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

Special tools required:

Type	Engine	Adapter Y from 17 0 100
E60/E61/E63/E64	All	17 0 113
E65/E66	M54/N52/N62/N62T/N73	17 0 105
E65/E66	M57S/M57T/M67/M67T	17 0 113
E70/E71/E72	All	17 0 113
E81/E82/E84/E87/E88/E89	All	17 0 113
E83	M54/N46/N52K	17 0 105
E83	M47S/M57S/M57T/M57Y/N47	17 0 113
E85/E86	All	17 0 105
E90/E91/E92/E93	All	17 0 113
R50/R52	W10	17 0 107 and 17 0 102
R50	W17	17 0 109
R52/R53	W11	17 0 109
R55/R56/R57/R58/R60/R61	All	17 0 109
F25/F26	All	17 0 113
F20/F21/F22/F23/F30/F31/F32/F33/F34/F35/F36	All	17 0 113
F80/F82/F83	S55	17 0 113
F15	All	17 0 113
F55, F56	All	17 0 109
F45	All	17 0 109
F16	All	17 0 113

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
Filling unit number 81 39 2 152 473
Drip pan number 81 49 2 152 347
Adapter: 17 0 100

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).

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

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Recycling

Observe country-specific waste disposal regulations.

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

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: Filling Cooling System

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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 MIXTURE RATIO .
- Observe capacities. Refer to N54 ENGINE or N55 ENGINE .
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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Shutoff valves (A) and (B) of the filling unit (1) must be closed.

(X) Expansion tank connection

Fig 4: Identifying Expansion Tank Connection And Shutoff Valves Of Filling Unit

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

(X) Expansion tank connection

Fig 5: Identifying Expansion Tank Connection, Nozzle, And Filling Unit

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Connect compressed air (1).

(X) Expansion tank connection

Fig 6: Identifying Expansion Tank Connection And Compressed Air Connection

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Open shutoff valve (B).

The venturi nozzle produces a flow noise.

Fig 7: Opening 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 8: Closing Shutoff Valve

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Shutoff valve (B) will remain open. Generate vacuum in coolant system for approx. 2 minutes. 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 9: Identifying Shutoff Valve

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

Fig 10: Identifying Shutoff Valves And Nozzle

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The cooling system must hold the vacuum for 30 s. 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: Checking For Cooling System Leaks

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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.

Fig 12: Identifying Shutoff Valves

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

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.

Fig 13: Identifying Shutoff Valves And Vacuum Meter

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Remove filling unit with adapter from expansion tank.

Adjust coolant level to maximum.

Close coolant expansion tank.

Fig 14: Identifying Coolant Expansion Tank Minimum And Maximum Mark

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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:

E84 N20
F25, F26 N52T, N55,
F25, F26 N20
E70, E71 N63, S63
E70, E71 N57 D30 S 1
E72 N63
F20, F21, F30, F31 F35, N13
F20, F21, F22, F23, F30, F31, F32, F33, F34, F35 F36 N20, N26
F20, F21, F22, F23, F30, F31, F32, F33, F34, F35 F36 N55
F30 N55 Hybrid car
F15 N55
F15 N63 B44 O1
F15 N57 D30 S 1
F55, F56 B38, B48, B46
F80, F82, F83, S55
F45 B38, B48
F25, F26, B47
F45, B47, B37
F55, F56, B37, B47
F16 N63 B44 O1
F16 N55
F16 N57 D30 S 1
F22, F23, B47

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:

NOTE: Do not open the coolant expansion tank sealing cap during the bleeding procedure.
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.

Connect battery charger.
Switch the ignition on.
Switch on low-beam headlight.
Set heating to maximum temperature. Take back blower to smallest stage.
FES (driving experience switch) must not be in ECO PRO!
Press accelerator pedal for 10 seconds to floor. Engine must not be started.
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).
Then adjust filling level in coolant expansion tank to maximum.
Check cooling system for leaks.
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.