17 00 039 Venting and filling cooling system with vacuum filling unit: 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. Observe mixture ratio. See RADIATOR - OPERATING FLUIDS .

  • Observe filling capacities. See COOLING SYSTEM - TECHNICAL DATA .
• 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: Connecting Filler Unit To Adapter Connection

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

(X) Expansion tank connection

Fig 2: Connecting Filler Unit To Expansion Tank Connection

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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 To Expansion Tank

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Open shutoff valve (B).

The venturi nozzle produces a flow noise.

Fig 5: 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 6: Venting Filling Hose

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Shutoff valve (B) remains 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.

Fig 7: Generating Vacuum In Coolant System

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Both shutoff valves (A) and (B) must be closed.

Then seal Venturi nozzle (1).

Fig 8: Sealing Venturi 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 9: Checking Cooling System For Leaks

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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.

Fig 10: Opening Shutoff Valve

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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 11: Filling Unit Container

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Remove filling unit with adapter from expansion tank.

Adjust coolant level to maximum.

Close coolant expansion tank.

Fig 12: Locating Maximum Coolant Level On Expansion Tank

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