(Fill the high-temperature cooling system with the vacuum filling equipment)

Vacuum filling equipment

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Vacuum filling equipment - connected to the coolant expansion tank

(Route the exhaust hose into a collecting vessel)

Precondition

The coolant expansion tank for the cooling system must be empty. The fluid tank of the vacuum filling equipment must have a sufficient quantity of pre-mixed coolant, 1 l to 2 l more than the specified capacity for the vehicle. The fluid tank of the vacuum filling equipment 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 filling equipment must be functional and free of dirt.

NOTE: TECHNICAL INFORMATION
See NOTES FOR WORKING ON THE COOLING SYSTEM .

NOTE: TECHNICAL INFORMATION
Immobilization period-long fill of coolant!
Do not reuse used coolant.
The coolant must be replaced when replacing and removing components which depend on the anti-corrosion effect of 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
Mixing different coolants is not permitted.

NOTE: TECHNICAL INFORMATION
Filling without the vacuum filling equipment (watering can filling) is not permitted.
Failure to observe these instructions may result in component 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
It must be ensured that the ignition (terminal 15) is switched off before filling with the vacuum filling equipment.

Not the type of coolant

Coolant in the collecting vessel of vacuum filling equipment

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Choose the correct coolant for filling.

In general, a vehicle must be filled with the coolant with which it was delivered from the plant.

NOTE: RISK OF DAMAGE
Damage to the engine or components in high-voltage vehicles
If the wrong coolant is used, corrosion or gelling can occur in the coolant circuit.

Only use coolants that have been approved for the specific vehicle.
Only fill the vehicle with the coolant with which it was delivered ex works.
Only mix compatible coolants. The color does not indicate the compatibility of coolants.
Selection of the correct coolant exclusively via part number.

NOTE: TECHNICAL INFORMATION
When using vacuum filling equipment to fill the coolant circuit, you must use the special tool 5 A31EF2 (strainer) to protect the inside of the coolant circuit from contaminants.

Connect special tool (2) 5 A31 EF2 to the vacuum filling equipment (1).
Connect the special tool (2) with the appropriate adapter (3) from the 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
G20/G21/G22/G23/G26/G28/G29	B42/B46/B48/B58	17 0 113

Fill the fluid tank of the vacuum filling equipment with 1 l to 2 l more than the filling capacity of coolant specified for the vehicle.

(TECHNICAL DATA SPECIFICATION)

High-temperature coolant circuit filling capacity G29
	B48B20O1/B46B20O1	8.4 l

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

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Check whether both shutoff valves (A) and (B) of the vacuum filling equipment (1) are closed.
Connect and lock connection (X) to the coolant expansion tank.

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Connect Venturi nozzle (1) to the vacuum filling equipment (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 the shutoff valve (A) again.

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

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Check the coolant hoses for porosity and, if necessary, replace them.
NOTE: TECHNICAL INFORMATION
During vacuum build-up, the coolant hoses will contract.
After a vacuum of -0.8 bar to -0.95 bar is reached in the coolant circuit (duration about 2 minutes), close shutoff valve (B).

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

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Check

Check whether the vacuum in the coolant circuit is maintained for at least 2 minutes.

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Result

» Vacuum drops.

Measure

Search for leaks, repair them, and start the filling procedure from the beginning.

Check

Check whether the vacuum in the coolant circuit is 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 shutoff valve (A) to the fluid tank of the vacuum filling equipment.

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

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Remove the vacuum filling equipment with the adapter from the high temperature coolant expansion tank (1).
Adjust the coolant level in the high temperature coolant expansion tank (1) to the lower edge of the coolant filler neck (2) of the high temperature coolant expansion tank (1).
After filling the engine cooling system using vacuum filling equipment, carry out the cooling system bleeding procedure also.

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