooling system for leaks. See CHECKING WATERTIGHTNESS (N55, N63 , CHECKING WATERTIGHTNESS (N63O1) , -or- CHECKING WATERTIGHTNESS (S63) .

Fig 9: Identifying Cooling System Vacuum Gauge

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IMPORTANT: There must be sufficiently premixed coolant in the filling unit container, 1 - 2 liters more than the vehicle FILLING CAPACITY .
Position the filling unit container at the same height as the coolant expansion tank.

Shut-off valve (B) remains closed during the filling process.

Fig 10: Identifying Shut-Off Valves

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To fill the cooling system, open shutoff valve (A) to filling unit container.

Coolant is now added.

The filling procedure is finished when the needle in the vacuum meter is at 0 bar or no longer falls.

If necessary, reduce remaining vacuum. Open shutoff valve (B) to do so.

Remove filling unit with adapter from expansion tank.

Adjust coolant level to maximum.

Fig 11: Checking Coolant Level

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Close coolant expansion tank.

Installation note:

Close the sealing cap (1) until the arrows line up.

Fig 12: Identifying Sealing Cap On Coolant Expansion Tank

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Only N63 and S63:

Check coolant level when the engine has cooled down. Adjust coolant level to (A) approx.110 mm - 160 mm below the upper edge of the coolant filler neck. If necessary, use a tape measure.

Fig 13: Identifying Coolant Level

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Only N63 and S63:

Close coolant expansion tank.

Installation note:

Close the sealing cap (1) until the arrows line up.

Fig 14: Identifying Sealing Cap Closed Position

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After the cooling system has been filled with the vacuum filling unit, another bleeding procedure must be performed for the following vehicles:

Check function of cooling system.

Visual inspection of cooling system for tightness.