Filling the high-temperature coolant circuit with the vacuum filler device

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
Before starting the automatic cooling system bleeding procedure, make sure that both coolant circuits are filled . The cooling system bleeding procedure is automatically started simultaneously for both coolant circuits. If the cooling system bleeding procedure is started while one of the coolant circuits is empty, there is a risk of damage to the electric coolant pump when running it dry.
Make sure that terminal 15 is not disconnected for the bleeding procedure . Switch on low-beam headlights and hazard warning lights. If the low-beam headlights and hazard warning lights are not switched on, the ignition (terminal 15) will switch off automatically after a certain period of time and interrupt the bleeding procedure.

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.

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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)

Precondition

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.

NOTE: TECHNICAL INFORMATION
FOLLOW NOTES FOR CARRYING OUT REPAIR WORK ON 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.

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/F31	B48/B58	17 0 103

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 coolant quantity for vehicle with manual transmission
		9.3 l
	High-temperature coolant circuit coolant quantity for vehicle with automatic transmission
		10.51

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

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Close shutoff valves (A) and (B) of the vacuum filler device (1).

(X) is the connection on the coolant expansion tank.

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Connect Venturi nozzle (1) to the vacuum filler device (2).

(X) is the connection on the coolant expansion tank.

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Connect compressed air (1).

(X) is the connection on the coolant expansion tank.

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Open shutoff valve (B).

The Venturi nozzle generates a flow noise.

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Open shutoff valve (A) until the filling hose (1) is full without bubbles.
Close shutoff valve (A) again.

» The filling hose (1) has now been bled.

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Check coolant hoses for porosity and replace, if necessary.

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

After having established a vacuum in the coolant circuit of -0.8 to -0.95 bar (approximate duration 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

Look 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 procedure.
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, relieve 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, perform the cooling system bleeding routine additionally.

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