Venting and filling low-temperature cooling circuit for electric drive motor (using vacuum filling unit)

Special tools required:

00 2 030
17 0 100

Type	Model	Adapter Y from 17 0 100
I01	i3, i3 REX	17 0 109

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:

applicable BMW Workshop Equipment Catalog
Filler unit no. 81 39 2 152 473
Collecting vessel no. 81 49 2 152 347
Adapter: 17 0 100

IMPORTANT: Risk of slipping due to coolant on the floor.
Injury hazard!
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.

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

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

Preconditions

Cooling system expansion tank must be empty.
There must be sufficient premixed coolant in the filling unit container, 1 - 2 liters more than the prescribed vehicle filling capacity.
- Use ONLY RECOMMENDED COOLANT .
- Observe MIXTURE RATIO .
- Observe filling capacity. See the "Fluid Capacities" tab for the selected vehicle.
Position the vacuum filling equipment 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).

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Shutoff valves (A) and (B) of the filling unit (1) must be closed.

(X) Expansion tank connection

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

(X) Expansion tank connection

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Connect compressed air (1).

(X) Expansion tank connection

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Open shutoff valve (B).

The venturi nozzle produces a flow noise.

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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.

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Shutoff valve (B) will remain 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.

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

Then close shutoff valve (B) again.

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

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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 the event of leaks, check cooling system for leaks.

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IMPORTANT: There must be sufficient premixed coolant in the filling unit container: 1-2 liters more than the vehicle filling capacity.
Position the vacuum filling equipment 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.

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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 shutoff valve (B) to do so.

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Remove vacuum filling equipment with adapter from expansion tank.

Adjust coolant level to maximum.

Close coolant expansion tank.

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After the cooling system has been filled with the vacuum filling unit, another bleeding procedure must be performed .

VENTING LOW-TEMPERATURE COOLING SYSTEM .

Check function of cooling system.

Check cooling system for tightness.