Fill the low-temperature cooling system with the vacuum filling equipment

Vacuum filling equipment

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Vacuum filling equipment - connected to the coolant expansion tank

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 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 6 bar. Ignition is switched off.

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.

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, i3 REX	17 0 109

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

TECHNICAL DATA SPECIFICATIONS

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

TECHNICAL DATA SPECIFICATIONS

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

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 to the coolant expansion tank.

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Connect Venturi nozzle (1) to the vacuum filling equipment (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 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 replace porous coolant hoses as needed.

NOTE: TECHNICAL INFORMATION
During vacuum build-up, the coolant hoses will contract.

After a vacuum of -0.7 to -0.95 bar has been reached in the coolant circuit (duration approximately 2 minutes), close the 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

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 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 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 cooling system with the vacuum filling equipment, also perform the cooling system bleeding procedure.

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