Filling the high-temperature coolant circuit for the Range Extender using the vacuum filling equipment

Vacuum filling equipment

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Vacuum filling equipment - connected to the coolant expansion tank

Vacuum filling equipment with pressure gauge and shutoff valves
Filling hose
Fluid tank with coolant
Venturi nozzle
Compressed air connection (7 bar)
Exhaust hose (route 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 premixed coolant, 1 I to 2 I 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
Notes for working on the engine 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.
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
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
You must protect the alternator from contamination by coolant before carrying out any repair work on the coolant circuit. Cover alternator with suitable materials.

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	Model	Adapter (Y) from 17 0 100
I01	i3 Range extender	17 0 109

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

TECHNICAL DATA SPECIFICATION

Cooling capacity of cooling system with range extender (SA4U7/SA4U8)
	Low temperature coolant circuit coolant volume	8.2 I
	Coolant volume of high-temperature coolant circuit	1.6 I

TECHNICAL DATA SPECIFICATION

Cooling capacity with range extender
	Low temperature coolant circuit coolant volume	8.0 I
	Coolant volume of high-temperature coolant circuit	1.6 I

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

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Close shutoff valves (A) and (B) of the vacuum filling equipment (1).
(X) is the connection on 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 hose for porosity, replace if applicable.
NOTE: TECHNICAL INFORMATION
During vacuum build-up, the coolant hoses will contract.
After a vacuum of -0.8 to -0.95 bar is reached in the coolant circuit (approx. 2 min), 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 min.

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Result

» Vacuum drops.

Measure
- Search for leaks, repair them, and start the filling procedure from the beginning.
Check
- The vacuum in the coolant circuit must be maintained for at least 2 min.
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Result

» Vacuum remains constant.

Measure
- Continue with the filling procedure.
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 coolant expansion tank.
Adjust the coolant level to the maximum mark.
After filling the engine cooling system with the vacuum filling equipment, also carry out the cooling system bleeding procedure.

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