Remove/install expansion reservoir · ar2030s4950ew · Mercedes-Benz WIS

AR20.30-S-4950EW

Remove/install expansion reservoir

29.05.2020

Engine	780.994 in model 639.603
	with code MA0 (E-CELL 60 kW)
	Vehicles with battery cooling circuit, battery cooling circuit expansion reservoir

Modification notes

28.05.2020

Work procedure revised.

The whole document

S20.30-4507-09

1	Coolant expansion reservoir	4	Retaining clamp	7	Retaining clamp
2	Cap	5	Clip	8	Screw
3	Screw	6	Coolant hose

 Danger	Risk of death when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC)	Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines.	AS00.00-Z-0035-01A
 Warning	Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.	Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses.	AS20.00-Z-0001-01A
Topical note	Notes on avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
Topical note	General information on vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system as well as personal protective equipment		AH00.00-Z-0300-01A
	Notes on coolant level		AH20.00-N-1142-01EV
 	Remove/install
1	Open hood and secure against falling down.	 Installation: Only close the engine hood after the leak test.
2	Perform power disconnect of high-voltage on-board electrical system.		AR54.10-S-1160EV
		 Installation: Only commission high-voltage on-board electrical system after leak test.
3	Carefully turn cap (2) at coolant expansion reservoir (1) by half a turn counterclockwise, release overpressure and remove cap (2).
4	Clamp off coolant hoses (6) with clamps.	 Clamp	*000589543700
5	Extract coolant from coolant expansion reservoir (1).
	Service Information: Coolant		SI20.00-S-0001B
		 Installation: Fill coolant into coolant expansion reservoir (1).
		 Engine 780.994 in model 639.603High-voltage cooling circuit with connected high-voltage battery cooling system	*BF20.00-N-1002-02A
		 Engine 780.994 in model 639.603High-voltage cooling circuit with shut-down high-voltage battery cooling system	*BF20.00-N-1003-02A
		 Hand pump	*210589007100
6	Release respective clamps (5) at coolant hoses (6).	 Installation: Check clamps (5) for damage.
		 Hose clamp pliers	*454589003700
		If damage is present:
		
		Replace affected clamps (5).
7	Remove coolant hoses (6) at coolant expansion reservoir (1).	 Collect escaping coolant using suitable vessel.
8	Remove respective screws (3, 8) of retaining clamps (4, 7) and remove coolant expansion reservoir (1) with retaining clamps (4, 7).	 Bolt, expansion reservoir clamp to cooler	*BA20.30-N-1001-01A
9	Remove retaining clamps (4, 7) at coolant expansion reservoir (1).	 Installation: Check retaining clamps (4, 7) for damage.
		If damage is present:
		
		Replace affected retaining clamp (4, 7).
10	Install in the reverse order.
	Check
11	Check battery cooling circuit for leaks.		AR20.00-S-1010EV
12	Bring vehicle to operating temperature during a test drive.
13	Check coolant level at coolant expansion reservoir (1).	If coolant level incorrect
		
		Correct coolant level.
		Service Information: Coolant	SI20.00-S-0001B

 Expansion reservoir

Number	Designation			Engine 780.994 in model 639.603/703 with code MA0 (E-CELL 60 kW)
BA20.30-N-1001-01A	Bolt, expansion reservoir clamp to cooler	M8	Nm	8

 Cooling system

Number	Designation			Engine 780.994 in model 639.603 ## up to 754075, 639.703 ## up to 717332 with code MA0 (E-CELL 60 kW)
BF20.00-N-1002-02A	High-voltage cooling circuit with connected high-voltage battery cooling system	Total filling capacity	Liter	15,0
		Filling capacity of anticorrosion or antifreeze agent down to 37 °C	Liter	7,5
		Filling capacity of anticorrosion or antifreeze agent down to -45 °C	Liter	9
		Sheet		BB00.40-P-0310-01A
		Sheet		BB00.40-P-0325-00A
		Sheet		BB00.40-P-0325-05A

 Cooling system

Number	Designation			Engine 780.994 in model 639.603 ## up to 754075, 639.703 ## up to 717332 with code MA0 (E-CELL 60 kW)
BF20.00-N-1003-02A	High-voltage cooling circuit with shut-down high-voltage battery cooling system	Total filling capacity	Liter	4,0
		Filling capacity of anticorrosion or antifreeze agent down to 37 °C	Liter	2,0
		Filling capacity of anticorrosion or antifreeze agent down to -45 °C	Liter	2,25
		Sheet		BB00.40-P-0310-01A
		Sheet		BB00.40-P-0325-00A
		Sheet		BB00.40-P-0325-05A

210 589 00 71 00

Hand pump

000 589 54 37 00

Clamp

454 589 00 37 00

Hose clamp pliers

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