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

Note on ordering:

• Workshop equipment
• Workshop equipment catalogue
• Filler unit no. 81 39 2 152 473
• Collecting vessel no. 81 49 2 152 347
• Adapter from tester 17 0 100

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

Recycling 

Observe country-specific waste disposal regulations.

Fig 1: Lifting Drip Tray Using Special Tool (00 2 030)

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Fig 2: Identifying Cooling System Components

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• 1) Filling unit with vacuum meter and shut-off values
• 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)

Requirements 

• 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 RECOMMENDED COOLANT AND OBSERVE PROPER MIXTURE RATIO .
  • Observe capacities.
• Position the filling unit container at the same height as the coolant expansion tank.
• Compressed-air connection with 6 bar pressure present.
• Set vehicle heater to maximum temperature.

Select adapter (Y) according to table and connect to coolant expansion tank.

Connect filler unit to adapter connection (X).

Fig 3: Identifying Adapter And Adapter Connection

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Shut-off valves (A) and (B) of the filling unit (1) must be closed.

X) Expansion tank connection

Fig 4: Identifying Filling Unit Shut-Off Valves

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

X) Expansion tank connection

Fig 5: Connecting Venturi Nozzle To Filling Unit

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Connect compressed air (1).

X) Expansion tank connection

Fig 6: Connecting Compressed Air Line

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Open shut-off valve (B).

The venturi nozzle produces a flow noise.

Fig 7: Opening Shut-Off Valve

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Then open shut-off valve (A) until the filling hose (1) is free of bubbles.

Close shut-off valve (A) again. The filling hose (1) is vented in this way.

Fig 8: Opening/Closing Shut-Off Valve

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Shut-off valve (B) remains open. Generate vacuum in coolant system for approx. 2 minutes. The final vacuum is reached at a vacuum of -0.7 to -0.95 bar. Green scale on the vacuum meter.

Then close shut-off valve (B) again.

Fig 9: Identifying Shut-Off Valve

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

Fig 10: Sealing Venturi Nozzle

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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 event of leaks, check cooling system for leaks.

Fig 11: Testing Cooling System Vacuum

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

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

Fig 12: Opening Shut-Off Valve To Filling Unit Container

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Coolant is now added.

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

If necessary, reduce remaining vacuum. Open shut-off valve (B) to do so.

Fig 13: Identifying Shut-Off Valve

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Remove filling unit with adapter from expansion tank.

Adjust coolant level to maximum.

Close coolant expansion tank.

Fig 14: Adjusting Coolant Level To Max

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

Switch on the low-beam headlights to perform the bleeding procedure. If the low-beam headlights are not switched on, the ignition (Terminal 15) will switch off automatically after a certain period of time and interrupt the bleeding procedure.

1. Connect battery charger.
2. Switch the ignition on.
3. Switch on low-beam headlight.
4. Set heating to maximum temperature. Take back blower to smallest stage.
5. FES (driving experience switch) must not be in ECO PRO!
6. Press accelerator pedal for 10 seconds to floor. Engine must not be started.
7. The venting procedure is started when the accelerator pedal is pressed and takes approx. 12 minutes. (Electric coolant pump was activated and shuts down automatically after approx. 12 min).
8. Then adjust fluid level in the coolant expansion tank to maximum.
9. Check cooling system for leaks.
10. If the ventilation has to be performed again, deactivate DME completely (remove ignition key for approx. 3 minutes). Then repeat from point 3.

Check function of cooling system.

Check cooling system for tightness.