17 00 039 Venting and filling cooling system with vacuum filling unit: 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 only recommended coolant and observe mixture ratio and capacities. See COOLING SYSTEM - OPERATING FLUIDS .
• 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 1: 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 2: Identifying Shut-Off Valves Of Filling Unit

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

X) Expansion tank connection

Fig 3: Connecting Venturi Nozzle To Filling Unit

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Connect compressed air (1).

X) Expansion tank connection

Fig 4: Connecting Compressed Air Line

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Open shut-off valve (B).

The venturi nozzle produces a flow noise.

Fig 5: 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 6: Opening And Closing Of 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 7: Checking Shut-Off Valve Opening Time

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

Fig 8: Closing Shut-Off Valve

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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 9: Identifying Vacuum Meters

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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 10: 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 11: Filling Coolant

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Remove filling unit with adapter from expansion tank.

Fig 12: Adjusting Coolant Level To Max

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Adjust coolant level to max.

Close coolant expansion tank.

Check function of cooling system.

Check cooling system for leaks.