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 Vaccum 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 litres more than the vehicle filling capacity.
- Use only recommended coolant. See RADIATOR -- OPERATING FLUIDS .
- Observe mixture ratio.
- 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: Connecting Filling Unit To Coolant Expansion Tank Using Suitable Adapter

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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: Connecting Compressed Air To Venturi Nozzle

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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: Venting Coolant Filling Hose Free Of Bubbles

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Shutoff valve (B) remains 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 buildup.

Then close shutoff valve (B) again.

Fig 7: Connecting Compressed Air To Venturi Nozzle

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

Fig 8: Identifying Venturi Nozzle With Shut Off 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.

Fig 9: Checking Cooling System For Leaks

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IMPORTANT: There must be sufficiently PREMIXED COOLANT in the filling unit container, 1-2 litres 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.

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

Coolant is now added.

Fig 10: Identifying Cooling System Shut-Off Valves

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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: Locating Coolant Maximum Level Mark

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Close coolant expansion tank.

Installation note:

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

Fig 12: Identifying Coolant Expansion Tank Sealing Cap

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Only N53, N63 B40/B44 O 1, S63 B44 T 0:

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. Use a tape measure where appropriate.

Fig 13: Identifying Coolant Level

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Only N53, N63 B40/B44 O 1, S63 B44 T 0:

Close coolant expansion tank.

Installation note:

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

Fig 14: Locating Sealing Cap

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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

F10, F11, F18 N52T
F10, F11 N53
F06, F07, F10, F11, F12, F13, F18 N55
F07, F06, F10, F11, F12, F13 N63 B40/B44 O 0/1
F10, F12, F13 S63 B44 T 0
F10 N55 Hybrid 5
F10, F11, F18 N20
F10, F11 N57 D30 S 1

Check function of cooling system.

Visual inspection of cooling system for tightness.