Filling The Low-Temperature Coolant Circuit With The Vacuum Filler Device

Vacuum filler device

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Vacuum filler device - connected to the coolant expansion tank

Vacuum filler device with pressure gauge and shutoff valves
Filling hose
Fluid tank with coolant
Venturi nozzle
Compressed air connection (7 bar)
Exhaust hose (lead exhaust hose into a collecting vessel)

Prerequisite

The coolant expansion tank for the cooling system must be empty. The fluid tank of the vacuum filler device must have a sufficient quantity of premixed coolant, 1 l to 2 l more than the specified capacity for the vehicle. The fluid tank of the vacuum filler device must be positioned at the same height as the coolant expansion tank. The compressed air connection must have a pressure of 7 bar. Ignition is switched off.

The vacuum filler device must be functional and free of dirt.

NOTE: TECHNICAL INFORMATION
Follow notes for repair work on the cooling system.
For additional information see: NOTES FOR WORKING ON THE COOLING SYSTEM .

NOTE: TECHNICAL INFORMATION
Immobilization period-long fill of coolant!
Do not 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 emptied and refilled.
In the case of other removal work involving the draining of part quantities of coolant, the coolant level must be topped up with new coolant.

NOTE: TECHNICAL INFORMATION
Filling without the vacuum filling equipment (watering can filling) is not permitted.
If this is not observed, there is a risk of component damage or engine damage.
The filling specification must be observed.
It is essential to visually check the vacuum filling equipment before use to check that it is functioning correctly and clean.
It is not permissible to operate the vehicle if the filling procedure has not been fully completed. Otherwise there may be functional limitations (degradation) or overheating.
A bleeding procedure is required after a part has been exchanged in the cooling system and/or after refilling the cooling system.

NOTE: TECHNICAL INFORMATION
Make sure that the ignition (terminal 15) is switched off prior to creating the vacuum with the vacuum filling equipment.

NOTE: TECHNICAL INFORMATION
When using vacuum filling equipment to fill the coolant circuit, you must use special tool 5 A31 EF2 (strainer) to protect the inside of the coolant circuit from contaminants.

Connect special tool (2) 5 A31 EF2 to vacuum filler device (1).
Connect special tool (2) with matching adapter (3) from set of special tools 0 494 417 (17 0 100).

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Select a suitable adapter (Y) from the set of special tools 0 494 417 (17 0 100):

Type	Engine	Adapter (Y) from 17 0 100
F30	B48 Plug-in Hybrid Electric Vehicle	17 0 109

The fluid tank of the vacuum filler device must be filled with 1 l to 2 l more than the specified capacity of coolant for the vehicle.

TECHNICAL DATA SPECIFICATION

Cooling system capacity
	High-temperature coolant circuit (without external radiator)	9.0 l
	High-temperature coolant circuit (with external radiator)	9.5 l
	Low temperature coolant circuit	5.7 l

Connect the selected adapter (Y) to the coolant expansion tank.
Connect vacuum filler device to connection (X) of the adapter.

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Make sure that the shutoff valves (A) and (B) of the vacuum filler device (1) are closed.
Connect and lock connection (X) to the coolant expansion tank.

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Connect Venturi nozzle (1) to the vacuum filler device (2).
(X) is the connection to the coolant expansion tank.

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Connect compressed air (1).
(X) is the connection to the coolant expansion tank.

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Open shut-off valve (B).
The Venturi nozzle produces a flow noise.

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Open shutoff valve (A) until the fuel filling hose (1) is full without bubbles.
Close shutoff valve (A) again.
» The filling hose (1) has now been vent.

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Check the coolant hoses for porosity and, if necessary, replace them.
NOTE: TECHNICAL INFORMATION
The coolant hoses contract during vacuum buildup.
After having established a vacuum of -0.8 to -0.95 bar in the coolant circuit (duration approx. 2 minutes), close the shutoff valve (B).

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Check whether the shutoff valves (A) and (B) are closed.
Disconnect the Venturi nozzle (1).

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Check

The vacuum in the coolant circuit must be maintained for at least 2 minutes.

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Result

» Vacuum drops.

Measure

Search for the leak, repair it and start the filling procedure from the beginning.

Check

The vacuum in the coolant circuit must be maintained for at least 2 minutes.

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Result

» Vacuum remains constant.

Measure
- Continue with filling.
Keep shutoff valve (B) closed during the filling process.
To fill the cooling system, open the shutoff valve (A) to the fluid tank of the vacuum filler device.

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Stop the filling procedure when the needle in the pressure measuring device is on 0 bar or it no longer drops.
If necessary, reduce remaining vacuum. In order to do so, open shutoff valve (B).

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Remove the vacuum filler device with the adapter from the coolant expansion tank.
Adjust the coolant level to the maximum mark.
After filling the cooling system with the vacuum filler device, also run the cooling system bleeding routine.

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