REP-TAT-P-1700-04 Filling the low-temperature cooling system with the vacuum filler device

Vacuum filler device

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Vacuum filler device - connected to the coolant expansion tank for the charge air cooler

Vacuum filler device with pressure gauge and shutoff valves
Filling hose
Fluid tank with coolant
Venturi nozzle
Compressed air connection (maximum 6 bar)
Out-going hose (lead out-going 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 6 bar. Ignition is switched off.

NOTE: TECHNICAL INFORMATION
Follow 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.
Failure to observe this rule runs the risk of component damage/engine damage.
Filling specification absolutely must be adhered to.
It is not permissible to operate the vehicle if the filling procedure has not been fully completed. Otherwise functional limitations (degradation) and/or overheating may result.
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.

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 0 109

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 SPECIFICATIONS

Cooling system capacity (low-temperature coolant circuit)
3.91

Connect special tool 0 494 426 (17 0 109) (Y) to coolant expansion tank for charge air coolers.
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 to the coolant expansion tank for the charge air cooler.

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

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

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Open shut-off valve (B).
The Venturi nozzle generates 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 bled.

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Check the coolant hoses for porosity and replace porous coolant hoses as required.
NOTE: TECHNICAL INFORMATION
The coolant hoses contract during vacuum build-up.
After a vacuum of -0.7 to -0.95 bar is reached in the coolant circuit (duration approximately 2 minutes), close the shutoff valve (B).

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Check whether the shut-off 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 30 seconds.

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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 30 seconds.

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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 shut-off valve (A) 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, the shutoff valve (B) is open.

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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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